Our customer has a blow molded automotive gas tank, final assembly operation. Our scope included time study of each station broken down by element. The processes included manual and semi-automatic operations with analysis of the man-machine interface. A process model for production line balancing was developed to indicate where better methods would result in reduced cycle time and labor content. Recommendations for improvement opportunities, lean manufacturing, ergonomics and cost reductions have been implemented. Future concepts for phase two assembly rearrangements with reduced labor were also developed.