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Examines the development of a flexible assembly machine, GENASYS[Generic Assembly System] which has been designed to produce a range of components. The machine comprises two manipulator arms, a tool changer and a shuttle system for the pallets on which the assembly operations are performed. Each manipulator is able to select a different tool from a carousel tool change mechanism that can accommodate up to 20 different tools. The machine can easily be programmed for a specific assembly operation and low batch numbers can be produced economically. Timescales for the design and installation of the machine are considerably shorter than for a dedicated assembly line and once installed in a factory new product variants can be accommodated within very short timescales and with low‐retooling costs.