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Tesla Model S
Assembly Line
How Tesla use Automation
to produce its Model S?
Overview
● Body Assembly
○ Raw Materials
○ Tandem Press Line
○ Undercarriage
● Painting Process
● Production of the Electric Motor
○ Bonus: An Automated Sewing Machine
● Problems in Automation
Body Assembly
Body Assembly
● 98% Aluminum
● Aluminum sheet is transferred to
the stamping press
Body Assembly
● 98% Aluminum Body
Raw Materials
● Production starts with raw materials
● Aluminum coils, 50 - 60 different types
Raw Materials
● First step is Decoiling
● Blanking Machine
● Then Laser Cutting the sheets
Tandem Press Line
● 1 part every 6 seconds
Tandem Press Line
● Sheets are flow through the conveyor belt to the Forming Press
Tandem Press Line
Body Assembly - Tandem Press Line
Body Assembly
Undercarriage
Undercarriage
● CMT - Cold Metal Transfer Welding
Joining Methods
● Cold Metal Transfer Welding
● Conventional Spot Welding
● Structural Adhesive
● Self Piercing Rivets
● Delta Spot Welding System
Body Assembly
● Side part positioned to the robot manually
Body Assembly
● Robots install side parts
Body Assembly
Body Assembly - Manual Work
● Door installment
● Front panel installment
● Inspection
Painting Process
Pretreatment
Pretreatment
● Basically a bath for the car in a giant dishwasher
● Get rid of unnecessary materials on body
Coating
● Once cleaned, the body receives a corrosion resistant electrolytic coating
○ Primer coat
○ Base coat
○ Clear coat
General Assembly
Smart Cart Robot
Smart Cart Robot
Smart Cart Robot
● Every car travels the factory by itself
Seat Assembly Robot
Seat Assembly Robot
Seat Assembly Robot
● Change its point
Seat Assembly Robot
● Apply adhesive
Seat Assembly Robot
Problems in Automation
Problems
● Over automation
● Complex structures for easy tasks
● Sometimes cheaper to pay an employee than the automation cost
Thank You.

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