0:00 / 0:00
The manual tire inspection challenge
While managers often view operations from a broad truck perspective, the reality comes down to daily inspections answering a critical question: should this vehicle be on the road, or does it need service? Today, many transportation and logistics teams still rely on manual tire inspections, handwritten notes, and manual tread depth gauges. These processes can be slow, inconsistent, and vulnerable to human error, especially when inspection methods vary by technician or location.
When tire inspection workflows rely on manual processes, high labour costs, and inconsistent data capture, the impact can extend across the fleet. Inaccurate wear tracking can make it harder to identify safety issues, support DOT compliance, and plan maintenance effectively. The result can be higher labour, fuel and operating costs, more vehicle downtime, reduced revenue potential, and a negative impact on customer satisfaction.
The outdated workflow and compliance risk solution
TC58e and TC78 mobile computers, Zebra Tread Intel Snap-on Accessory, and Zebra Mobility DNA OCR Wedge streamline commercial fleet tire inspections and warranty claims. In under five seconds per tire, the Tread Intel accessory captures accurate tread depth measurements within 1/32" (0.79 mm), while Mobility DNA OCR Wedge uses the device camera to capture TINs, VINs, and license plates. Together, these Zebra solutions create a reliable digital record that can support stronger warranty submissions, better wear prediction, optimised maintenance schedules, and fewer emergency repairs or vehicle downtime.
Potential benefits
Fast tread depth measurement
in under 5 seconds per tire within 1/32nd of an inch accuracy
Accurate wear prediction
optimises maintenance schedules based on actual vehicle usage
Reduced manual entry errors
accelerates tire safety assessments
Improved data accuracy
helps create more reliable inspection records for warranty claims, compliance documentation, and maintenance tracking
How the solution works
Capture and connect fleet inspection data
Paired with the Zebra Tread Intel Snap-on Accessory, Zebra TC58e and TC78 mobile computers enable digital capture of tire tread depth, vehicle details, tire IDs, photos and barcodes. This digital approach replaces slow, manual recording with accurate, real-time data synced directly to maintenance systems. With TC58e connectivity and TC78 rugged, outdoor performance, fleet operators can standardise inspections, better predict tire wear, optimise maintenance schedules, reduce downtime, and support DOT compliance.
Measure tread instantly
The Zebra Tread Intel Snap-on Accessory attaches to the TC78 or the TC58e to evaluate tire wear rapidly. It utilises a highly accurate, dual-laser, image sensor that measures tread depth within 1/32nd of an inch in under 5 seconds per tire. This accessory eliminates the inconsistencies of manual gauges, providing precise and immediate readings to determine road readiness.
Automate vehicle identification
Zebra Mobility DNA OCR Wedge enhances vehicle inspections by automatically capturing critical data directly on Zebra mobile devices. Using the device camera, it extracts TINs, VINs, and license plates in real time, eliminating manual data entry. The result is faster inspections, improved data accuracy, and greater operational efficiency.
Enhanced safety and operational efficiency
Investing in these devices and solutions provides financial and strategic value by minimising fuel consumption and lowering tire replacement costs. Organisations meet regulatory requirements for tread depth, avoiding DOT fines while increasing fleet reliability and keeping vehicles on the road.
Note:
Use case figures, savings estimates and images are illustrative only and may be derived from customer data, projections, or controlled testing. They do not represent guaranteed results, and actual outcomes will vary by application; customers should consult a Zebra sales representative to evaluate their specific environment.
