Nikhil Tiwari

• Championed cross-functional and site-level execution of automated PW3 TIM removal cell - owning mechanical integration, supplier engagement, and end-to-end project management across 2 Gigafactory teams from 90% design review through commissioning. • Devised Clamping mechanism & Robotic End mill stack of automated PW3 TIM removal cell, led full-cycle execution across CAD design, prototyping, in-house fabrication, functional testing, & mechanical installation, ensuring robust integration with Robot EOAT, Lift & Locate, & Conveyance systems. • Initiated Tesla’s first transparent yet soundproof OSHA-compliant ultrasonic leak test enclosure; iteratively validated design through dB-level isolation testing, enabling elimination of water leak tests and 50% headcount reduction. • Programmed 2D vision sensor to enable mistake-proofing of homologation press operations for EU/NA components—leveraging AI-based OCR and part differentiation eliminating mis-presses and improving product quality.

• Designed precision label stencil fixture & Go/No-Go gauge, allowing accurate labeling for 750 PW3 units per shift, achieving a 54% reduction in cycle time and reducing labeling workforce by 50%, ensuring Optical Character Recognition (OCR) across the entire PW3 production line. • Developed a custom tool to replace faulted PW3 PV Sidecar connectors, authored the Manufacturing Instructions (MI), and trained staff across all three production shifts, saving ~$3.2M in 6 months. • Coded PLC logic for a NO proximity switch sensor with stop rocker assembly on PW3 conveyance, eliminating unit collisions and preventing product damage, decreasing Hi-Pot false fails, improving overall efficiency and minimizing downtime. • Led spare part analysis and developed a PW3 production line master tracker covering 70+ high-priority assemblies; standardized CAD, BOM, and vendor data to streamline inventory planning, and enable cross-site cost reduction in collaboration with Spares team. • Engineered a common camera bracket for 5 PW3 fastening stations, enhancing ease of Root Cause Analysis (RCA), reducing downtime from 25 minutes to 10 minutes, and increasing FPY by 4%.

• Designed and developed an Upper frame(UF or chassis) of Reduced Tail Swing (RTS) class of excavators • Pioneered steel casting design integrating engine and counterweight mountings on RTS UF improving packaging and lift capacity • Implemented 4 cost-saving measures for welding/fabrication driving design commonality and leveraging DFM principles in UF across RTS family, resulting in estimated savings of $270,000 • Utilized Inspire, Sim-Solid for FEA/structural analyses of parts & assemblies streamlining design efficiency, optimized weld sizes, minimized iteration cycles to achieve target life goals • Analyzed CMM reports of flawed swing bearing pattern holes on UF & confirmed their compatibility with swing bearing, resulting in saving 4 weeks lead time and avoiding part rejection • Drafted 4 complex weldment-level drawings of UFs with high-quality scores using GD&T • Performed hand calculations: Factor of safety of UF web plates, bolt thread engagement, clevis sizing, Hood opening hand force • Modeled solutions by rapid concepting, securing leadership, team & supplier alignments in review forums, adhering to project timelines • Mentored school students (STEM CSR), crucial for robotics success in FIRST Tech Challenge 2023, Pune, India • Coordinated orientation training of PGETs/GETs 2022 batch

• Prepared 100+ high-quality, robust, & cost-effective parts by preparing detailed geometries & drawings with GD&T • Identified potential operational challenges, redesigned and improved functionality of Fuel filter hose routings & brackets • Worked with cross-functional teams in Hydraulics, Powertrain, Manufacturing, Quality, and Service to conceptualize, refine, and finalize the best designs of structural components • Applied comprehensive understanding of high-volume manufacturing processes and materials to optimize design • Spearheaded mass roll-ups of all excavators, ensuring precise data for lift capacity analysis • Collected data and conducted comprehensive excavator competitor benchmarking analyses for new product charter

• Utilized Statically Indeterminate Beam (SIB) concept & Clapeyron’s theorem of three moments to build an internal tool focused on feedwater heaters of coal-based power plants • Created & validated excel based calculator using SIB concept to calculate saddle reactions of Feedwater heaters & authored its SOP

Summer '25 Course(s) - Adv Math for Engineers & Physicists I Spring '25 Course(s) - International strategies Summer ‘24 Course(s) - Independent Study: Autonomous Hi-speed Race-car Simulation Spring ‘24 Course(s) - Mechatronics, Lean Manufacturing, Vehicle Dynamics Fall ‘23 Course(s) - Business Analytics, Product and Process Design, Design and Control of Production and Manufacturing Systems, Advanced Thermodynamics, Entry-Level programming in Python