Tesla Model-Y Automation Line
Program Overview
Ongoing Role - More to ComeI drove cross-functional execution for the Tesla Model-Y door-hinge automation line, a $10M program with critical strategic importance. My role involved managing system architecture, mechanical integration, and vendor coordination under extremely tight timelines to ensure successful delivery from design through onsite integration.
Project Media
Bottleneck Resolution
Resolved a critical project bottleneck where final assembly parts were failing tolerance checks, specifically at the dowel locations in the Y direction. Due to significant part variation, consistent clamping was impossible, leading to machining errors.
I developed a regression-based machining offset model using airgap sensors to analyze the part's tilt and seating position. This allowed for intelligent, dynamic adjustment of machining parameters, correcting systemic tolerancing issues and reducing the machining range by 25% while ensuring we complied with our contract.
Custom Tracking Framework
Architected and built a custom project management framework using weighted task tracking and automated velocity charts. This tool provided granular visibility into the system integration phase, enabling the team to clearly define new work packages, accurately track week-over-week progress, and predict schedule slips before they impacted the critical path.
The framework became the single source of truth for cross-functional alignment, facilitating better resource allocation and risk mitigation during the high-pressure ramp-up phase.
Strategic Negotiation
Negotiated scope changes with the customer through data-backed trade-offs, protecting cost and schedule while saving $500K in costs.
Example: The initial plan relied on an LMI laser scanner to measure the forged body relative to a fiducial representing the door leaf. However, this proved unreliable because the part would "walk" or shift at each station when engaged by the toggle clamps. I validated an alternative approach using airgap sensors, proving that parts seated within specific thresholds (based on airgap data and surface flatness) would guarantee machining accuracy, securing customer buy-in for this robust solution.
Executive Reporting
Reported directly to Eclipse’s CEO and executive leadership team, escalating risks and delivering concise, data-driven updates on cycle-time, quality, and program status.
More to come...