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Tesla is addressing its repair service challenges by doubling capacity in 2019

(Photo: Claribelle Deveza)

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As Tesla heads towards the mass market with vehicles like the Model 3 sedan and the upcoming Model Y SUV, the challenges of supporting an ever-growing fleet is becoming more and more evident. Over the past month, numerous Tesla owners, including influencers with large followings on social media, have brought up the issue of the company’s vehicle service problems. In its recent Update Letter and following earnings call, the electric car maker provided some insights into this issue.

Tesla stated that it is currently operating 378 service centers around the world by the end of the fourth quarter, with 300 of the sites being located outside of CA. Augmenting this support system is a fleet of 411 mobile service vehicles. While this might seem sufficient to provide service to the company’s Model S and Model X, these sites are quickly proving insufficient when faced with the company’s increasing sales and its ever-growing Model 3 fleet.

In 2018, for example, Tesla delivered 245,240 vehicles across the globe. This year, Tesla noted in its shareholder letter that it aims to increase vehicle deliveries to 360,000 to 400,000 worldwide — an increase of 45% to 65% compared to 2018’s already record-breaking numbers. With this in mind, there is a need for Tesla to ensure that its service capabilities are enough to support the company’s increasing number of vehicles. 

During the recently held earnings call, Tesla noted that it would be rolling out vast improvements for its parts distribution systems. Elon Musk added that Tesla’s strategies for servicing vehicles have been pretty inadequate, at one point candidly describing the policies as “boneheaded.” Musk also noted that some of its service processes were “super dumb,” referring to a system where a part made in China gets shipped to the US, only to be sent back to China where they were ordered.

“We’re also improving parts distribution. I think we made a strategic error in the past about not having service parts located at our distribution centers. We had them in parts distribution warehouses which basically meant it was impossible to have a fast turnaround on service on your car because the car would come in, then the parts would be requested (before) they come to the service center. Basically, for even for a very simple repair, it could take days.

“We’re going to move to stocking all common parts at the service centers, so it’s possible to get your car service in 20 or possibly 15 minutes. Lightning fast. It’s also gonna make sense for our service centers to do basic bodywork or essentially if all you need to do is replace a front or rear feature, it makes sense to pre-stock the front-rear feature in the common colors. So unless you have (an) unusual color, we can literally replace your feature in 15-20 minutes, and there’s none of this like weeks at a body shop stuff.”

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One thing that the company emphasized in the earnings call was the potential of its Tesla Rangers service, which sends certified mechanics to customers’ homes or offices to repair cars on the spot. Considering that the Rangers could address around 80% of repairs needed for Tesla’s electric cars, a serious ramp of the mobile service would likely result in an improvement for the company’s vehicle service systems.

In its Q4 2018 Update Letter, the company noted that its centers would be moving to two-shift operations in order to double the capacity of a site. Improvements to the Tesla app are also expected to make scheduling service an easy and seamless affair. Ultimately, these initiatives are expected to allow the electric car maker to vastly improve its capabilities to address its owners’ vehicle concerns.

Tesla’s areas for improvement in its service systems appear to be a notable topic for Elon Musk. In last year’s Annual Shareholder Meeting, Musk announced that Tesla is opening in-house body shops to reduce the time it takes for vehicles to be repaired. Tesla eventually launched several in-house repair centers across the United States, and the reception from the community has largely been positive. Model 3 owner and YouTube influencer Kim of Like Tesla, for one, shared her experience with one of the company’s in-house body shops, which was able to complete the repairs to her damaged vehicle in 24 hours.

Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Elon Musk

SpaceX turned a heralding moment for Starship into its greatest

Starship reached orbit despite losing an engine, deployed 26 Starlink V3 satellites on Flight 14.

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SpaceX’s Starship reached orbit for the first time on Monday, and for a few nail-biting minutes it looked like it wouldn’t. During ascent on Flight 14, one of Ship 41’s six Raptor engines shut down early, and SpaceX’s livestream host Dan Huot told viewers the team had decided not to commit to orbit. Minutes later, after what Huot described as a lot of conversation in the control room, the final poll came back in favor, and a roughly 19 second burn of a single Raptor pushed the ship into orbit about 170 miles up.

The reversal matters because SpaceX had written the exit ramp into the mission plan. The company said it would only fire the orbital insertion burn if flight controllers confirmed enough backup hardware remained for the deorbit burn, a condition Teslarati laid out ahead of the flight. Losing an engine was exactly the scenario that rule was built for.

Pressing forward fits Elon Musk’s history. Falcon 1 failed three straight times before its fourth launch reached orbit in 2008, with SpaceX nearly out of money, and Starship was developed by flying prototypes until they broke. What changed this year SpaceX going public, and with $SPCX sliding below its IPO price in July when Flight 13 slipped, the short interest climbed significantly, as Teslarati reported at the time. A Starship potentially lost today with revenue generating next-gen Starlink satellites aboard would have landed directly on shareholders.

That pressure showed up after orbit. SpaceX cut a flight planned to last nearly 10 hours to about three, moving splashdown from west of Chile to the North Pacific near Hawaii. SpaceX gave no reason, though Musk said this month the company was being extremely cautious about debris risk. The single Raptor for deorbit worked, and Ship 41 completed its flip and landing burn before breaking apart in the water, an outcome SpaceX expected. Musk has structured SpaceX’s governance to shield long term bets from market pressure.

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The payload is the bigger business story. Musk posted that all 26 Starlink V3 satellites deployed and are “operating nominally.” Each V3 is rated for about 1 Tbps of downlink and 160 Gbps of uplink, so this single launch adds roughly 26 Tbps, about 10 times what a Falcon 9 load of V2 Mini satellites adds. The V3 is too large for Falcon 9, making Starship the only vehicle that can build out the planned 100,000 satellite constellation, at up to 60 per flight once it reaches routine service. Unlike the 20 V3 units on Flight 13, which reentered on a suborbital path, these will raise their orbits and could begin serving customers within weeks and bring in hundreds of millions of additional dollars in projected Starlink revenue.

SpaceX has already begun winding down Falcon 9 Starlink launches from Florida in favor of Starship. Reported targets put Flight 15 as early as October 19, leaving about three weeks to diagnose Monday’s engine shutdown before the next orbital attempt.

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Elon Musk

SpaceX just got the green light Starship has waited years for

The FAA has cleared Starship Flight 14, setting up SpaceX’s first orbital attempt on Monday.

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SpaceX has cleared the last regulatory hurdle standing between Starship and its first trip to orbit. The Federal Aviation Administration issued the launch license for Starship Flight 14 late Saturday, keeping the mission on track for liftoff Monday, September 28, from Pad 2 at Starbase, Texas.

The 75 minute launch window opens at 7:15 a.m. Central, and Boca Chica Beach closures are also scheduled for September 29 and 30 as backup dates. This will be Starship’s first revenue generating mission.

The license was the missing piece after SpaceX completed a full wet dress rehearsal with Booster 21 and Ship 41 on September 24. At the time, the company said the flight remained on track pending regulatory approval. Because Flight 14 flies an orbital profile, the FAA had to sign off on a modified license that met its safety, payload and financial responsibility requirements.

Observers combing through the new FAA paperwork also noticed that lightning no longer appears among Starship’s listed launch hazards. If that holds, it matters more for where Starship is headed than for Monday’s attempt. Florida and Louisiana, home to LC-39A and the planned Starbase Louisiana site, see some of the most frequent lightning in the United States.

SpaceX tells the FCC that Starship Flight 14 is going to orbit

Flight 14 is the mission SpaceX has been building toward for months. Ship 41 will carry 26 Starlink V3 satellites, the first operational V3 units to be deployed, and attempt roughly six orbits at about 275 kilometers over a flight lasting just under 10 hours. SpaceX says the ship will only perform its orbital insertion burn after flight controllers confirm enough hardware redundancy remains for the deorbit burn at the end of the mission. Ship 41 is targeting a splashdown in the Pacific west of Chile, while Super Heavy will return to the Gulf of Mexico.

The date carries some symbolism as well. A Monday launch would come 10 years and one day after Elon Musk first presented the Interplanetary Transport System, the design that became Starship, at the International Astronautical Congress in Guadalajara, Mexico.

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SpaceX has not announced what comes next, but air traffic planning slides reported this week, list Flight 15 no earlier than October 19 and a first Starship launch from LC-39A in Florida no earlier than October 30. Both dates depend on how Monday goes.

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Investor's Corner

Tesla Optimus Gen 3 shows off a cleaner, factory-ready design in new app discovery

Renders hidden inside Tesla’s Android app show Optimus Gen 3’s design before any official reveal.

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Tesla Optimus Gen 3 [Credit: Tesla]

Tesla may have accidentally given a first look at its newest Optimus Gen 3 humanoid robot when photos were found in the Tesla smartphone app.

Design files tucked inside a recent Android version of the Tesla app appear to show the third generation humanoid robot next to the older Gen 2.5 prototype. The assets were extracted from the app package by Tesla community member @wholemars, who posted the renders on X late Tuesday night before deleting them. The Tesla Newswire reshared the side by side comparison on Wednesday, and the images have circulated widely since.

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

Tesla Optimus Gen 2.5 vs Gen 3 comparison via @WholeMars on X

The files are labeled “gen3” and were built as models for Tesla app’s own interface, as validated directly by Grok to be official.

The comparison shows a robot that looks built for a factory line rather than a lab bench. Gen 2.5’s exposed mechanical linkages and gold plating on the knees and shins are gone. In their place, Gen 3 uses matte black fairings on the lower legs, paired with a more contoured champagne gold body. Flexible covers now seal the joint where the torso meets the upper thighs, keeping bearings and moving parts sealed from debris and unnecessary contact.

The body panels fit more tightly, and the hands, which Tesla has said carry 22 degrees of freedom, look far more refined than those on earlier units.

This most recent leak fills a gap Tesla has left open for most of the year. Elon Musk said on March 31 that Optimus 3 was walking around but needed “some finishing touches” before it could be shown, a delay Teslarati covered when Tesla missed its first quarter reveal target. Musk later said Tesla would hold the design back until closer to production, partly to keep competitors from copying it. No reveal date has been announced.

The app itself has been preparing for Optimus for months. In July, code in the Tesla app pointed to a dedicated robot phone key, a consent screen for collecting video and spatial data while Optimus works inside a home, and an alert system for low battery and mechanical faults. Finished 3D models of Gen 3 suggest the interface owners will eventually use is moving past placeholder code toward something Tesla intends to ship.

Manufacturing is moving in parallel. Tesla tore out the original Model S and Model X lines at Fremont this summer to make room for Optimus production, with a planned capacity of one million robots a year. At Giga Texas, the steel frame of a dedicated Optimus factory is nearing completion ahead of a targeted 2027 start, with Musk pointing to an eventual output of 10 million units annually.

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