Model 3 PCS1 cost-down
The work
Moving the on-board charger from a 48 A architecture to 32 A took $100M a year out of the cost, a 30% reduction, and shipped on the Model 3 and Model Y Standard Range. Rameez drove the mechanical architecture and the magnetics redesign behind it, along with the EMI and compliance testing every change had to pass.
The work ran on simulation and measurement together: ANSYS structural and thermal analysis, bench validation and production validation, with global supplier teams engaged on the components that changed. He also supported production capacity for high-volume manufacturing of the individual components and assemblies, through RC1 testing and the initial launch.
48A PCS1
Image: sourced from public teardown websites
32A PCS1 cost-down
Image: sourced from public teardown websites
Once discrepancies were found, the correct self-heating and power losses were added back to simulations to predict future design constraints better
Standing with amazing individuals who worked tirelessly to build and ship cars
Building the first Model 3s in the GA4 tent at Fremont Factory to support the initial production ramp.
All engineering teams left their desks and took wrenches to work every day. Tasks ranged from delivering cars to customers, washing them, installing heavy assemblies, and anything to get cars out of the factory.