Identification & Tracking

Overview

Know Where Every Part Has Been

Vision-based identification links every product to its complete history — the materials used, the tests it passed, the lines it ran on, and the customers it reached. When something goes wrong, traceability tells you exactly which products are affected and why.

Machine vision reads codes that manual scanners miss — damaged, low-contrast, or directly marked onto the part itself. At production speed. Without slowing the line.

Opsistech builds identification and tracking systems that integrate with your existing MES, ERP, and database infrastructure — turning vision data into operational intelligence.

Capabilities

What We Read & Track

1D Barcodes

All standard symbologies — Code 128, Code 39, EAN, UPC, ITF — read at line speed across label, print, and direct-marked surfaces.

2D Codes

QR codes, Data Matrix, and PDF417 decoded reliably — including orientation-independent reading and damaged or partially obscured codes.

Direct Part Marking (DPM)

Reading of laser-etched, dot-peen, and inkjet-marked codes applied directly to metal, plastic, and ceramic surfaces — no label required.

OCR / OCV

Machine-readable character recognition for lot numbers, expiry dates, serial numbers, and human-readable text — with optical character verification to confirm print quality.

Multi-Code Reading

Multiple codes of different types read simultaneously in a single image — reducing the number of reading stations and simplifying line layout.

MES / ERP Integration

Decoded data sent directly to production management systems in real time — enabling automatic work order selection, genealogy tracking, and quality data linkage.

Process

How It Works

Code Acquisition A camera positioned at the reading station captures the product as it passes. Trigger signals synchronised with conveyor encoders ensure every unit is imaged — even at high line speeds.

Decoding Vision software locates and decodes all codes present in the image — handling rotation, perspective distortion, low contrast, and print defects with robust decoding algorithms.

Content Verification The decoded content is validated against expected format rules, check digits, and database lookups — confirming not just that a code was read, but that it contains the correct, expected information.

Data Routing Decoded and verified data is transmitted to MES, ERP, SCADA, or custom databases via standard protocols — triggering downstream process steps, routing decisions, or quality holds as required.

Traceability Log A full audit trail is created for every unit — recording which code was read, when, where, by which system, and what action was taken. This log is available for quality review, recalls, and regulatory audits.

Applications

Where We Deploy

Automotive Serialisation

VIN reading, part-level traceability, and supplier code verification — linking every component to the vehicle it was assembled into.

Pharmaceutical Track & Trace

2D code reading on blister packs, vials, and cartons — supporting serialisation requirements under EU FMD and global track-and-trace regulations.

Food Production

Lot code and date code verification on packaging lines — confirming correct codes are applied and legible before products leave the facility.

Logistics & Sortation

High-speed omni-directional barcode reading for parcel identification, sortation, and warehouse management system integration.

FAQ

Frequently Asked Questions — Identification & Tracking

What barcodes can industrial vision systems read?

Modern systems read all standard 1D codes (Code 128, Code 39, EAN, UPC, Interleaved 2 of 5) and 2D codes (Data Matrix, QR Code, PDF417, Aztec, MaxiCode). We also work with DPM (Direct Part Marking) laser-engraved or dot-peened marks on metals, plastics, and components — even with low contrast or partial damage.

Does OCR work on damaged or degraded labels?

Yes. Modern deep learning OCR can read printed text even with partial wear, low contrast, skew, or on curved surfaces. We train models specific to your fonts and conditions to maximise accuracy — sometimes outperforming classic template-based OCR in challenging industrial conditions.

How does traceability data integrate with ERP/MES systems?

Reads are transmitted in real time to MES, ERP, or WMS systems via OPC UA, REST API, SQL databases, or XML/CSV files. We can generate traceability events (operation start, end, rejection), component genealogy, and per-batch production reports — integrated with SAP, Oracle, Siemens MES, or custom solutions.

What is the maximum barcode reading speed on a production line?

Modern industrial cameras read 100–500 codes per second, depending on code type, size, and print quality. For ultra-fast lines (bottles, blisters), we use line-scan cameras and synchronised multi-camera systems that process thousands of reads per minute — without slowing production.

OPSISTECH