Tesla recently offered a glimpse into its state-of-the-art electric vehicle production facility, Giga Berlin, located in Germany. The factory’s videos showcase the extensive automation and skilled workforce that make it a “machine that builds the machine” while producing exceptional vehicles.
Giga Berlin has been producing the Model Y for almost a year now, and it has achieved an impressive annual production rate of over 250,000 electric vehicles. By the end of Q4, the facility ramped up production to nearly 3,000 vehicles per week, helping Tesla maintain a strong foothold in the German and European markets.
In its latest update, Tesla revealed an exclusive view of Giga Berlin, highlighting the various stages of production, from casting and stamping to the world-class paint shop and general assembly lines. It’s an excellent opportunity for Tesla enthusiasts and industry professionals alike to witness the advanced technology and processes that drive the manufacturing of Tesla’s popular electric vehicles.
See also: German Officials Confirm Tesla Giga Berlin Facility Ready for Production Ramp
Overall, Tesla’s dedication to innovation and sustainability in the automotive industry continues to impress, and Giga Berlin remains a testament to the company’s commitment to excellence.
IDRA Giga Press
In Berlin, Tesla employs the IDRA Giga Press, as it does in its other factories. This not only enhances manufacturing efficiency but also enhances vehicle quality and safety. Tesla showcased various casting design procedures for the Model Y in several videos, revealing that 13 distinct body parts are stamped with a combined force of 7,300 tons on a press line that operates at speeds of up to 16 parts per minute. Tesla also demonstrated parts of the rear casting process that streamlines the manufacturing process for the Model Y by reducing the number of components by more than 70.
Rear chassis underbody pieces are cast in single pieces using a custom aluminum alloy, replacing 70+ metal parts pic.twitter.com/Ka0OnHEW1X
— Tesla (@Tesla) February 13, 2023
More than 600 robots are utilized to weld stamped parts and castings together. When it comes to transporting the car to the paintshop, Tesla employs “Godzilla,” which the company claims to be one of the largest industrial robots ever, for lifting purposes.
Rear chassis underbody pieces are cast in single pieces using a custom aluminum alloy, replacing 70+ metal parts pic.twitter.com/Ka0OnHEW1X
— Tesla (@Tesla) February 13, 2023
Paint Shop
The paint shop at Giga Berlin is truly state-of-the-art, with the capacity to produce multi-layered coatings that create a sense of depth and dimensionality, as well as a hand-painted look that sets Tesla’s cars apart from the competition.
One of the key advantages of Tesla’s new paint system is its ability to apply multiple layers of coating in a single pass, reducing the time and energy required to produce a high-quality finish. This process not only saves time and money, but it also reduces the environmental impact of the paint shop, making it a more sustainable solution for the automotive industry.
In addition to its cutting-edge technology, the paint shop at Giga Berlin is staffed by a team of highly skilled technicians who work diligently to ensure that every car that comes through the facility receives a flawless finish. From the smallest touch-up to the most complex multi-layered coating, these technicians are experts in their craft, and they take great pride in producing the highest quality finishes possible.
Since its opening, the Giga Berlin paint shop has already made a significant impact on the European market, introducing new colors such as Quicksilver and Midnight Cherry Red that have quickly become popular with Tesla fans across the continent. As Tesla continues to expand its global presence, it’s clear that the company’s commitment to innovation and quality will continue to set it apart from the competition.
Giga Berlin is home to our most advanced paint system yet, enabling multi-layer painting for depth, dimension & a hand-painted look pic.twitter.com/W4mCZWfF7D
— Tesla (@Tesla) February 13, 2023
Assembly Line
At Tesla’s Giga Berlin factory, the Model Y comes to life as both humans and machines work together on the General Assembly line. With over 1,000 people working at any given time, crucial elements like HVAC, power electronics, and drive units are installed to put the final touches on the vehicle.
In the past, CEO Elon Musk admitted to overreliance on automation, undervaluing the contributions of human workers. However, the latest look at Giga Berlin shows how the automaker has achieved a balance between the two, creating a cohesive process that streamlines production.
Through a series of videos, it’s evident how “the machine” at Giga Berlin builds “the machine” that is the Model Y, with Tesla leveraging both robots and humans to optimize its manufacturing process. This approach demonstrates how the automaker has refined its methods and recognizes the importance of both automation and human expertise.
In summary, Tesla’s Giga Berlin General Assembly line showcases the collaboration between humans and machines in building the Model Y, representing a shift towards a more balanced approach to production that emphasizes the value of both automation and human labor.
Finally, the vehicle moves to General Assembly, where seats, HVAC, power electronics, drive units & more are installed, using 20+ automated stations.
This is our biggest shop by headcount—on any given shift, 1k+ people are helping build Model Y pic.twitter.com/IgSrCpH5DR
— Tesla (@Tesla) February 13, 2023
