IBC Vehicles, part of the Stellantis Group, is one of the UK’s largest light commercial vehicle manufacturing facilities. Based in Luton, the site produces vehicles for multiple global automotive brands and operates at high production volumes where quality, consistency and efficiency are critical to success.
IBC needed a solution to inspect the rear bump stops during vehicle assembly. The existing process relied on manual operator checks which was slowing down production and causing rework.
The objective was to detect assembly errors and then carry out a corrective intervention. Solutions also needed to improve upon the existing cycle time of 18 seconds.
Following a detailed assessment of the application, Abbey designed and delivered a fully integrated automation solution using a collaborative robot and intelligent vision system.
Our solution combined robotics with a vision system to inspect each bump stop installation. Our engineering team also designed and manufactured bespoke end-of-arm tooling to enable an automatic intervention when a component was not fully seated.
The automated process verifies that the correct part has been fitted and confirms it has been installed correctly. If a part is incorrectly seated, the cobot automatically applies the required force to complete the installation. If an incorrect component is detected, visual and audible alerts are triggered to prevent the issue progressing further down the line.
The entire system was integrated seamlessly into the existing production environment while maintaining operational efficiency.
“Abbey were instrumental in helping us achieve our goals for automating this process. The solution has already delivered in time saving and improvements to quality. Everyone at IBC was impressed with the turnaround time of the project and quality of the installation work carried out”
Kevin Shortt | Manufacturing Chief Engineer
The new automated inspection system delivered immediate improvements in both quality control and production efficiency.
By removing manual inspections and introducing automated verification and intervention, IBC significantly reduced the risk of assembly errors while ensuring every vehicle met quality requirements. The solution also improved production speed, exceeding the original cycle time target and helping maintain throughput across the manufacturing line.
The project was completed in under six months, from concept and feasibility testing through to installation and commissioning, allowing IBC to realise the benefits quickly.
Abbey Industrial Solutions has worked closely with IBC for more than eight years, providing engineering expertise and innovative manufacturing solutions that help improve productivity and operational performance.
By combining manufacturing automation expertise, engineering capability and hands-on project management, we delivered a solution tailored specifically to IBC’s production requirements.
For this project, our team managed every stage of the process, including:
The successful outcome further strengthens a longstanding partnership built on trust, technical expertise and a shared commitment to continuous improvement.
