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Market turbulence forces assembly plants to constantly adjust their production volume of products, variants and quantities. At the same time, assembly plant managers must protect long‐term investments in the flexible assembly system. For reconfigurability and agility the best solution is the modular semi‐automatic approach by combining flexible automation and human skills. It gives managers possibility to adjust volume by adding new modules or to automate the manual tasks step by step. The control of material handling and information flow in the agile assembly system is important. To keep flexibility, the combination of an intelligent pallet, i.e. use of escort memory, carrying a single product together with other hardware providing paperless production even supports a lot size of one. The article shows how to create flexible capability and capacity in the final assembly systems.

Market turbulence drives assembly plants to constantly adjust their production volume of products, variants and quantities. At the same time, the assembly plant managers must protect the long‐term investments in the flexible assembly system. The best solution is the modular approach, which gives managers possibilities to adjust volume by adding new modules or to automate the manual system step by step. To keep flexibility, the combination of intelligent pallet, i.e. use of escort memory, and individual product together with other hardware providing paperless production supports even lot size one.

For such a small country Finland has a strong programme of R&D in assembly processes. In this article, projects to assemble water taps and wire harnesses are described.