DFM, process development, conceptualization, building, and launch of manufacturing lines for HV battery packs and subcomponents in all global Tesla factories

Five total manufacturing lines launched across Fremont, Shanghai, Austin, and Berlin factories. Was responsible for all phases of manufacturing equipment lifecycle: DFM, process development, RFQ, concept/build, installation, commissioning, testing/approval, handoff.Direct management of engineers and interns.

Equipment design and testing; powder coating process creation and implementation; capital equipment design and fabrication; novel powder coating process Chinese vendor selection/qualification/validation/production ramp in 2.5 months.

Process and equipment development, commissioning, and maintenance of 140 HC powder coating and post-processing line during Model 3 production ramp. Installation of automated equipment, maintenance instruction creation and PM system enforcement, manufacturing instruction development and training, process development through experimentation and data collection, powder coating process validation and optimization, equipment and tool design and implementation.

Process, product, and control development through data and root cause investigation. On-site powder coating development with vendor for 3 months. PFMEA and Control Plan development for four separate production lines (powder coating, energy product assembly, battery module assembly), first pass yield and scrap rate improvement through investigation and data science, supplier quality relations, tool and check fixture design and development.

Active problem solving and root cause analysis on several production lines. Data collection, spec recommendation and enforcement, manufacturing instruction and process development, gauge design and fabrication.

Product Creation, Marketing, Web Development, Business Administration, Networking, Company DirectionDeveloped a subscription consulting service for alternative fuels, including eBook, website, Shopify cart, A/B market testing, Google and Facebook ads, financial system setup, business registration, and tax filing.

Responsible for:-Plastic injection molding quality control-Inspector training and management-Six Sigma control

-Daily Operations-Food prep & baking-Customer service & sales-Hiring & management-Marketing

Start a new club from scratch, with no precedent to work off of, with the help of a few other enterprising students.- Project technician and manager – Audi A8 methanol fuel conversion, Honda XR100 methanol fuel conversion, tractor waste vegetable oil tank and fuel system addition, automated biodiesel reactor programming and testing, large 6-tank biodiesel reactor redesign and testing, solar-powered waste vegetable oil filtration system. The last four of which were managed concurrently with working teams of 5-7 each.- Research – paper and published article on the benefits of methanol as an alternative fuel; led research into catalysts for the depreciation of formaldehyde in methanol combustion exhaust.- Outreach – held yearly exposition for alternative fuels and green technologies, the largest of which was May 2015 where 20 cars were shown, 26 exhibitors had booths, 2 bands played, food was sold, and cars were test driven by an estimated audience of 3000.- Business Administration – recruited and managed group up to 20 people, set up administration system, led educational and board meetings, acted as liaison to overseeing groups including Cal Poly, the State of California, and City of San Luis Obispo.

Developed skills throughout precision metal job shop:-Turnkey assembly-Spot Welding-Arc Welding (TIG, MIG) - passed shop certification test-PEM Hardware Installation-Machining-CNC Punch Press Programming and Operation-Sales Operations-Production Planning

-Drafted and edited grant proposals; presented and defended in front of city council-Worked public relations events, spreading awareness of mission and key government decisions-Educated the public in the field, as well as enforced regulations-Performed community service,such as fauna management, trail building, and storm damage road repair