Flexibility has become an important priority in the formulation and implementation of manufacturing strategies. This in turn has opened up a new class of design problems for such systems. Flexible assembly systems (FAS), consisting of a variety of processors and operations, provide the opportunity for improving product manufacturing flexibility, hence gaining competitive advantages. This paper considers a particular design decision problem for FAS. A matrix-based, polynomial-time lower bound algorithm is presented. Simulated annealing and tabu search metaheuristics are formulated to address the problems. Computational experience with these metaheuristics is reported.