Welcome to our first edition of “Inside Tesla!” This series of Tuesday updates is designed to take you behind the scenes of Model S production as we count down the days to our first customer deliveries in the United States. Three years ago we set out to build the world’s first premium sedan designed from the ground up as an electric vehicle. Less than two years ago, we purchased the Tesla Factory in Fremont, California. Our incredible Manufacturing team, led by Gilbert Passin, has delivered a world-class production line designed specifically to build the most innovative cars of the 21st century. Over the next few weeks we will showcase various areas of the factory to give you a glimpse into how your car will be built. The images and video included in this update will take you through the first stage of building Model S - the stamping process. As you read this update, keep in mind we are now building cars to be delivered on June 22nd!
STAMPING
Tesla is one of the few companies in the world producing a steel-reinforced aluminum car. Aluminum reduces the overall weight of Model S to help maximize efficiency and range.
Your Model S actually starts as a huge aluminum coil that weighs up to 20,000 pounds. This coil is unfurled and fed into our Blanking Line that cuts the aluminum into large rectangles aptly called “blanks.”
Our Press Line stamps the aluminum blanks into 3D parts using huge molds called “dies.” The large black and yellow dies weigh up to 40 tons and are design-specific to stamp each aluminum piece of Model S.
The hydraulic Press Line shown here enables Tesla to produce large panels of the car, like doors and hoods, in-house, rather than outsourcing this production. Our Press Line is the largest of its kind in North America and is capable of producing one part every six seconds.
Our state-of-the-art Kuka robots move aluminum blanks into the press, and then, using over one thousand tons of force, the blank is formed, trimmed and pierced. It’s very impressive to watch as flat aluminum blanks go in one side and shaped, paint-ready panels come out the other.
We have assembled a short video to give you a sense of how this all works together. The video doesn’t do justice to the size and scale of the presses, but it does show how automation helps move parts through the process one step at a time.
Next Tuesday we’ll show how these newly pressed parts are assembled together. Suddenly parts that alone resemble doors, fenders, and body panels are joined together and become recognizable as Model S! It is the first step in the process where your car actually begins to take shape and it’s amazing to watch robots align and connect major sections of the car!
Visit our Tesla Gallery for more photos of the stamping area.
NEXT GENERATION DESIGN STUDIO
It has always been a primary objective at Tesla to design, engineer and deliver an incredible car. In order for our mission to be complete, this incredible car must be coupled with a forward thinking, innovative customer experience. Later this week we take another step forward to deliver that experience. I am happy to announce that in the next few days we will go live with our next-generation Design Studio. Tesla's Design Studio is the go-to destination both in-store and online to build your Model S. You can choose exterior options and interior decor and, within seconds, see it just as it would appear in your garage.
With the launch of our new Model S configurator, the Design Studio experience is elevated to the next level by empowering you to fully design and build your car online. You will now be able to view every option, package and price as you customize and configure your Model S! The experience is both informative and fun to use. It provides an easy way to configure your Model S when the all-important email saying, “It’s Time to Build Your Model S” arrives!
Approximately three to four months prior to delivery of your Model S, Tesla will let you know that it's time to send YOUR order to the factory. Up until now, all final configurations have taken place on the phone or via email. Going forward, you can use the new Design Studio to create the exact “final configuration experience” you prefer — on the phone, online or in one of our Tesla Retail stores! We look forward to sharing the configuration process with you in whatever way makes you smile!
In the coming months we’ll take another step forward by enabling you to complete all of your ordering documentation online. Believe it or not, at that point you will be able to order your Model S from start-to-finish 100 percent online.
You can stay connected throughout the process via our updated MY TESLA dashboard. Access your own private dashboard at teslamotors.com and see exactly where your car stands at any point in the process. The updated Design Studio is a big part of bringing your MY TESLA garage to life. Be sure to check out how these two updated features work seamlessly together and let us know what you think.
As you can see, there is a lot going on this month. Follow us on Facebook and Twitter to stay up to date. Next Tuesday, Inside Tesla will go to the Body Assembly area with Model S, and perhaps deliver a few surprises... We are working on a few things that could be shared as early as next Tuesday. Hold onto your hat, next week could be very interesting!
Twenty-three days and counting!
GeorgeB
Thanks George. Congrats to you and all of Tesla on being so close to delivering the first Model S.
very excited for you all at Tesla!
Can anyone confirm that they have been contacted by Tesla to configure their car? If so, can you tell us what the process was like and what your number is? Based on George's comment that it takes four months to design and deliver your car, that means that even Signature holders are at least four months out from taking delivery if they haven't been contacted yet?
I wish this article never ended. It is very interesting to follow the progress and nice video. Have been waiting all morning (Eastern time) for this.
What secret will they reveal next week?
Ohaq,
Same here. George, keep the good news flowing! I'm so excited - even though my Model S may not be ready 'til early next year (P5058). I tell myself that it means that I'll have a VERY nice Christmas this year!
Larsso: go to the Tesla forums. I'm Sig 353, and was contacted last week.
Very Cool! June 22nd will be a historic day for EVs, the auto industry and U.S. manufacturing.
ohaq, it did not end. It will be continued next Tuesday! :-)
larsso, yes, many Sig reservation holders have already been contacted. If you are a reservation holder yourself, you can follow the progress in this thread:
http://www.teslamotors.com/forum/forums/highest-signature-be-contacted-f...
The highest sequence number reported so far in the forums is 353, but that doesn't mean a lot. Obviously, many reservation holders do not read or at least not post to the forums.
response to larsso: Can anyone confirm that they have been contacted by Tesla to configure their car?
I've designed mine (Sig #21, which is AFTER the insiders get theirs), signed the paperwork, and expect delivery in mid-July. Easy process, with DC Store folks, as usual, guiding and advising, and answering all questions along the way. TM has hired a contractor to handle the actuial delivery and to train new owners, so should be even easier than Roadster (tho I had no complaints with Roadster delivery 9befoer local Store opened), Sedan has more "stuff"). fyi, krj
Thank you so much for the look inside the factory. Johann from Germany
@LARSSO
There are threads on the Model S forum that provide substantial discussion and information on this issue- going back several weeks.
Larsso, we configured our car (#30) March 22 at Santana Row and the process was fun. Other customers have detailed the process on the TeslaMotorsClub forum.
Following comments on teslamotorsclub.com over 250 have been asked to finalize their configuration. So work appears to be progressing.
Thanks George,
Great stuff!
Larry
Great! Now, WHEN DO RIGHT HAND DRIVE PRODUCTION MODELS APPEAR,!???
Mr. B thanks for allowing us all to go behind the scenes.
We were contacted a few weeks ago to build our Model S - Special Signature #225. We have a Roadster #1235 so I think the "Special" simply is another name for "Friends and family". The configuration/sales process was very fast, perhaps, 3-5 minutes to configure and then 6 or 7 intials and a signature or two on a few docs and now we just wait......
We've been told to expect delivery in September but it was also mentioned that early delivery was a possibility.
I'm # 261 and have placed my order a week ago. They called me and went over everything I wanted, sent me emails to confirm everything and then sent the paper work for me to sign. EXCITED! And becoming more inpatient now that it's in the works. My neighbors are driving me crazy asking when is it coming, I tell them it will be here when it gets here. We have all waited so long there is no reason to rush it now. Even all the Tesla employees can't wait to see the S finally in production. I would send a case of champagne but I don't won't anyone messy up my car. LOL
I feel like I'm watching the opening credits or teaser trailer of a sci-fi movie about the construction of a super-weapon/army of robots/etcetera. And since now the star super-villain of the film has a fleet of rockets to launch from his own private island in the South Pacific... ehhh... O_o
Another @
http://www.teslamotorsclub.com/showthread.php/8290-Latest-quot-Finalize-...
This is great! I've been following Tesla for years and I love electric vehicles.
The model S looks great, but as a single guy, I don't want anything nearly that big and I definitely don't want an SUV.
Now, if you could take the model S internals and make a stripped down roadster (of course with slightly lower performance), I'd be at your door tomorrow with $50k.
George,
Thank you for posting this. I am as excited as ever to see these new stores opening and to see a running factory! This whole process seems like it has lasted forever up until now, however, in the history books it will be merely the introduction paragraph.
Let's keep writing history.
Kellan - Santa Monica
IMPRESSIV!
My boss is on the Signature list (I'm on General Production) and he was contacted today by Tesla.
Very exciting George! It would be great to hear a little about your Lean processes, Just In Time, and/or anything taken from the GM/Toyota NUMMI manufacturing days.
If you compare the normal auto industry with a phone. Then it must be a Nokia. Once they had 90% market share, today everything is lost to Apple. Tesla is the cars' response to an Iphone. Go Go Tesla!
Omg, I can't wait to see next week all these panels Beeing assembled. I have been in the factory during the opening and I was super impressed by all the welding which is going on in there.
I have been in other automotive plants but have never seen such equipment in my life.
This will be good!!!
These Tuesday blogs are just amazing and finally there is a car manufacturer who gives an inside behind he scenes. It seams like all he other once are afraid of showing what you actually have to drive. It can not be a secret to other manufacturer since everybody is doing the same thing anyways.
Keep it up Tesla team and you will succeed. You all can be proud of what you have done so far.
Thanks. I am glad to see there is a forum for this info.
I am just exciting about this amazing challenge, and this beautiful car ... I am waiting for it in France as soon as possible !!!
Félicitations!
Sortie d'usine plus tôt que prévu. J'ai hâte de l'acheter en Belgique. En espérant qu'elle soit vendue plus tôt que prévu en Europe. Je suis l'évolution du modèle depuis 2 ans et m'apperçoit que cette période a permis de bien faire évoluer la Tesla S.
Très sympa de pouvoir suivre la production en usine.
Congratulations!
Factory earlier than expected. I can not wait to buy it in Belgium. Hoping it was sold earlier than planned in Europe. I'm changing the model for 2 years and I perceive that this period has much to change the Tesla S.
Very nice to follow the factory production.
I really like the idea of making each car custom per customer order. There won't be any giant parking lots of blue tesla's and a salesman eagerly trying to push the stock he happens to have. It sounds really efficient.
Thanks for a look into the factory, and the stamping process. Looking forward to this blog in the future.
I'm around # 2750 but its a Performance. I heard they were building the 85kw cars 1st so I wonder where that would put me for delivery? Makes sense to build the most expensive orders 1st.
I already drive an electric car since spring (MiEV). The feel not having a combustion engine is amazing. My favorite is to use the electric motor as a break and not having to use the break pads unless I need to come to a complete stop.
I assume Tesla will come out with a basic electric vehicle eventually as I do not need a fancy car to run around town to get from A to B. I guess the Electric Toyota RAV fills that segment for now. Keep up with the very exciting venture.
I called to configure the car. Given 30 days to sign. I will go out to LA to test drive it a few days before the 30 days. I would prefer the $3500 downgraded tires but feel foolish to pay the same price. I was also curious about the 8 year battery warranty, but I could not get any details yet on how weak the battery can go before it would be replaced under the warranty. On one hand I'm exited about the car #365?, but a bit nervous about a car that may be significantly improved at a reduced cost in a few years. Not sure if it will be a "collectors" car or another electronic device that becomes obsolete when the next version comes out. Time will tell !
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