Hello, after experiencing the similar windows unable to complete the format error problems recently with my 16GB Toshiba USB drive, I learned there were several methods to resolve such drive issues:
1). Check this flash drive is write protected or password protected. If it is, go remove the password protection or write protection at first.
2). Format it in Disk Management again
But, if it is not, merely go try to perform a format on your drive in Disk Management of your PC.
3). Use flash drive formatting software.
Or if that also does not work, just go download a memory card formatting program to have a try.
Hope these words also help.