The Power of Fixed Scanning & Machine Vision in Manufacturing

Efficiency is a top priority in any business. For most, the ability to increase throughput while reducing production defects would be an ideal strategy. For that, businesses must rely on advanced automation technologies.  Two game-changing solutions—fixed industrial scanning and machine vision—work together to optimize workflows, enhance traceability, and improve overall production outcomes. By leveraging automated visual data capture, manufacturers can streamline their operations, enabling real-time inspection, error-proofing, and data-driven decision-making.

Understanding Fixed Industrial Scanning and Machine Vision

Fixed industrial scanners are designed to automatically capture barcode and label data to track products, components, and assets throughout production and distribution. These scanners provide a high-speed, hands-free method of data collection, ensuring every product is accurately identified and traced without slowing down the workflow. Typical use cases include:

• Supply Chain and Logistics: Tracking raw materials, work-in-progress (WIP), and finished goods.
• Manufacturing Execution Systems (MES): Verifying product movement across different production stages.
• Automated Sorting and Routing: Ensuring items are directed to the correct processing station or packaging unit.

Machine vision, on the other hand, goes beyond barcode scanning by performing complex, image-based inspections that ensure product quality and process accuracy. Using high-resolution cameras and advanced image processing algorithms, machine vision systems detect product defects, measure components, and confirm assembly correctness. Applications include:

• Defect Detection: Identifying surface flaws, misalignments, and missing components.
• Precision Measurement: Ensuring parts meet dimensional tolerances.
• Guidance and Positioning: Aligning robotic arms and automated machinery for accurate assembly.

Key Differences and Complementary Strengths

While both technologies enhance automation, their capabilities differ significantly, making them highly complementary.

Scanning vs. Vision

• Complexity of Analysis: Fixed scanners efficiently capture and decode barcodes, QR codes, and other machine-readable symbols. In contrast, machine vision systems analyze entire images to identify defects, measure dimensions, or verify complex assembly features.
• Application Scope: Fixed industrial scanners focus on identification and tracking, ensuring accurate routing and inventory management. Machine vision systems provide detailed visual inspection, verifying quality and preventing defects from advancing in the production process.
• Use Case Scenario: A single production line can use fixed scanners to track product movement and machine vision to inspect surface quality. For example, a beverage bottling facility might use fixed industrial scanners to verify labels and machine vision systems to check for improper cap seals or label misalignment.

Integrating Fixed Industrial Scanning and Machine Vision into Automated Systems

One of the biggest advantages of these technologies is their ability to integrate seamlessly into existing automation frameworks, including MES, ERP, and warehouse management systems (WMS). By combining both solutions, businesses can:

• Eliminate Manual Inspections: Reducing reliance on human operators for quality checks, minimizing human error.
• Enhance Productivity: Increasing throughput with real-time data capture and analysis.
• Achieve Better Traceability: Ensuring each product meets regulatory compliance and quality standards before reaching customers.

Zebra Technologies’ fixed industrial scanners and machine vision systems provide an end-to-end solution for manufacturers looking to optimize their production lines. These AI-powered devices deliver high-speed, high-accuracy scanning and imaging capabilities, ensuring every product is accounted for and inspected with precision. Learn more about Zebra’s solutions here.

Real-World Impact: How Businesses Are Transforming Production

Companies across various industries are leveraging these technologies to drive efficiency and quality improvements:

• Automotive Manufacturing: Fixed scanners track individual parts, while machine vision inspects welds, bolts, and surface defects to ensure vehicles meet safety standards.
• Pharmaceuticals: Scanners verify barcodes on medication packaging, while machine vision ensures labels are correctly placed and expiration dates are readable.
• Electronics Production: Machine vision checks soldering quality on circuit boards, while fixed scanners validate serial numbers for traceability.

A global consumer goods manufacturer recently integrated Zebra’s fixed scanning and machine vision solutions into its automated packaging process. As a result, the company achieved fewer labeling issues, reduced retailer fines and diminished worker stress, all contributing to offsetting the initial costs of the system’s implementation, demonstrating the real-world benefits of these technologies.

Join Our Webinar to Learn More!

Fixed industrial scanning and machine vision are revolutionizing modern manufacturing, and we’re excited to share insights into how these solutions can enhance your operations. In our upcoming webinar, we’ll explore real-world applications, integration strategies, and best practices for implementation.

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