Flexographic printing is a widely used technique in modern packaging production. A major challenge in this process is plate wear, which leads to color inconsistencies and reduced print quality. This study systematically examines the impact of halftone dot failure on color accuracy, quantified using the ΔE metric. A simulation-based approach is employed to model halftone dot area reductions at various levels (10%–30%) for the CMYK color channels. Regression analysis is performed to determine the maximum permissible dot loss while keeping ΔE within the industrial threshold of 5%, calculated using the Average Color Method (ACM) in the CIELAB color space. This method measures perceived color shifts by averaging pixel intensities and computing color values. The results indicate that the failure limits are 16.58% for cyan, 9.34% for magenta, 12.08% for yellow, and 18.05% for black. These findings provide a quantitative framework for monitoring plate wear and assessing print quality deterioration. By integrating this approach into quality control workflows, manufacturers can enhance defect detection, optimize plate replacement schedules, and ensure consistent color reproduction.