Here are a couple of old articles about the Volt. Probably quite representative of the auto industry. Clarification: GMs Chevy Volt Build Schedule for 2010 Transition From Integration to Pre-Production Begins Now: Thousands of Chevy Volts to be Built Early Next Year So, GM only built less than 100 non-saleable Volts on the actual production assembly line. They expect to do all the "debugging" during that time. After that the actual production starts - but slowly. They make a small number of cars in the beginning per day - inspecting all of them carefully - ramping up as they gain confidence and fine tune the assembly process.