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Purpose

This paper seeks to describe a new flexible, robot‐based welding line, installed at an American DaimlerChrysler vehicle assembly plant.

Design/methodology/approach

This paper first considers the motivations behind flexible manufacturing strategies (FMSs) and then describes a system installed at the Sterling Heights DaimlerChrysler plant.

Findings

This paper shows that the adoption of robot‐based flexible assembly allows different models and model variants to be assembled on a single line, yielding operational, commercial and financial benefits.

Originality/value

This paper illustrates the value of adopting an FMS at a vehicle assembly line.

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