● Supported high-volume mass production of Tesla Model Y Headliners and Liftgate assemblies, sustaining 3,000+ parts/day across automated lines operating 2-3 shifts.

● Owned SCAR and SORT execution, Defect analysis, and customer containment actions, driving overall defect reduction 43% to 26%, rework reduction from 52% to 38% and scrap reduction from 4.5% to 2.8% in 5 months

● Performed SPC and Cpk analysis on Headliner assemblies and Liftgate Upper process; improved Liftgate Upper Cpk from 1.43 to 1.96 through tolerance optimisation without impacting throughput.

● Developed Defect Heatmaps, Pareto analyses, and executive dashboards used by upper management to prioritise corrective actions and allocate resources across Production, Manufacturing, CI and Customer Team.

● Drove SWI improvements, including redesign recommendations for the KAB drop-test gage to improve part retention and test repeatability following impact.

● Supported ISO9001 and automotive quality audits, maintaining document control compliance and closing minor audit findings.

• Designed and implemented noise abatement solutions for the CFA System, achieving a 15 dB noise reduction through acoustics and vibration evaluation, enhancing system performance.

• Optimized calculations for the Electrolyte Transfer System, improving flow efficiency and scalability for massive-scale battery production.

• Conducted Computational Fluid Dynamics (CFD) simulations to evaluate airflow dynamics and thermal characteristics in battery packs, contributing to improved design accuracy.

• Supported commercial emissions analysis to ensure compliance with CAL-OSHA air quality and workplace protection guidelines, maintaining regulatory standards.

• Collaborated with cross-functional teams, including method engineers and automation professionals, to improve manufacturing performance and thermal control in HVAC system procurement.

• Developed and deployed Tableau dashboards for real-time tracking of Kaizen implementation and worker development, which enhanced decision-making for senior management.

• Conducted assessments on Lean Manufacturing concepts, identifying inefficiencies and proposing system improvements for manufacturing workflows.

• Evaluated the effectiveness of Daily Work Management (DWM) across 120+ employees, leading to improved operational efficiency.

• Assisted in Product Lifecycle Management (PLM) strategies, ensuring streamlined layout-to-production transitions with optimized BOM control.

• Supported data-driven process optimization initiatives, improving manufacturing throughput and resource allocation.