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Manufacturers and Logistics Providers Embrace AI for Enhanced Barcode Reading Performance

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A recent survey by Cognex reveals widespread anticipation for AI's role in improving barcode reading technology across manufacturing and logistics sectors. The study, encompassing 283 participants from Asia, North America, and Europe, found that 90% of users expect AI to enhance accuracy, ease of use, and decode rates. The survey identified key challenges: 41% struggle with damaged or smudged barcodes, 39% face issues with distortion and reflections, and 35% deal with problematic code sizes and locations. Nearly half (47%) of respondents expect AI to deliver higher read rates. The findings highlight that reliability and maintenance ease are top priorities, particularly significant given that only 21% of users identify as experts while one-third are novices. Cognex's Executive VP Carl Gerst emphasized the company's commitment to embedding AI in their barcode reading solutions, including their DataMan 290 and 390 products.
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Positive

  • 90% of users anticipate AI improvements in barcode reading performance
  • Strong market presence across Asia, North America, and Europe with 283 survey participants
  • Company already has AI-powered solutions in market (DataMan 290 and 390)
  • Clear understanding of customer pain points and market needs

Negative

  • Only 21% of users are experts in barcode reading technology
  • Significant challenges remain with damaged codes, distortion, and code placement
  • High dependence on maintenance and reliability due to user expertise gap

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Survey reveals 90% of users anticipate AI will improve accuracy, ease of use, decode rates, and more

NATICK, Mass., June 3, 2025 /PRNewswire/ -- As traceability and security concerns continue to rise in manufacturing, barcode reading is becoming increasingly vital on production lines worldwide. A survey conducted by Cognex reveals that manufacturers are looking to AI to address their biggest barcode reading challenges and improve overall performance.

"Leveraging advanced technology to make our customers' jobs easier is at the core of everything we do at Cognex. This survey reinforces the value of embedding AI into our barcode reading solutions," said Carl Gerst, Executive Vice President of Vision and ID Products. "Our innovative AI-powered barcode reading solutions deliver unparalleled performance, reliability, and customer experience, addressing the most pressing challenges facing our customers."

The survey, which included 283 participants from manufacturing and logistics businesses in Asia, North America, and Europe, highlights the growing importance of AI in barcode reading applications. Key findings indicate that reading difficult codes is the primary concern for users, and they expect AI to deliver better performance and reliability.

Key Insights

  • Reading difficult codes: The survey identified that damaged, smudged, or wrinkled barcodes are the top challenge for 41% of respondents, followed by issues with distortion, reflections, and curved surfaces (39%), and troublesome code sizes and locations (35%).

  • AI expectations: Respondents overwhelmingly believe that AI will enhance barcode reading performance, with almost half (47%) expecting higher read rates. Other leading expectations include more accurate detection and improved reading of damaged codes, with logistics providers in particular emphasizing accurate detection.

  • Reliability and maintenance: When choosing a barcode reader, reliability and ease of maintenance are the top priorities for users. This focus on dependable performance is understandable since only 21% of respondents said they're experts, while a third said they're novices. That lack of expertise makes maintenance issues even more pressing when making a buying decision for crucial day-to-day operations.

The free report is available for download at cognex.com/barcode-insights.

The insights from this survey underscore the critical role of AI in transforming barcode reading technology. As manufacturers seek to overcome challenges and improve efficiency, AI-powered barcode readers like the recently introduced Cognex DataMan 290 and DataMan 390 are poised to meet these demands with advanced decoding capabilities. For more information, visit cognex.com/dataman-290 or call 1-855-4-COGNEX.

About Cognex Corporation
For over 40 years, Cognex has been making advanced machine vision easy, paving the way for manufacturing and distribution companies to get faster, smarter, and more efficient through automation.

Innovative technology in our vision sensors and systems solves critical manufacturing and distribution challenges, providing unparalleled performance for industries from automotive to consumer electronics to packaged goods.

Cognex makes these tools more capable and easier to deploy and thanks to a longstanding focus on AI, helping factories and warehouses improve quality and maximize efficiency without needing highly technical expertise.

We are headquartered near Boston, USA, with locations in over 30 countries and more than 30,000 customers worldwide. Learn more at cognex.com.

IR Contact
Greer Aviv
Senior IR Consultant
Cognex Corporation
ir@cognex.com

Media Contact
Jeremy Sacco
Senior Manager, Global Content Marketing
Cognex Corporation
pr@cognex.com

FAQ

What are the main challenges in barcode reading according to Cognex's survey?

According to the survey, 41% struggle with damaged/smudged barcodes, 39% face issues with distortion and reflections, and 35% deal with problematic code sizes and locations.

How many participants were included in Cognex's barcode reading survey?

The survey included 283 participants from manufacturing and logistics businesses across Asia, North America, and Europe.

What percentage of users expect AI to improve barcode reading performance?

90% of users anticipate AI will improve accuracy, ease of use, and decode rates in barcode reading performance.

What are the latest AI-powered barcode readers from Cognex (CGNX)?

Cognex has introduced the DataMan 290 and DataMan 390 as their latest AI-powered barcode readers.

What percentage of barcode reading users consider themselves experts?

Only 21% of respondents identified themselves as experts in barcode reading technology, while one-third classified themselves as novices.