Why is the sensor missing production counts?

Updated July 08, 2026 12:17

If your sensor is missing production counts, the most likely cause is that the sensor's detection distance has been configured too short. As a result, some products may not enter the detection area and will not be counted.

You may need to retrain the sensor following this approach:

Remove all objects from in front of the sensor.
Press the TEACH button quickly (between 25 ms and 1 second).
Place an object at the position where products will normally pass through the sensor.
Press the TEACH button quickly again.
Wait for the sensor to display Success.
After teaching is complete:
The sensor automatically sets the detection threshold between the background and the detected object.
If no object is detected during one of the teaching steps, the sensor automatically uses the maximum detection distance (150 mm for HL150 or 500 mm for HL500) as the teaching point.
This is the default and recommended teaching method for most production counting applications.

If you have done this and are still experiencing issues, we recommend sending us a recording showing what your setup looks like along with product/items passing through the sensor.

An orange sensor light remaining on while a product is in front of the sensor is expected behavior. The sensor only registers a single count for each detection event, regardless of how long the product remains in front of it.
If products are consistently being missed, the sensor may need to be taught again using a shorter detection distance. A common recommendation is to teach the sensor using a hand or similar object positioned around the middle of the conveyor, rather than using the product itself. This helps ensure all products enter the sensor's detection zone.
For more information, feel free to look at Omron's sensor guide here

An orange sensor light does not indicate multiple counts or a sensor fault.
An incorrect sensor teaching distance can result in missed counts.
This guidance assumes the hardware is functioning correctly and the issue is related to the sensor configuration.