There were many issues found during vehicle integration testing related to poor wiring quality and design errors. To address this, an electrical vehicle check (EVC) process was implemented using wiring harnesses on fixed test benches. This allowed all vehicle wiring configurations to be thoroughly tested before assembly, significantly reducing unexpected reworks. Issues were also better anticipated and documented in tracking systems. The EVC process improved quality and ensured vehicles met sign-off timing for proving ground tests.

1. GMI700/31Ux – Use of A-
frame – Integration Phase
(a bench with slave parts of the vehicle) to test the
wiring supplied for each vehicle to avoid reworks
during assembly process due to quality issues from
supplier or mismatch between property options and
wiring circuits.

2.  GMI700/31Ux Program – New mid size truck & SUV
for emerging markets (like Chevrolet Colorado in the
US). Join Venture between GM and Isuzu Japan.
There were About 300 vehicles assembled in the
experimental engineering (50 mules, 250 integration).
 Many issues in integration phase were found during
final check of vehicle before calling sign off. Issues
related to the poor quality of wiring prototypes and
related to the wiring design process.
 Consequence: unexpected reworks in a urgency way
in order to not jeopardize the sign off date and delivery
to proving grounds. Wiring is a hidden part and time
wasting in unavoidable depending on the kind and
location of the issue (engine or passenger
compartments).

3.  What was the challenge: reduce the risk of rework activities
during complete vehicle final check and impact in next step
(sign off and tests beginning in the proving ground).
 There was about 250 vehicles to be assembled in the
experimental engineering in five different buckets (one year
and a half). Many features and features combinations in the
same time (engines, cabins, drive lines, drive sides, others).
 Electrical laboratory examined only few combinations due to
space, time and cost constraints. Visual checks and beep
tests in the supplier were not able to got all the issues once
bad crimpings were hidden inside connector’s housing. Other
issues were related to EPL’s (Electronic Part List containing
all harness part numbers) and Netlist’s (list of all circuits of
vehicle) files quality and markup manual selection of part
numbers.
 Consequences: harness part numbers selected were not
compatible with vehicle features or were delivered with
missing, inverted or wrong circuits (short/long/others).

4.  Two additional benches were built by the electrical laboratory and
sent to PPO (Pre Production Operations). Benches contained all
electrical parts used in all vehicle versions (batteries, fuse boxes,
ECU’s, clusters, switches, power window motors, door lock motors,
head lamps, rear lamps, others). One bench was arranged for LHD
(left hand drive) version and the other one for RHD (right hand
drive) version according to each harness different layout
configuration.
 A list with all vehicles to be assembled during a specific bucket was
printed from GM Embassy system. The list contained the property
number and the RPO’s (sequence of features codes) applied to it.
 The complete schematic of all vehicle versions and used for
harness construction was provided and two electricians were
allocated to execute the two EVC’s – Electrical Vehicle Check. A flip
chart to write all issues found during the EVC of each vehicle was
used by the operators. All parts in the bench remained fixed (slave
parts) except the wiring harness set. Each property wiring harness
set was tested connecting and energizing all parts and testing the
most common functions (lighting, power windows, power mirrors,
radio, ventilation, others). Complete activity including installing and

5.  There was a drastic reduction of unexpected reworks due to electrical issues caused by wirings
during final check of complete vehicle. More confident to call sign off and deliver vehicle to
proving ground on time (big 4). Interference issues and other issues related to the layout of the
harness still found in the vehicle during assembly process however the impact of those in the
activities were small.
 It was possible to anticipate and register schematic, EPL and Netlist issues into PRTS (Problem
Resolution Tracking System) before starting vehicle assembly.
 It was possible to anticipate and register supplier quality issues into PRR (Problem Resolution
Report). Supplier provided a part time resident engineer to perform wiring reworks during the EVC
activity.
 All reworks were registered in time by Design Release Engineer (DRE) into GM E2 system
through edition of a WO BSD (Work Oder – Built Site Direction).
 Change in the MRD (Material Request Date) for wiring harness set in order to accommodate the
time necessary to complete EVC activities. Supplier agreement to deliver the set in anticipation to
the official MRD provided by the program management.
 Possibility to convert the two benches to LHD or RHD versions depending on the amount of
vehicles of a specific configuration in a bucket.
 Extension of the EVC activity to other programs and platforms. Started in GMI700 (Mid Size
Truck), extended to GMI31Ux (SUV), Global Small Vehicle (GSV – Cobalt and Spin) and others.