How do you design a flexible assembly system capable of producing multiple vehicle architectures?

Flexible assembly design: 1) Common process architecture - identify operations common across vehicles (marriage, fluid fill, test) versus model-specific (trim variations); 2) Tooling flexibility - programmable fixtures adjusting to different bodies, quick-change tooling, universal assist devices; 3) Conveyor systems - flexible spacing, multiple body sizes on same line, intelligent routing; 4) Parts flow - kitting systems delivering model-specific parts, flexible storage and retrieval; 5) Information systems - build data driving tool settings, part selection, and verification; 6) Workforce flexibility - cross-training, team-based assignments accommodating mix changes. Investment analysis compares dedicated versus flexible equipment. Simulation validates mixed-model sequencing, identifies constraints, and optimizes scheduling. Change management processes ensure quality through model transitions.