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Bespoke inspection and reject machine for rivet nut stud assemblies (GESIPA)

GESIPA develops joining technology and processing solutions across blind rivets, blind rivet nuts and associated tooling.
For this project, Barair supported the development of a dedicated inspection and reject solution to help prevent non-conforming rivet nut / stud assemblies progressing downstream, with clear design intent, practical manufacturability, and documentation suitable for sign-off. This project highlights the importance of jigs and fixtures design in ensuring quality control and optimal manufacturing processes, showcasing the critical role of jigs and fixtures design.

Project at a glance

  • Client: GESIPA (UK)

  • Application: Rivet nut / stud assembly verification (automotive-style throughput and quality expectations)

  • Core function: Automated inspection + positive reject of non-conforming assemblies

  • Barair role: Mechanical design, integration approach, verification thinking, documentation for build and commissioning

The problem

In high-volume assembly environments, even a small escape rate (wrong component, incomplete assembly, damage, orientation error, missing features) can create:

  • downstream rework and line stoppages

  • quality containment activity

  • customer returns and brand risk

The requirement was a repeatable, maintainable inspection method that could be integrated into a production workflow and provide a clear “pass/reject” decision.

Key requirements and constraints

  • Defect modes to detect: incorrect assembly and damaged components

  • Inspection method: Vision-based feature checks supported by sensors as required

  • Reject method: Positive reject that prevents mixed output (no “maybes”)

  • Throughput / cycle time: 1-2 Seconds

  • Handling: Robust part presentation (repeatable datum, controlled lighting, controlled orientation)

  • Maintainability: Fast changeover / accessible cleaning / simple calibration approach

  • Safety: Guarding and safe access for jam clearance and routine maintenance

  • Evidence: Documentation suitable for internal review and practical sign-off

Barair’s engineering approach

Barair’s focus was to turn the requirement into a system that is decision-grade (it either passes or rejects with controlled uncertainty), and buildable:

  • Define the acceptance criteria
    What constitutes a conforming assembly, what must be measured/seen, and what is “non-negotiable”.

  • Design the part presentation
    Vision systems live or die on repeatability. The mechanical design prioritised stable location, controlled orientation, and lighting discipline.

  • Integrate inspection + reject as one controlled sequence
    The reject mechanism was designed as part of the process flow, not an afterthought, to minimise false passes and reduce operator dependence.

  • Document assumptions and interfaces
    Clear interfaces for electrics/controls/vision integration, plus practical notes for build and commissioning.

The solution

A bespoke inspection station concept comprising:

  • Controlled infeed / part location (repeatable datums and restraint)

  • Vision inspection envelope (stable lighting geometry, predictable background/contrast)

  • Decision logic (pass/reject thresholds aligned to acceptance criteria)

  • Reject mechanism (positive routing of non-conforming assemblies)

  • Operator-friendly access for maintenance, cleaning, and fault recovery

Outcome

The delivered approach supports:

  • reduced risk of non-conforming assemblies proceeding downstream

  • repeatable inspection driven by controlled presentation and defined criteria

  • practical maintainability (less “tribal knowledge”, more documented method)

Picture of Adrian Lowes BEng(hons) CEng MIMechE ASME

Adrian Lowes BEng(hons) CEng MIMechE ASME

Adrian Lowes is a Chartered Mechanical Engineer and the founder of Barair Systems Limited, with over two decades of experience delivering innovative engineering solutions.

A graduate of the University of Bradford, he has worked on projects from automated vision systems for the automotive industry to oil and gas research with Cranfield University. He has developed products for brands including Microsoft, ICI, Toyota, and Florette. His expertise spans machinery design, finite element analysis, CE marking, and industrial accident investigation.

A lifelong musician, Adrian has directed Skipton Brass and Brass Ten, and served on the Alumni Committee of the National Youth Brass Band of Great Britain. Based in West Yorkshire, he combines technical precision with creative problem-solving in every project.

Where this capability fits

If you’re facing similar needs; automated inspection, error-proofing, or production process stabilisation, this sits within Barair’s broader work in:

Call to action

If you need an inspection station, poka-yoke fixture, or integration support for an automated step, use the Request a Design Review form and share:

  • part drawings and variants

  • defect modes you need to catch

  • throughput targets

  • available space / line interfaces

  • success criteria for acceptance

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