How Zenni Optical Built a Faster, Smarter, More Scalable Fulfillment Line

California-based eyewear brand Zenni Optical has built its reputation on delivering affordable, high quality eye glasses to millions of customers worldwide. With annual sales of six to seven million pairs—and double digit growth every year—the company’s distribution and fulfillment operations must run with precision and speed.

“Anyone wearing eyeglasses is our customer,” said Simon Goh, Director of Distribution and Facilities at Zenni Optical, who explained that as volume increased, so did the critical need to scale smartly.

Zenni had explored robotics for years, but earlier solutions lacked the flexibility and intelligence required for their unique packaging workflow. The challenge centered on reliably scanning barcodes through Zenni’s branded eyeglass cases—something traditional systems struggled to do consistently at high speed.

That changed when Zenni discovered OSARO.

“When it comes to machine learning, AI, and vision, OSARO actually has an all in one solution,” Goh explained. OSARO specializes in warehouse automation, focusing on applications like kitting, depalletization, and robotic bagging. For Zenni, OSARO deployed a robotic bagging cell powered by FANUC industrial robots and OSARO’s machine learning driven perception software.

The robotic cells pick up each pair of eyeglasses in its protective case, scan the unique barcode through the case, and place the item into an automated bagging machine. The system then seals the package and sends it directly into the shipping stream.

To achieve the required scanning accuracy, OSARO integrated Cognex vision technology alongside FANUC robotics and industrial automation components from long time partners FANUC and PreciTaste. The combination delivered the reliability Zenni needed.

“The scanning part is crucial,” Go noted. “Once OSARO brought in the Cognex scanner, scanning became the least of our concerns.” Before automation, the packaging workflow required five manual steps. With the robotic system in place, Zenni reduced manual steps to just two.

“We always try to get to 100% accuracy, which is very difficult,” Go said. “But the robot’s design and process reduce errors to nearly zero.”

OSARO’s HyperCare™ customer success model ensured Zenni had hands on support throughout installation, commissioning and ongoing operation. “We have to integrate with so many different pieces of equipment,” Go said. “It would be impossible without a professional company like OSARO.”

Since deployment, Zenni has seen an 80% increase in throughput, along with more consistent quality and a more scalable fulfillment process. With automation proving its value, Zenni is well positioned to continue expanding its product offerings and customer base.

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Our customers and potential customers can see we’re committed to the future. Our willingness to commit to automation makes a statement that says we’re going to be around a long time.

Simon Goh Director of Distribution and Facilities – Zenni Optical