In the era of e-commerce, Zenni Optical, a global leader in online eyewear retail, sells over 6 million pairs of glasses annually. However, it faced a unique and complex challenge—processing orders by scanning barcodes inside eyeglass cases. Traditional manual methods had reached a process bottleneck, demanding a more automated and scalable solution. To address this challenge, Cognex partnered with robotics integrator OSARO to successfully enhance Zenni Optical’s distribution efficiency.

Customer

Zenni Optical

Founded in 2003 and headquartered in California, USA, Zenni Optical delivers high-quality, affordable eyewear directly to consumers. With a wide variety of styles, customizable options, and strong product quality, the company has steadily grown its market share in the eyewear industry.

Challenge

High-Speed Barcode Reading Through Semi-Transparent Packaging

OSARO’s AI-powered robotic arms could easily pick up Zenni’s smooth eyeglass cases. However, the scanning process required reading barcodes located inside the sealed plastic packaging of the glasses, through a blue semi-transparent case—posing the following challenges:

• Barcodes inside the case were difficult to scan, requiring a highly accurate automation solution

• A high-performance barcode reading system was needed to reduce misreads and increase throughput

Solution

Cognex DataMan 370 Barcode Reader

The DataMan 370 series of fixed-mount barcode readers features Cognex’s latest decoding algorithms, a multi-core processor, and a newly integrated lighting system. With twice the computing power of comparable standard readers, the DataMan 370 delivers faster decoding speeds and solves challenging 1D and 2D barcode reading applications on labels—ensuring higher throughput across every logistics facility. Combined with OSARO’s robotic arm, the solution significantly improved operational efficiency at Zenni’s distribution center:

• Equipped with High-Powered Integrated Torch lighting (HPIT), the Cognex reader easily scans barcodes through Zenni’s eyeglass cases

• The robotic arm rotates the case within the field of view of four DataMan 370 readers arranged in a C-shape at the top of the workcell, enabling successful barcode reads

Results

Automated Order Fulfillment for Zenni Optical

The new solution combining OSARO’s AI-driven robotic arm with Cognex’s barcode readers enables processing of 350 to 410 eyeglass cases per hour, achieving efficient automated sorting:

• Throughput increased by 80%

• Labor required to monitor the robotic cell reduced from 3 to 2 personnel

• Achieved a 99.5% read rate and 100% system processing accuracy

"I was very skeptical at first, but the results turned out to be extremely reliable. The whole process went quite smoothly. We never have to worry about barcode reading issues during our weekly meetings."

— Simon Goh, Director of Distribution and Facilities, Zenni Optical