ARTICLES YOU MAY BE INTERESTED INAbstract. This paper provides a design procedure for the bypass subline in a mixed-model assembly line. The bypass subline is installed to reduce the effect of the large difference in operation times among products assembled together in a mixed-model line. The importance of the bypass subline has been increasing in association with the rising necessity for efficiency and flexibility in modern manufacturing. The main topics of this paper are as follows: 1) the conditions in which the bypass subline effectively functions, and 2) how the load should be distributed between the main line and the bypass subline, depending on production conditions such as degree of difference in operation times among products and the mixing ratio of products. To address these issues, we analyzed the lower and the upper bounds of the line length. Based on the results, a design procedure and a numerical example are demonstrated.