The fascia is a common automotive part, also known as a bumper. Usually, this part is made with injection molded plastic and then painted to match the car's color code.

One common problem seen with plastic parts is warping, which can occur for many different reasons. The purpose of this project was to root cause why the rear fascia on the Tesla Model 3 was warping.

Pictured on the left are examples of normal and warped fascia. These parts were determined as warped by failing a go/no-go gauge.

After determining what a "warp" is, the next action was to collect data on exactly which skids were causing parts to warp. This was done by creating a custom PowerApp that allowed operators to quickly enter information whenever a warped part was seen. Afterwards, the skids with unnaturally high warp counts were light scanned and compared with known good skids. The results were dimensional deviances in the bad skids at the location of the warpage. This issue was then resolved by ensuring all skids met positional tolerances.