This is the first year base funding of a five-year National Science Foundation Young Investigator Award. The overall goal of this research is to establish a science base for automated assembly by analyzing its basic components. The research involves development of algorithms and interactive systems that analyze the low-level geometry of assembly lines and their components, such as part feeders, sorters, and fixtures. An underlying theme is the use of simple sensors and actuators such as light beams and parallel-jaw grippers. Although the hardware bears a close resemblance to existing "hard'' automation systems, this research introduces computational methods to rapidly configure and reliably control this hardware. At a higher level, modular components such as flexible feeders and conveyor belts are interactively configured to facilitate the design and evaluation of assembly lines prior to installation. The research addresses basic theoretical questions such as the complexity and completeness of algorithms and involves several companies in efforts to transfer basic results into industrial practice.