● 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.