Charlie Bilgin

Experience

1. Senior Process Engineer

   Tesla

   Jan 2023 — Present

   Working on sustaining, and continuously improving Winding and X-Ray process yield. • Managing tabless process engineering technician team with 10+ techs • Developing Winding Process Flow Diagram (PFD), Process FMEA and Control Plan to identify the potential failure modes. • Developing new winding process and recipes for New Production Introduction (NPI) projects. • Root causing Winding and X-Ray yield issues and developing Out of Control Action Plans (OCAPs) to sustain. • Executed following projects to continuously improve process yield, product quality and to reduce quality escape risks: 1. Winding Cut Position Deviation Reduction DMAIC to reduce Cut Position Deviation scrap cost ($/kWh) by 85% 2. Anode Spool Orientation Locking Project to provide higher traction at spool rollers to improve web handling and center lining electrode alignment. Vacuum Nozzle at Winding Flag Former Project to design and implement vacuum nozzle at all winders. Reduced particle contamination and Cathode Flag Fold & Cathode Slit Edge Meander scrap cost ($/kWh) by 22% 4. EPC Smudge Detection DMAIC to develop and implement process for alerting operator when EPC sensors are too dirty to track slit edge in high accuracy due to dust accumulation. Reduced Anode & Cathode Slit Edge Meander and X-Ray scrap cost ($/kWh) by 30%