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The benefits of integrated design and manufacturing systems in mid to high volume production are widely accepted. The low production volume, large component size and high complexity product domain is less well served by this technology. Examples of this kind of product are machine tools, ships, aircraft and buildings. Design for assembly techniques are a method by which design and manufacture can be integrated and aid the realization of full‐process concurrent engineering. Quantifies the significance of this product domain to the UK economy, describes the particular nature of these designs for assembly processes, reviews existing work in the field and specifies the problems encountered. Defines an industrial and academic solution programme. Proposes an integrated approach to applying design for assembly to this repetitive direct engineering domain.

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