Sai Durai

About Sai Durai

I started my engineering career through my undergraduate studies at Easwari Engineering…

Experience

1. Quality Engineer

   Tesla

   Feb 2024 — Present · Sparks, NV, US

   Implemented a scrap reduction project worth per annum with damaged PCS in production by using 8D analysis and implemented a new conveyor design in solid works to prevent it and also, introduced an approved rework to continue using those PCS to avoid scrap.• Proactively worked on continuously improving the process of manufacturing using the DMAIC technique which prevented many unpredicted quality issues from happening and improved the FPY from 95% to 98%.• Implemented a new Keyence vision system through Siemens PLC to catch the uninsulated high voltage terminal in the battery pack, to prevent getting fully assembled. This 100% prevented VOR risk to the customer and safety risk for the person working in the battery pack. Also, made an interactive HMI in Ignition to alert the person working on the battery pack to check the presence of insulators.• Worked with a cross-functional team for a smooth launch on a major improvement in the battery pack history to make it carbon-compliant and performed all quality validations to close the production gaps that create quality issues.• Contained a major quality escape due to a misplaced HVC clip which would have potentially created a production-down situation in general vehicle assembly. Prevented the rework and scrap cost of 500 battery packs, which is approximately worth.