Personally, I believe that at the time they decided to go their own way they were fairly divided as people. Arguments seemed to have dogged their Republic days and when all said and done, New Order was probably the last thing on their minds. As such, Barney teamed off with Johnny Marr and that marriage was made their and then... a world away from New Order as you could possibly get (which could of only happened at that point in time).
After a few releases the chances of Marr then joining New Order were very slim after Electronic snatched a little success... after all, wouldn't that negate Marr's infulence on Electronic as a stand-out individual? - He himself probably wouldn't want to show a lack of faith in the quality of Electronic to take the easy route and hit some riffs for NO - also, Marr is a legendary guitarist, and truth be told, would his supreme playing really fit the Order?... wouldn't the likes of the Hookster be a teeny bit jealous? - do they really need Marr?
About Electronic... your right, some songs are superb, real classics. However, the production has let them down and they have been perpetually inconsistent. They do sound cheap, and they will never escape this now after sowing the seeds of doubt in us all. Quality only happens every now and then... New Order and Joy Division are the now and then.