Krishnan Eswar

- Reduced 10 processes by using VSM and 5S principles thereby saving $1.4M annually - Designed and printed jigs for parts with no datum, reducing part to body gap issues by 80% - Led group Kaizen activities to ensure labor utilization does not exceeded 90% - Evaluated make vs buy scenarios based on labor, tooling and scrap cost to outsource Model S door panels - Commissioned a manual conveyor for Model S & X front knuckle build reducing downtime by 11% - Performed process capability studies to calibrate radar install process, reducing failures by 5% - Proposed hardware commonization, based on torque, joint strength and bolt paraments, saving $50K a year - Deployed 8 torque tool reaction arms for tools with torques over 50Nm, to prevent ergonomic injuries - Responsible for setting up and maintaining processes on Final 1,2 & 3 lines, in compliance with safety, quality and rate - Working closely with New model introduction and Pilot teams to streamline product launch and deployment - Introduce / maintain tools required for continuous production

- Established work standard for over 80 processes, within 1 month, on the Model S and X production line - Reduced 100 mins of downtime/week by eliminating NVA work and introducing higher RPM tools - Proposed and implemented a design change on Model X, reducing fitment issues from 75%  3% - Performed Gage R&R to identify taper gage resolution inaccuracy, in measuring Model X body gap - Solved over 50 ergonomic issues by introducing jigs, tools and modifying work standards - Eliminated 70 recurring quality issues through part scanning and torque interlock Poka-yoke - Led, associate and lead, training sessions to promote and explain quality in station

- Calibrated Model X upper glass install process using DMAIC resulting in 96% First pass Yield - Reduced $100K a year in scrap by modifying Model S spoiler install location and packaging - Designed and added compartments to delivery totes, eliminating part mutilation and missed parts - Replaced holding fixtures for Model X, improving worker safety - Assembled all final line parts to identify workability and quality related problems in line - Practiced continuous improvement by allotting and storing tools/ jigs for easy access and replenishment at Trim lines

- Underwent technical training for New Gen i20 model at Hyundai headquarters, South Korea • Conducted geometric dimensioning and tolerance analysis for exterior parts • Conducted FMEA for FEM work assist loader accommodating five models and installed new loader in final line • Assembled the prototype car to identify process, quality and ergonomic complications • Prepared process sheet, part identification sheet and standard work instructions - Eliminated offline rework manpower and WIP by installing ‘Glass Vision System’ for primer and sealant - Installed and integrated tool torque data with MES for critical jobs - Raised design change requests to avoid stacking order issues at the prototype stage - Standardized sealant, Radiator coolant, AC gas and Gasoline consumption per vehicle

- Calculated and proposed new operator time standards using MODAPTS code - Introduced rack & lamp system for all model logos - Modified existing FEM work assist loader saving 35,000$ on new loader investment - Set conformance standard for head lamp aiming tester - Simulated flow of new model in production line to check for equipment compatibility - Day wise problem follow up and countermeasure preparation for trim & final lines - Studied and documented each department’s contribution towards final vehicle build - Attended productivity and quality training sessions