The assembly of fuel cell stacks presents some unresolved engineering challenges. The aim of this work is to provide a comprehensive solution concept that addresses the identified issues. A product analysis was conducted, from which the assembly process chain could be derived. Subsequently, the problems encountered during assembly were structured and presented. Finally, a solution concept was developed that addresses both the overarching problem and the process-specific difficulties. The analysis shows the necessity of a cost degression of the stacks through full automation of the assembly systems. However, this represents a significant economic risk, which is why a scalable assembly in terms of automation level is proposed. The problem of process complexity and a generally low level of product knowledge is addressed by the introduction of cognitive and physical assistance systems in the low automation stages. To increase the speed of knowledge building in terms of product, process and equipment, algorithms for self-optimizing processes or for outputting action recommendations are used. The control complexity arises from high speed and accuracy requirements of the stacking process, which is addressed in a novel approach using continuous drive technology.