IN THE CURRENT ENVIRONMENT OF AUTOMATED ASSEMBLY MACHINES, SIMULTANEOUS ENGINEERING CONSTRAINTS HAVE MADE IMPLEMENTATION OF CONTROLS SYSTEMS MORE COMPLEX. AUTHORITIES IN THE AUTOMATION INDUSTRY RECOMMEND THE USE OF COMPUTER SIMULATION AS THE KEY TO PROPERLY DEALING WITH THIS PROBLEM. THIS PAPER PRESENTS A PRACTICAL AND AFFORDABLE ALTERNATIVE TO THE COSTS AND COMPLEXITY OF COMPUTER SIMULATION. THE METHODOLOGY PRESENTED STRESSES THE APPROPRIATE APPLICATION OF SKILLED BRAIN POWER RATHER THAN COMPUTER POWER IN THE IMPLEMENTATION OF CONTROLS SYSTEMS. A SEVEN-PHASE PROCESS IS DESCRIBED THAT RESULTS IN CONTROLS DESIGNS THAT ARE EASY TO UNDERSTAND, MANAGE, AND MODIFY. THE CONCEPTS PRESENTED ARE REAL-WORLD AND ARE CURRENTLY BEING APPLIED TO ASSEMBLY SYSTEMS. THE METHODOLOGY'S ULTIMATE GOAL IS IMPLEMENTATION OF CONTROLS SYSTEMS THAT ARE CORRECT AND WORKABLE BEFORE INTEGRATION WITH THEIR ASSOCIA