Car manufacturers are enhancing customisation and precision while reducing costs through advanced 3D and AI solutions. Zebra Technologies Corporation, a leader in workflow digitisation and automation, has announced that Sentinel’s automotive clients are utilising the Poka Yoke inspection system — a method aimed at mistake-proofing — resulting in a 10-15% decrease in defect rates. This system simplifies production lines and reduces maintenance expenses and system complexity.
The Poka Yoke solution is powered by Zebra’s AltiZ Series High-Fidelity 3D Profile Sensor with a GigE Vision® interface. It integrates seamlessly with Sentinel’s Vision Core AI software and KAI Maker platform, facilitating easier implementation and user interaction. Machine commissioning time has been dramatically reduced from three months to three weeks, significantly accelerating deployment and project completion.
Joel Alves, Chief Commercial Officer of Sentinel, stated, “The system delivers lasting value across various visual inspection projects with its scalability and adaptability, enabling Sentinel’s manufacturing clients to swiftly reconfigure inspection processes for different automotive brands and components.”
Based in Portugal, Sentinel specialises in machine vision solutions for automotive manufacturers, including complex car door assembly. Modern car doors consist of over 80 components per panel, with variations in size, layout, and design. Previous customer solutions depended on traditional, inflexible mechanical sensor inspection methods requiring costly, custom configurations for each project.
“To offer our customers the best quality, we collaborated with Zebra and Clearview, a Zebra Industrial Automation Distributor, to transform the mechanical sensor inspection approach with more flexible, scalable, and precise vision technology,” Alves added. The new system can replace up to 500 mechanical sensors, achieving the required customisation and precision at a reduced cost. The dual-camera, single laser 3D sensor offers more accurate and detailed door panel renderings than traditional single-camera systems.
Luca Gallo, Machine Vision Manager at Zebra Technologies, commented, “Zebra and its partners are equipping frontline workers with solutions that enhance asset and workflow visibility and deliver intelligent automation. We’re enabling them to improve operations today, preparing to capitalise on future opportunities.”
The success of the Poka Yoke inspection system has allowed Sentinel to expand into other sectors, such as pharmaceuticals and food and beverage. This demonstrates the versatile nature of the Poka Yoke solution and its broad applicability for quality control and intelligent automation across multiple industries.
