Tesla: Model X Keyfob

Cost-Saving Process Improvement

  • Strengths demonstrated: Design of Experiment, Mechanical Design, Iterative Design, Testing, Process Improvement
  • Tools used: CATIA, Soldering, Multimeter
  • Company Team: Tesla Autopilot and Electronics Product Design Team
  • Project date: 2020

What?
As the Product Owner for the Tesla keyfobs, I faced a process issue which resulted in the keyfob arriving to customers with the battery half drained. This was a result of the keyfob being paired to the car upon production and the battery being engaged from that point till delivery, which could last many months.

How?
Working collaboratively with the Assembly Process Managers of the production floor, I was able to implement an innovative battery pull-tab that allowed the factory workers the ability to engage the battery by pulling the tab and pair the keyfob to the car at the factory, and then disengage the battery by pulling the tab in the opposite direction for the duration of shipping.

Results
The implementation into the process was both innovative and intuitive and resulted in over $200,000 of savings per year for Tesla for a cost of less than $5,000 for the mold and placement tool.