Battery Systems · Manufacturing Quality · Fleet Analytics

Your energy programme.
Delivered on time.
At Gigafactory quality.

Energy storage OEMs, battery manufacturers, and utilities hire me when a programme is complex, the stakes are high, and they need someone who has actually shipped at scale.

Ex-Tesla Sr. TPM · Powerwall 3 launch · 7 years Gigafactory · Independent since 2026

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20%
Yield improvement
PW3
Launched on time
7+
Years at Tesla
GW
Battery line scale

Specialist Solutions for Energy & Industrial Excellence

From battery systems to manufacturing optimization and fleet analytics, we deliver measurable results through deep technical expertise and strategic partnership.

Service 01

End-to-End Programme Ownership

Full lifecycle battery energy storage system development and deployment, from concept through operational excellence.

Deliverables

  • • Site assessment and feasibility analysis
  • • System design optimization
  • • Vendor selection and procurement
  • • Project execution and commissioning
  • • Performance monitoring
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Service 02

Production Excellence & Quality Assurance

Optimize manufacturing output and quality metrics through data-driven insights and continuous process improvement.

Deliverables

  • • Production baseline assessment
  • • Quality metrics framework setup
  • • Root cause analysis for defects
  • • Process optimization recommendations
  • • Monthly performance dashboards
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Service 03

Fleet Intelligence & Predictive Health

Real-time monitoring and predictive diagnostics for electric vehicle and battery storage system fleets.

Deliverables

  • • Fleet telemetry integration
  • • Real-time health dashboards
  • • Predictive failure algorithms
  • • Maintenance scheduling optimization
  • • ROI tracking and reporting
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Delivered, on time, at scale.

7 years building and shipping battery and energy systems.

Programme Delivery

Powerwall 3 Launch

End-to-end programme ownership, 20+ cross-functional teams, launched on time without critical field issues.

Tesla Inc. · 2023–2025

Manufacturing Quality

20% Yield Improvement

Battery line scaling: 8D and DMAIC six sigma applied, scrap reduction sustained at gigawatt production volume.

Tesla Gigafactory · 2018–2020

Fleet Analytics

Remote Fault Detection

Fleet monitoring deployed across energy portfolio, processing 1M+ telemetry points daily, early anomaly detection.

Tesla Inc. · 2023–2025

Let's do the same for you.

Request a consultation

Clear engagement from day one.

Discovery, planning, execution, delivery. No surprises. No junior staff. Direct access.

1. Discovery Call (45 min)

We talk through your programme, constraints, and where it's at risk. I ask hard questions. You get clarity on whether this is a fit.

2. Proposal & Agreement

I send a scoped proposal with timeline, deliverables, and rate. No long contracts. You can pause or adjust scope anytime.

3. Execution & Sync (Weekly)

I take ownership of the work. Weekly check-ins, slack/email access, visible progress. You're never waiting for status.

4. Delivery & Results (Impact)

Clear deliverables: report, system, strategy, or resolved issue. Not a deck—real outcomes you can act on.

Pick what fits your budget & timeline.

Retainer

16–40 hours/month. Ongoing support, strategic advice, continuous improvement.

$8k–$15k/month

Project

Defined scope, fixed timeline. Manufacturing audit, fleet analysis, programme reset.

$30k–$150k

Advisory

Hourly or sprint-based. Specific problem, fast decision, expert input.

$200–$500/hour

Let's start with a conversation.

Schedule a discovery call

Direct access. No layers. No overhead.

You get me—not a junior consultant, not a bench fill-rate, not a firm chasing utilization targets.

Direct Access

You work with me. Not an associate, not a "case leader" who touches your work for 10%. When you call, I answer. Slack. Email. Phone. Real-time.

No Overhead Billing

You don't pay for office space, bench staff, or firm profit margins. My rate is clean—just expertise and delivery. No hidden costs.

Aligned Incentives

My success is your success. You shipped the product. You reduced scrap. You have happier customers. That's how I measure myself—not by billable hours.

Speed

I move fast. No approval chains, no steering committees, no "I'll sync with the partner track." Issues get flagged, decisions happen, momentum stays.

Candor

I tell you what I think. If your plan won't work, I say so. If a decision is wrong, you hear it early—not after we're locked in. That's what you're paying for.

Continuity

Your work doesn't change hands between engagements. I know your context, your team, your constraints. That context is worth a lot.

Independent vs. Big Firm

Big Consulting Firm

  • ✗ 3–5 layers between you and decision-maker
  • ✗ Junior analysts on your work, partner on your invoice
  • ✗ Incentive to extend engagement, not end it
  • ✗ Methodology-first, problem-second
  • ✗ Leveraged utilization, bench-fill pressure
  • ✗ Committee-based decisions, slow

Independent Consultant

  • ✓ You work with me directly, always
  • ✓ Deep expertise, 7+ years in your domain
  • ✓ Incentive to solve it, move on, repeat
  • ✓ Problem-first, method applies as needed
  • ✓ No overhead, no bench pressure
  • ✓ Fast decisions, real accountability

Let's talk.

Schedule a discovery call, send an email, or share your programme details. I'll respond within 24 hours.

Details

Email
sumit@smahato.com

Location
Bengaluru, India
(Working across time zones)

Response time: Within 24 hours