Analysis of a product’s assembly properties is needed during the initial design stage in order to identify potential assembly problems. These problems affect product performance in the later stages of a product’s life cycle. An analysis methodology has been developed that supports product design analysis for assembly during the initial design stage. The methodology, referred to as the Assembly Design Evaluation Metric (ADEM), utilizes the incomplete nature of initial design data and a generic model of assembly operations in the analysis of a product design. ADEM generates ratings for each component of a product design and each process that would be needed to assemble the components together. From the individual component and process ratings, ADEM computes overall ratings for the product design itself. These overall product ratings can then be used to compare the differing iterations of a product design. Because ADEM provides an explicit model of assembly operations, different levels of data and process abstraction can be maintained and analyzed. This enables ADEM to evaluate product designs earlier in the design stage than existing design analysis methods such as DFA (design for assembly) techniques.