Electric Vehicle University - 201a Building the Model S
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THE CENTRAL QUESTION ... How is the Model S built and what makes Tesla Motors' approach somewhat different than the approach used by other automotive manufacturers? COURSE ABSTRACT Tesla Motors' manufacturing approach, factory, capacity and layout are considered. The NUMMI plant and the Gigafactory are discussed. Course level: Introductory
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Electric Vehicle University - 201a Building the Model S
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- 2. 2 Building the Model S MS-201a This course is presented as part of Evannex University—a free, open learning environment that presents concise, video-based mini-courses for those who have interest in electric vehicles (EVs) …
- 3. The factory Made in the USA factory in Fremont, CA, capable of building 400,000 cars per year 5.4 million square ft, 380 acre campus with test track robotics and automation dominate build bodies, motors, and batteries 3
- 4. The Gigafactory The growth of EV is constrained by battery capacity availability of high capacity batteries Tesla is building a “Gigafactory” $4 - 5 billion investment accommodate battery needs for 500,000 EVs per year 2020 output = 50gWh / year 4 Source: Hybrid Car Report
- 5. The NUMMI Plant Production rate for the Model S 2013: 22,000 2014: 35,000 2015: ~ 50,000 Plant upgrade in 2014 5
- 6. In Tesla’s own words “… advanced robots … can lift and maneuver entire cars with optimum precision while taking up less room” “… our new robots will even be able to install battery packs in the cars, … reducing installation time from four to two minutes.” “… cars now move down the assembly line as associates work on them, enabling a streamlined and more consistent workflow.” “ The line is now running at about 1,000 cars a week with the potential for significantly more with minor adjustments.” 6 Source: http://www.teslamotors.com/blog/factory-upgrade
- 7. How the Model S is made There have been a number of good on-line videos that describe the Tesla Motors automobile factory Wired: https://www.youtube.com/watch?v=8_lfxPI5ObM National Geographic: https://www.youtube.com/watch?v=i7J-tlrkVEE Tesla Motors (factory upgrade): http://www.teslamotors.com/videos/tesla-factory-upgrade The Science Channel program How It’s Made has a spin-off program entitled How It’s Made/Dream Cars one episode was dedicated to the Tesla Motors plant in the next part of this mini-course, you have an opportunity to watch the video 7
- 8. 8 … a free study guide for all EVU mini-courses is available for download from our website … For a complete list of mini- courses and the study guide, visit: www.evannex.com
Editor's Notes
- In the introductory mini-course in the Model S curriculum track we discussed two tesla Motors factories briefly, the automobile factory and the planned battery factory.. In this mini-course, we’ll focus our attention of the automobile factory, and in a later mini-course, we’ll consider the battery factory, nicknamed the “gigafactory” Let summary our earlier discussion: >> The Model S is made in the USA. Tesla Motors purchased an empty car factory—the NUMMI plant—from Toyota for $42 million in 2010 >> the factory is located in Fremont, CA and is capable of building 400,000 cars per year >> it encloses 5.4 million sq ft, and sits on a 380 acre campus with test track >> robotics and automation dominate the factory, >> where Tesla builds bodies, motors, and batteries
- >> The growth of EVs is constrained by >> battery capacity which limits the range of electric vehicles, >> and the availability of high capacity batteries that will be in short supply as the number of vehicles sold grows >> To solve both problems, Tesla is building a “Gigafactory” in Nevada with a >> $4 - 5 billion investment >> The gigafactory will accommodate battery needs for 500,000 EVs per year >> with a projected 2020 capacity output of 50 giga-watt-hours per year The Gigafactory is currently under construction. When completed it will produce Li-Ion cells and full battery packs. For those of you who are unfamiliar with battery fabrication technology, spend a few moments taking EVU mini-course, EV-210, which covers the subject in some detail.
- But back to the automobile plant itself. The NUMMI plant was completely re-outfitted after it’s purchase in from Toyota in 2010. >> Production rate for the Model S has grown steadily. >> in 2013: 22,000 >> in 2014: 35,000 >> in 2015: ~ 50,000 >> In order to meet growing product requirements and the need to accommodate Model S variants and the new Model X, the plant was upgraded in 2014
- As a consequence of the plant upgrade, Tesla Motors has increased both manufacturing efficiency tend production throughput. Here are a few excerpts from the Tesla Motors website: >>“… advanced robots … can lift and maneuver entire cars with optimum precision while taking up less room” >>“… our new robots will even be able to install battery packs in the cars, … reducing installation time from four to two minutes.” >>“… cars now move down the assembly line as associates work on them, enabling a streamlined and more consistent workflow.” >> “ The line is now running at about 1,000 cars a week with the potential for significantly more with minor adjustments.”
- The normal EVU presentation style is inadequate to fully describe the Tesla Motors production approach. Therefore, a video presentation is necessary. >> There have been a number of good on-line videos that describe the Tesla Motors automobile factory >> Wired presents a two part behind the scenes look at the factory, presented in the words of Tesla’s designers, engineers and workers >> National Geographic presents an outstanding documentary that provides excellent insight in the factory >> Tesla Motors provides a brief, but engaging, video of their factory upgrade All can be viewed at the links shown on your screen >> In addition, The Science Channel program How It’s Made/Dream Cars dedicated on episode to the Tesla Motors plant >> In the second part of this mini-course, you have an opportunity to watch the video