SAI KIRAN HANUMAKONDA

Master's

Industrial Engineering

Tesla

Process ENgineer

• Saved $750K in annual costs and increased the yield 75% by initiating and standardizing new material flow process in the paint shop. • Automated the breakdown analysis model and designed dashboards to track KPIs: downtime, UPH, FPI, scrap, and rework quantities. • Gathered and analyzed airflow data to predict the yearly requirement of filters; worked with vendors to reduce overall cost by 30%. • Developed a visual tool to measure Overall Equipment Effectiveness (OEE) by grouping data from multiple disconnected sources. • Introduced standardized work instructions for the loading zone in the South Paint to enhance the efficiency and safety of the process. • Conducted cycle time study for various stations and identified critical paths by creating Gantt Charts and Yamazumi for visibility. • Analyzed production planning data to streamline manufacturing process to achieve the milestone of 5000 model 3 cars in a week. • Established performance indicator by analyzing data to identify root causes and resulting 20% increase in First Pass Yield (FPY). • Collaborated with the design and production team to validate plastic part design, reducing fallout by 50%.