Introduction
The assembly line is a great achievement in modern manufacturing. Since the Industrial Revolution, it has allowed manufacturers to make goods at an unprecedented pace and scale. In the last 10 years, however, the assembly line itself has undergone something of a revolution. With new digital technologies now commonplace in factories, the assembly line has had to adapt. This post will give a quick history of it and describe how new technologies are transforming it, altogether.
What is an Assembly Line?
Let us briefly go over the very definition of it. It is a manufacturing system or systems in which work-in-progress moves from station to station in a sequential fashion. At each workstation, new parts are added, or new assemblies take place, resulting in a finished product at the end. Assembly expedited the entire manufacturing process by conveying semi-finished products from process to process. This was a massive improvement to previous methods, in which complex production routing and disconnected processes added complexity to assemblies.
Further, it enabled workers to develop process-specific expertise that helped full lines work more efficiently. As a result, manufacturers could finish complex products like cars, aircraft, and industrial machines at a faster rate with more precision than ever before.
A Short History
While some forms of assembly lines have existed for thousands of years, it was only in the last 100 that they became a mainstay in factories. It helps to understand how manufacturing processes were designed before its advent. Prior to the Industrial Revolution, objects were often manufactured from end-to-end by single artisans. If a given assembly required 20 parts and 30 steps to manufacture, a single individual would work through the assembly in order, until they produced a finished product.
How did assembly lines make mass production possible?
With the industrial revolution, manufacturers began to place operators on specialized tasks. So rather than complete a single object, they would specialize in a single process. For example, cutting, lathing, or a particular manual assembly. By the early 20th century, all of the parts were in place for the modern assembly line to emerge. With the advent of interchangeable parts, electric conveyor belts, and new types of machining processes, assembly lines were poised to make the world.
The Henry Ford Era
The automotive plant is the first thing many people think of when they hear “assembly line.” Henry Ford of Ford Motor Company is often credited with inventing it. There’s some dispute, however, as to whether or not Henry Ford invented the automotive assembly line. In reality, many manufacturers were experimenting with assembly line systems in the 20th century. Ransom Olds, an early innovator in the automotive industry is credited with inventing the first automotive assembly line system. The consensus among historians seems to be that while Ford wasn’t first, he did do more to advance the assembly line than his contemporaries.
Ford set ambitious production goals, set faster production rates than his peers, and made a science of assembly line design and line balancing. On Ford’s assembly lines, an empty chassis became a complete car in a matter of hours, not days. This precedent was quickly imitated and improved by competitors, leading to a rapid evolution in manufacturing processes. By mid-century, millions of cars rolled off Ford’s unit, paving the way for America’s auto-first transportation culture.
Soon, the optimized assembly lines spread to other industries. By mid-century, these were present in industries beyond discrete manufacturing, including chemicals, oil, and other continuous manufacturing industries. The assembly line–or at least a more sophisticated iteration–is a fixture in manufacturing across industries and product specializations.
Evolution with automation
While assembly lines made some manufacturing processes significantly more efficient, some manufacturers looked for new ways to improve accuracy and lower costs. Thus, as various forms of automation matured over the course of the 20th century, manufacturers incorporated them into their processes. Gradually, automated tools began to take over simple, repetitive tasks. Over time, the amount of automation increased significantly.
While there are examples of fully automated assembly lines, most of it are mixes of humans and automated labor. Humans perform the assemblies and tasks that are too sensitive or complex for machines, while machines do the work that’s too repetitive, dangerous, or error-prone for humans.
The Legacy
So, how have the industries benefited from assembly lines? Below are some areas to note in this regard:
| Mass production & Safer working conditions. | Consumer market friendly automobile pricing. |
| Bolstered the United States position as an economic power. | Higher wages for workers for much of the 20th century. |
The Future
Just as the invention of steam power instigated an industrial revolution in the 18th century, digital technologies are sparking a new industrial revolution today. While it’s tempting to imagine the future of the assembly line as a fully automated endeavor, the reality is a little more complex. The biggest advances in assembly line production will come less from automation and more from increased visibility into industrial processes.
Indeed, modern assembly lines are close collaborations between humans and machines, coordinated by applications, not unlike those you find on your smartphone. With IIoT, big data, computer vision, and other Industry 4.0 technologies, it continues to feature some of the most advanced technology on the planet.
Features of the Modern Assembly Line
In modern assembly lines, sensors and IoT devices continuously collect real-time data from both humans and machines, improving overall efficiency. Advanced robotics and collaborative automation enable closer interaction between workers and machines, allowing for more seamless operations. Unlike traditional linear assembly lines, many modern systems dynamically route work between different lines and cells based on needs. Additionally, high demand for customization and sophisticated error-proofing technology allows these lines to produce hundreds of product variants, offering greater flexibility in manufacturing.
Summary
The article traces the evolution of the assembly line from manual, artisan-based production to its transformation during the Industrial Revolution, led by figures like Henry Ford. It highlights how automation has optimized production over time, blending human labor with machines. Today, advanced technologies like IIoT and robotics are making it more flexible, efficient, and collaborative, with future innovations focusing on improved data visibility and human-machine coordination.
Please note, not to cite the above blog by Dropslab as an academic reference, It is for information purposes only.
FAQs
What is an assembly line, and how does it work?
An assembly line is a manufacturing system where work-in-progress moves sequentially from one station to another. Each workstation adds parts or completes specific tasks, leading to a finished product, saving much time.
How has automation transformed assembly lines?
Automation has transformed it, making it much more efficient. This has been made possible by taking over repetitive, dangerous, or error-prone tasks.
What technologies define modern assembly lines?
Modern assembly lines leverage technologies such as the Industrial Internet of Things (IIoT), big data, computer vision, and advanced robotics. These systems enable real-time data collection, dynamic workflow routing, and error-proofing, offering flexibility and customization in manufacturing.
