Bosch Diesel Jihlava: Cognex Machine Vision Increases Error Catch Rate from 85% to 99-100%

Bosch Diesel s.r.o. in Jihlava, Czech Republic manufactures high-precision automotive components for the Common Rail diesel injection system — including high-pressure injection pumps, rails, and pressure control valves — where permitted deviations are measured in micrometers. At that tolerance level, an 85% error catch rate was operationally unacceptable: defective pump bodies were reaching downstream stations and risking shipment to customers. Beyond accuracy, the manual scanning process created workplace hazards, as operators carried wired readers across slippery production floors. The plant also lacked reliable traceability, with no consistent way to track components through all key operations using Data Matrix codes. Bosch deployed approximately 80 Cognex ID readers — roughly 75 of them wireless — alongside In-Sight machine vision systems across twelve sections of the CP3 department. The Cognex DataMan readers verify the legibility of 6mm Data Matrix codes imprinted on pump bodies, while In-Sight vision systems control work and finishing operations on production lines, detect defects, and identify error sources in real time. Fixed-mount barcode readers replaced handheld manual scanning at key stations. The headline outcome was a near-elimination of missed defects: error catch rate rose from 85% to 99–100%. 75 of ~80 ID readers were deployed wirelessly, eliminating cabling hazards on slippery floors. Processing times were reduced and labor costs decreased through fixed-mount automation. Full component traceability was established — operation time, worker name, machine, spindle, DMC code quality, and body status all recorded per part. Back-search capability was enabled via recorded production images, supporting root-cause analysis. The ease of use and reliability prompted Bosch Jihlava to plan purchase of three additional vision systems.