Shifts in the automotive marketplace from price based competition to value added competition (such as quality, short delivery lead time and product variety) have increased the need for developing effective final assembly sequencing methods. Further, recent trends such as component modularity, and high frequency just-in-time deliveries tightened the operational linkages in the supply chain between the assembly plants and suppliers. These factors contribute to the need for not only developing effective assembly schedules, but also developing methods to eliminate the deviations from the planned sequence.
In this paper, we identify and discuss major issues (such as quality, load smoothing in the final assembly line, leveling material requirements from suppliers, and operational economies resulting from batching operations) to be considered in developing final assembly schedules. Then we review causes for deviations in the actual sequence from the planned sequence (process variations, scrap, and rework etc.), and how these deviations impact costs. We also discuss methods for evaluating the effectiveness of planned final assembly sequences, and measuring the actual sequences. Future research directions are indicated.