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The design for an assembly line is determined by analyzing the steps necessary to manufacture each product component as well as the final product. All movement of material is simplified, with no cross flow, backtracking, or repetitious procedure. Work assignments, numbers of machines, and production rates are programmed so that all operations along the line are compatible.
An automotive assembly line starts with a bare chassis. Components are attached successively as the growing assemblage moves along a conveyor. Parts are matched into subassemblies on feeder lines that intersect the main line to deliver exterior and interior parts, engines, and other assemblies. As the units move by, each worker along the line performs a specific task, and every part and tool is delivered to its point of use in synchronization with the line. A number of different assemblies are on the line simultaneously, but an intricate system of scheduling and control ensures that the appropriate body type and colour, trim, engine, and optional equipment arrive together to make the desired combinations.
Automated assembly lines consist entirely of machines run by machines, with little or no human supervision. In such continuous-process industries as petroleum refining and chemical manufacture and in many modern automobile-engine plants, assembly lines are completely mechanized and consist almost entirely of automatic, self-regulating equipment.
Many products, however, are still assembled by hand because many component parts are not easily handled by machines. Expensive and somewhat inflexible, automatic assembly machines are economical only if they produce a high level of output. However, the development of versatile machinery and the increased use of industrial robots have improved the efficiency of fully automated assembly operations.
