This paper presents a total automation scheme for the manufacturing of headliners, optimizing quality, while maintaining minimum amount of labor for low cost manufacturing. The system approaches a “lights out” concept of manufacturing. The system consists of automated manufacturing lines providing flexible manufacturing, control, and diagnostics, SPC, process status and tracking with each cell operating as a separate manufacturing entity monitored by a communication network. Cell controllers provide control coordination, data collection, and downloading of component programs. An automated guided vehicle (AGV) material handling system provides transport and inventory control of materials. A factory management computer system provides dynamic scheduling, inventory control, SPC/SQC data collection and production analysis. A communication network provides an interconnection of all automation components including assembly plant data with the future potential of office work station connection. The automated scheme complies with all goals and guidelines targeted for a cost effective flexible automated manufacturing scheme.