I was doing to looking into the matter last night and had a short correspondence with Paul, who writes The Ballcap Blog and provided some useful info.
"Hi James,
This is a very common problem, especially with caps made during the season such as this World Series cap. The problem is mainly that the production is rushed. There was a time when (up until recently), New Era would repair defective caps for free, but they stopped last year. You're better off returning it. Always check to make sure the seams on the outside of the front panels are in the same place on each side of the visor (brim/bill) stitching.
Hope that helps,
Paul"