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The challenge of high-speed sorting errors
High-speed logistics and warehouse environments rely on conveyors and sortation to route thousands of packages per hour with precision. However, a conveyor jam can trigger a catastrophic "line down" event, causing manual intervention and package recirculation. The root causes often lie in the sheer volume and velocity of items, where minor misalignments or blockages can quickly escalate, leading to widespread disruption and delayed shipments.
The consequences of these failures are severe, extending beyond immediate operational chaos. Unplanned downtime results in significant revenue loss, while missed SLAs lead to customer dissatisfaction. These issues create operational bottlenecks that erode efficiency, increase labor costs, and damage brand reputation, turning a critical asset into a major liability.
The conveyor jam detection solution
Zebra’s integrated machine vision solution provides an automated monitoring system that keeps your operations flowing by intelligently distinguishing between a true and false jam on the conveyor. By combining high-resolution cameras and AI-powered software, this solution identifies true jams as they happen, allowing operators to act quickly and determine the most efficient remedy to avoid delays or disruptions.
Potential Benefits
By shifting from reactive problem-solving to proactive monitoring, your operation can move beyond constant disruption. This solution transforms your sorting process into a more resilient, efficient, and profitable system, delivering tangible outcomes that strengthen your entire supply chain.
Up to 30% Increase
in throughput
Reduced sorter downtime incidents
that keep your operations moving and prevent costly bottlenecks
Reduced re-circulation of packages
by preventing unnecessary belt closures caused by false jams
Fewer missed shipments
leading to lower return costs and higher customer satisfaction
How the solution works
Capture high-fidelity sorter images
The Zebra Iris GTX smart camera is strategically positioned to monitor package movement and to cover the entire conveyor area. The smart camera enables fast high-resolution image sensing, efficient dual-core embedded processing, and comprehensive I/O capabilities. Bundled with Aurora Design Assistant vision software, these edge IoT devices handle traditional machine vision workloads along with deep learning AI-capabilities. Iris GTX also uses AI-powered edge vision to analyze real-time package flow, accurately distinguishing between minor package hesitations and actual blockages to prevent false alarms, minimize downtime, and maximize operational throughput.
Analyze and detect potential jams
Zebra Aurora Design Assistant uses flowchart-based development and flexible deployment options to reduce development costs and increase productivity. This advanced software acts as an automated monitoring system, executing algorithms that detect the difference between a true and false jam. When a true jam is identified, the system instantly triggers an alert and provides an image confirmation of the jam, enabling operators to take corrective action before a costly disruption occurs.
Protect revenue and eliminate costly downtime
This automated vision solution delivers a strong return on investment by preventing costly downtime and eliminating the financial impact of sorting errors. You can achieve greater operational stability, protect your revenue, and build a more reliable and competitive logistics network.
Note:
Use case figures and savings estimates 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.
