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GM executive chief EV engineer says reducing cost of plug-in vehicles is 'huge priority'

As we know, another major automaker investing heavily in electrified vehicles is General Motors, and it's doing things much differently than rivals BMW, Ford or Nissan. The Chevrolet Volt extended-range EV is a modest seller at its $35,000 sticker price but a huge hit with owners. The Chevy Spark BEV, still in limited availability, puts smiley faces on its owners and drivers. The just-introduced Cadillac ELR, a sharp-looking, fun-driving $76,000 luxocoupe take on the Volt's EREV mechanicals, has admittedly low sales expectations. With this interesting trio in showrooms and much more in the works, the third vehicle electrification leader I collared for an interview at Detroit's North American International Auto Show (see #1 and #2) was Pam Fletcher, GM's executive chief engineer, Electrified Vehicles. ABG: Why do your EREVs need four-cylinder power to extend their range when BMW's i3 makes do with an optional 650 cc two-banger? "We designed [the Volt and the ELR] to go anywhere, any time" - Pam Fletcher PF: I get that question all the time: why not something smaller? You don't really need that much. You use the electric to its ability, then you just need to limp. But we designed those cars to go anywhere, any time, and we don't want their performance to be compromised. If you're driving through the mountains, we don't want you to be crawling up grades, or to be limited on any terrain. So it's optimized to be able to travel literally the biggest grades and mountain roads around the globe at posted speeds. Because what if you can't? Another good reason: when the engine is on, you have to run it wide open throttle, max speed, most of the time. And while we can do a lot with acoustics, and the ELR has active noise cancelation, a small-displacement, low cylinder-count engine at high speed, high load all the time isn't something you want to live with. That's how we came up with the balance we did among the key factors of performance, NVH [noise, vibration and harshness] and range. ABG: Where you go from here? Is the range-extender engine due for an update? PF: We know and love the current Volt, and there is still a lot of acclaim about it, so we think it's a good recipe. But we are heavily in the midst of engineering the next-generation car, which I think everyone will love and be excited about.

GM marks 500 million vehicles

General Motors is marking a major global milestone, as 500 million vehicles have rolled off its assembly lines since the company's founding in 1908. To mark the occasion, the automaker is continuing to invest in production and offering a one-time discount to some customers. GM North America boss Alan Batey used the festivities to announce the Fairfax Assembly factory in Kansas as one of the sites earmarked for the company's $5.4 billion in upcoming investments. The plant will get $174 million of that money for new equipment and technology to build the 2016 Chevrolet Malibu. Among the upgrades will be a shake-and-rattle booth that will simulate road conditions to find squeaks. To commemorate both the production milestone and the Fairfax plant, Batey and company CEO Mary Barra also gave away a 2016 Malibu to a wounded Iraqi war veteran, and the two execs announced that in the third week in May all GM employees can share a one-time customer appreciation discount with friends to help get them into the automaker's products. Barra also gave a speech to the workers there about some of the other milestone's in the company's history, which you can read below. Innovation on the Line: GM Manufacturing Milestones Many of General Motors' most important innovations have occurred behind the scenes, in its manufacturing facilities. Concepts such as changeover, flexible assembly, automation, computer simulation, machine vision and robotics were developed at GM. Over the decades these innovations have helped enable improvements in vehicle quality, efficiency and competitiveness. 1901: Ransom Olds' famous Curved Dash Oldsmobile, designed with simplicity, reliability and value in mind, was the first American car built in a factory designed specifically for automobiles and in standardized volume production. GM acquired Oldsmobile in 1908. 1908: Cadillac wins the Dewar Trophy, Europe's most prestigious award for precision and excellence in manufacturing, by demonstrating the auto industry's highest standards for precision and interchangeability of parts by disassembling three Cadillacs and mixing the parts randomly before reassembling and driving them before a contingent of judges. 1922: GM hires William Knudsen to lead Chevrolet's turnaround. Knudsen implements flexible mass production, which helps Chevrolet incorporate annual styling changes and take market share from Ford.

Weekly Recap: The implications of strong new car sales

New car sales are on a roll in the United States this year, and analysts are optimistic the industry will maintain its torrid pace. Sales increased 1.6 percent in May and reached an eye-popping seasonally-adjusted selling rate of 17.8 million, the strongest pace since July 2005, according TrueCar research. That positions the industry for one of its strongest years ever, as consumer confidence, low interest rates, low fuel costs, and an influx of new products propel gains. In addition to the positive economic factors, May also featured warmer weather across much of the US, an extra weekend, and it came on the heels of relatively weak April sales. Analysts suggest income tax refunds and the promise of summer driving and vacations also traditionally help May sales. "While 2015 will be one of the best years in the history of the US industry, in some ways it may be the very best ever," IHS Automotive analyst Tom Libby wrote in a commentary. "Not only are new vehicle registration volumes approaching the record levels of the early 2000s, but now registrations and production capacity are much more closely aligned so the industry is much more healthy." Capacity, an indicator of the auto sector's health, is also expected to grow. Morgan Stanley predicts it will eventually hit at least 20 million units per year, as many companies, including General Motors, Ford, Tesla, and Volvo are investing in new or upgraded factories. "The best predictor of US auto sales is the growth in capacity, and frankly, we're losing count of all of the additions – there's literally something new and big every week," Morgan Stanley said in a research note. Transaction prices, another telling indicator, also continue to show strength. They rose four percent in May to $32,452 per vehicle, and incentives dropped $10 per vehicle to $2,661, TrueCar said. "New vehicle sector and segment preference indicates consumers are confident about the economy and their finances," TrueCar president John Krafcik said in a statement. Still, Morgan Stanley noted the robust sales did little to immediately impact automaker stock prices and suggested it might be a prime time to sell if sales reach the 18-million pace. "Perhaps the biggest reason may be that investors have seen this movie before," the firm wrote.