Portuguese footwear industry has improved dramatically to become one of the main world players. This work is part of a project in cooperation with a large footwear company, operating a new automated assembly equipment, integrating various lines. Balancing such lines implies going from an almost manual preparation executed by experienced operators, to a planning supported by optimisation systems. These complex mixed-model lines have distinctive characteristics, which make balancing a unique problem. The paper proposes the ASBsm – Assembly System Balancing Solution Method, a new method that integrates a constructive heuristic and an improvement heuristic, which takes inspiration from Tabu Search. The solutions obtained, based on real instances, are quite encouraging when compared with other effected factory solutions. Consequently, the balances obtained by ASBsm are now being implemented and articulated with sequencing methods.