Tesla is a global leader in electric vehicle manufacturing and energy solutions, known for pushing the boundaries of innovation in battery technology, automation, and sustainability. The Fremont Factory is one of Tesla’s most critical manufacturing hubs, producing battery packs and vehicle components at an immense scale.

In the summer of 2022, I joined Tesla’s Battery Manufacturing Engineering team as an engineering intern, working in the maintenance and manufacturing engineering department for the battery production lines. My work focused on reducing downtime, increasing throughput, and improving reliability within the factory’s battery pack assembly. Over the course of my 12-week internship, I contributed to multiple projects aimed at predictive maintenance, failure analysis, and process improvements.

One of the biggest challenges in Tesla’s battery manufacturing was the reactive maintenance approach—fixing failures only after they happened, leading to costly downtime. My main project was to develop a condition monitoring system that could predict failures before they occurred, allowing for proactive maintenance scheduling.

I first explored designing a custom vibration monitoring system using a Raspberry Pi, accelerometers, and 3D-printed components. While this approach worked in testing, it was not scalable for the factory’s needs. I determined that the most effective solution was to contract a specialized company to provide an integrated condition monitoring system. This required extensive research, sourcing reputable vendors, and evaluating cutting-edge proprietary technologies beyond traditional accelerometer-based monitoring.

To move forward with this initiative, I was responsible for handling vendor selection, NDAs, facility access, and CAD file sharing. I worked directly with external companies to coordinate private tours, gather technical requirements, and ensure compatibility with Tesla’s existing control systems. Although my internship ended before full implementation, I documented my findings and transitioned the project to a full-time engineer to see it through to completion.

One of the recurring mechanical failures in the facility was a pulley shaft failure on a conveyor belt system. After multiple failures in a short period, I worked with the team to analyze the cause, install a replacement, and develop a long-term solution.

I modeled the failed shaft and its loading conditions, then used FEA simulations to determine what forces led to its failure. Through this analysis, I discovered that the work instructions did not specify proper belt tensioning, which was leading to excessive stress on the shaft. Using my findings, I updated the work instructions to include proper tensioning guidelines, preventing future failures and improving equipment reliability.

Clear and accurate work instructions are critical in a fast-paced manufacturing environment, yet I found that many existing instructions were unclear, lacked necessary details, or did not include proper illustrations. I worked on correcting and improving work instructions, adding diagrams, arrows, and pictures to make complex processes more understandable.

Working at Tesla gave me firsthand experience in high-volume manufacturing, automation, and industrial problem-solving. I learned how to approach large-scale engineering challenges, navigate complex manufacturing environments, and think critically about efficiency, reliability, and cost-effectiveness. Additionally, learning how to coordinate with vendors, handle technical documentation, and work within a highly automated factory environment has made me a more well-rounded and effective engineer moving forward.