Launch of Model 3 General Assembly
Model 3 GA is a highly automated, high volume production line.
During the launch of the line, several strategic projects were commissioned to unlock full line throughput.
I worked on the successful completion of these projects in Door On, Doors Off, Door Line, Glass Assembly stations predominantly - all fully automated.
My projects ranged from redesigning automation systems from new learning at launch, to designing equipment upgrades, implementing continuous improvements, fixing bottleneck stations and launching new processes.
I collaborated across various teams - production, design, controls, maintenance, line side logistics (specifically supply of materials into automation cells), fabrication silos; enhancing my overall expertise in factory design.
Key Contributions
Diagnostic & Tool Design
Utilized CATIA V5 and Atlas Copco Torque Tools Automation Software to diagnose issues with automated doors installation and design production tools.
Automation System Improvements
Developed PLC flowcharts, HMI dashboards, robot programming, and automation process design for the optimisation of various cells.
Part Outflow System Redesign
Re-designed and implemented a part outflow system for the quarter glass assembly cell, improving efficiency and material flow.
Root Cause Analysis & Troubleshooting
Conducted in-depth root cause analysis to diagnose and resolve issues in bespoke automated door handling equipment.
Process Rebalancing
Re-optimized automation cells with minimal impact to production, ensuring improved cycle times and efficiency.
Data Analysis & Process Insights
Leveraged a custom MES package for data analysis, identifying trends and optimizing system performance.
Glass Installation - One of my main automation cells
Check out this to really see why the Fremont Factory is often described as an engineer’s theme park. Start at 6:44 for AVGs