Hand Assembly vs. Automated Assembly: How to Choose the Best Method

Ever since automation entered the market, companies have debated whether or not to turn over their manual processes to machines. Because every product is different, it’s hard to know at a glance what type of assembly method is ideal, especially if you’re unfamiliar with automation.

To add to the pressure, many companies are being asked to automate outdated processes to boost efficiency. However, automation isn’t a silver bullet and comes with several considerations. This guide will explain the differences between hand assembly and automated assembly, focusing on the best applications for each, along with their inherent advantages and disadvantages. 

Hand Assembly vs. Automated Assembly
The hand assembly process involves human teams handling and assembling components directly. In some production lines, this may mean having a system of individual workbenches for each stage of the assembly process. More often, it means having a singular assembly line with a manual transfer conveyor, where employees manually move parts down the line until the finished product is assembled. Because it involves people working directly with the product, this assembly method often requires teams to have specialized, technical skills.

Automated assembly limits or fully removes human interaction from the manufacturing process. In a fully automated process, parts are loaded into automated feed systems that control the entire assembly process, from testing to unloading.

Neither method is inherently better than the other, but each has their own strengths and weaknesses.

Pros and Cons of Hand Assembly
Hand Assembly Advantages:

• A human is always in the loop. If there is an issue in production, teams can address it quickly.
• Hand assembly is well suited to low-volume production, making it ideal for custom products or prototypes. 
• For very complex designs with intricate or irregular components, automation may not be possible. 
• Companies need a lower initial investment to begin hand assembly.
• This method offers more flexibility if product designs need to be updated.

Hand Assembly Disadvantages:

• Low-volume manual assembly isn’t suited for mass-produced production lines where speed is the priority.
• There’s always the risk of human error during assembly.
• This method can be difficult to scale over time.

Pros and Cons of Automated Assembly 
Automated Assembly Advantages:

• Automation can match the needs of high-volume, high-speed production.
• Automation can sometimes be easier to scale.
• Product timelines can become much more consistent and predictable with automated assembly.
• Automated systems offer advanced process monitoring capabilities.
• Automated systems can provide succinct data that analytics teams can use for assembly line optimization.

Automated Assembly Disadvantages:

• Automation may not be able to manufacture specialized, custom parts.
• There’s less flexibility if designs need to be altered quickly.
• Automation often requires a higher initial cost to get started.

Material Considerations for Manual vs. Automated Assembly
Material type is another important consideration when choosing an assembly method. Every plastic has different characteristics, and some are more suitable for one assembly type than others. Properties like impact resistance and thermal stability can influence which materials work in which contexts, so it’s important to test a given material’s compatibility with an assembly method before committing to a full run. 

Choosing an Assembly Method for Manufacturing
Choosing the right method for your business isn’t a one-size-fits-all kind of thing. If you’re working on a small-scale batch of prototypes or custom products, manual assembly may make the most sense from a budget and resources perspective. The higher volume you go through, the harder this method is to scale effectively. If you plan to mass-produce your products, or if they require rigorous precision standards to meet regulations, automation may be the preferred option.  

If you’re wondering when to use hand assembly vs. automation, consider calculating your potential short-term and long-term ROI for each method. This can give you a jumping-off point to discuss with your team.

Alltrista for Manual and Automated Assembly
Whether you’re looking for manual or automated assembly for your next project, we can help. Our decades of experience in product development allow us to bring almost anything to life. From initial design and engineering to new product introduction, we help support teams from start to finish. The Alltrista team of experts can help you determine which assembly method is right for your product and processes.

Once your product is ready for production, our assembly, filling, and kitting services let you delegate your manufacturing needs to our experts, so you can save money, time, and stress. Learn more about your assembly options with Alltrista here.