Analysis: Tesla’s new car-making process stokes debate among industry experts

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Tesla Inc's new vehicle-assembly system, which created instant buzz when it was unveiled in March, ignited a debate among auto manufacturing experts on whether CEO Elon Musk's so-called unboxed process is radical, revisionist or derivative - or all of the above.

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Investors have been waiting for Tesla, the world's most valuable automaker, to announce what is perceived as the company's The assemblage of new techniques will not be fully tested until the system is installed in late 2024 at Tesla's new $5 billion plant in Monterrey, Mexico, where the company plans to build a new generation of sub-$30,000 EVs.

Tesla is still testing various elements of the system, including the use of large front and rear subassemblies built on single-piece underbody castings, which are then joined to a central structural battery pack. Body panels are painted separately, then joined together toward the end of the assembly process.

At its core, the Tesla method "is an assembly process" while Toyota has developed a far broader and more comprehensive "production management system" that helps automakers run assembly processes and related operations more efficiently, said Womack, a professor at the Massachusetts Institute of Technology and co-author of "The Machine That Changed the World," the 1990 book on Toyota's lean production philosophy and methods.

Another question is whether Tesla can produce multiple vehicle models of different sizes and body styles on the same production line with the unboxed system.

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