Case Study: Bosch cuts reject rate to 5% and automates injector inspection with Zebra's Aurora vision system

Stronger Outcomes for Automotive Component Machining with Enhanced Vision System

Bosch’s Curitiba facility, which manufactures diesel injector nozzles for automotive and commercial vehicles, needed to improve mark-reading, verification and traceability to reduce post-production manual inspection and higher reject rates. The production team wanted a more automated, reliable vision system to read laser engraving on cylindrical metal parts and verify shot-peening while integrating with existing line control.

They implemented an Aurora Design Assistant–based vision solution built on a Zebra Concord PoE frame grabber, Indio I/O card and Intel i7 industrial PC, with three GigE cameras, KUKA robot handling and LumiVision lighting. Using area-scan image stitching and OCR/verification steps, the system runs three inspections simultaneously, simplified setup and operation, and cut false rejects to 5% at a production rate of 7,000 parts per day—backed by local support and on-demand training.

Bosch

Moises Santana

Vision System Designer