Mr Price continued: "Not only can we build error proofing into every assembly, but we are introducing error proof management capabilities into the systems. We can now sequence deliveries direct to production lines with the exact part to fit the exact vehicle going down the line, supplied by us just-in-time."

"This isn't just a step forward in automotive production, this is a worldbeating first and everything has been developed by us in-house with the full involvement of our disabled workforce."

Remploy Automotive was set up as a division of Remploy Limited two years ago and has expanded rapidly. It has grown from six to nine factories, has a workforce of more than 500 people, the majority of whom are disabled, and a turnover in excess of £50 million.

The intelligent jigs typically include as many as 70 individual quality checks. The job cannot be released from the machine until every check has been carried out and verified. Printed compliance stamps can also be added to each component.

Critical functions carried out include the correct orientation and presence of individual parts, torque settings on bolts and screws, leakage tests on emission sensitive parts and the correct operation of electrical components.

The intelligent jigs are already being used for contracts Remploy Automotive has won from Aston Martin, Honda, Jaguar, Land Rover, MG Rover, BMW MINI and JCB.

They are used for making components such as thermostat assemblies, water passages, fuel burning heaters, fuel pump and filter systems, mounting brackets, charcoal emission canisters, heaters and many more.

Remploy Automotive has now developed more than 70 of the jigs, each tailored to individual jobs, which are used in its factories at Kitts Green in Birmingham, Coventry, Bridgend and Stoke-on-Trent.

Audio and other systems built into the Remploy Automotive intelligent jigs allow blind and deaf employees to use the devices with 100% accuracy.

www.remploy.co.uk