Aaron Kasinski

- Led a team of three engineers to deliver first-principles material flow designs for the Cybercab program covering Casting, Stamping, Plastics, Welding, Coating, and Assembly shops - Developed Tesla's first comprehensive make v buy analysis, coordinating with manufacturing and finance to integrate brownfield cost and constraints for specific assemblies. This model guided concept layouts and reduced cost per vehicle for multiple programs - Selected for my speed and efficiency to lead future model material flow designs, conducting end-to-end analyses for seamless part transport from supplier to assembly line

- Led material flow design for the Cybertruck Stamping and Casting shops, designing innovative manual material handling processes while optimizing headcount and equipment usage through Monte Carlo simulation - Conducted studies to quantify cost savings in Cybertruck’s outer panel welding by consolidating similar efficiency processes, reducing process steps, minimizing buffer requirements, and shortening production lead times - Identified future dock and vertical capacity gaps, proposing a first-of-its-kind building design for Tesla to efficiently transport pallets to the consumption point with minimal process steps

-Developed a factory-wide vertical movement strategy, managing requirements, and presenting a CAPEX request with justification. Supported by a dynamic model to assign material routes during production ramp-up - Led material flow design for the Cybertruck Battery Pack and Drive Unit shops, conducting automation business case analysis, calculating headcount and equipment needs, and collaborating with simulation teams to justify intermediate buffers to mitigate efficiency loss

- Championed the use of advanced turn radius software, creating AutoCAD 2D layouts to optimize aisle widths and validate lineside automation dolly interfaces - Led the material flow design for the Gigafactory Texas Model Y Plastics Shop. Determining headcount, equipment needs, and replenishment routes. Engineered ergonomic carts and dollies for process efficiency - Conducted business case analyses for automation projects within Model Y Battery Pack and Drive Unit shops, and contributed to first-principles material flow designs supporting new product introductions in a brownfield setting

- Worked in a remote capacity to standardize and document processes - Created company wide tools to share best practices and ignite continuous improvement initiatives

- Developed tools to optimize workflow and standardize tasks - Facilitated 5S and Kaizen events to reduce non-value added time searching for components - Worked with MRP to correct stock and ensure on-time delivery

- Designed and implemented fixtures to account for variation in parts - Developed facility layouts to improve flow for AGV's - Created a lead time macro to decrease station downtime

- Designed fixtures to address ergonomic and production related concerns - Participated in 5S and Kaizen events to determine root cause and eliminate waste. Resulted in inventory reduction - Developed and wrote documentation to aid in standard work

- Utilized HMS CAPP and FactoryLogix software to improve the clarity and efficiency of production documentation - Selected to develop an interactive virtual document for domestic visitors using SharePoint software. Program still in use - Invited back to continue project work over academic breaks