If there is not enough contrast between these two barcode elements, a barcode reader may be unable to distinguish the barcode from its substrate, and the result may be a no-read.įigure 2: Dark barcodes printed on dark backgrounds (like this 1D barcode on cardboard), or light symbols marked on light or reflective materials (like this 2D Data Matrix on metal), can cause no read results due to poor contrast between light and dark symbol elements.Īnother example of low contrast is lack of uniformity of the light and dark barcode elements. Depending on the method used to apply a barcode (whether printed by ink or marked by abrading a material’s surface in the case of direct part marks), as well as what kind of material is used, light or dark elements may alternately manifest as either the markings on a surface (the code itself), or the background (substrate material) onto which the marks are applied. Both element types are essential for proper decoding, enabling a barcode reader to obtain the precise patterns of barcode elements that represent encoded data in the symbol. In order to extract data from the elements (1D bars or 2D cells) of a barcode, a barcode reader must be able to differentiate between the light and dark elements of the symbol. The most common causes of unreadable barcodes are low contrast, quiet zone violations, improper reading position, print or mark inconsistency, and damage or distortion. It also allows businesses to safeguard their processes and profitability by equipping their operations with the optimal tools and conditions for preventing data loss and process failures further down the line. Understanding the primary reasons for decoding failures can save operators valuable time and effort when diagnosing reading issues. However, this symbol does not meet barcode quality requirements for some industries and may be unreadable by certain barcode readers. However, the root cause of unreadable barcodes is often one of a handful of common problems that can easily be solved with simple adjustments to either the barcode or the technology used to decode it.įigure 1: To the human eye, this Data Matrix symbol may appear to be flawless. For seemingly high-quality codes, it is a common misconception that no-read results are due to obscure or undetectable barcode characteristics that the reader is simply unable to address, causing frustration for operators whose intention is to maximize the efficiency of an automated barcode reading process. Although a barcode may appear to have no noticeable flaws to the human eye, subtle inconsistencies in the code, substrate, or even the positioning of the code in relation to the reader may result in no-reads. Barcode readability is impacted by a number of technical and environmental factors. The readability of barcodes is determined by how well a barcode reader can decode the data stored in the symbol. This white paper describes potential solutions for the most common causes of unreadable barcodes, including: Understanding the root cause of unreadable barcodes and using technology appropriately to prepare for or resolve these issues is simple to do and it can mean the difference between success and failure in automation. When poorly-marked or damaged barcodes result in “no-reads” or failures, loss of data can have disastrous effects on product integrity and corporate reputation – not to mention potential legal implications and serious risks to consumer welfare. Item identification and data acquisition through barcodes is critical to the function of automated operations, from ensuring that the correct components are used in the assembly of a smart phone to recording accurate patient data for samples in a laboratory. Understanding, Preventing, and Resolving Decoding Failures
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