GM avoided redesign of defective switch in 2005 to save US$1 each
Print Edition
GENERAL Motors in 2005 decided not to change an ignition switch eventually linked to the deaths of at least 13 people because it would have added about a US dollar to the cost of each car, according to an internal GM document provided to US congressional investigators.
The US House Committee on Energy and Commerce released the documents on Tuesday as lawmakers asked CEO Mary Barra why GM failed to recall 2.6 million cars until more than a decade after it first noticed a switch fault that could cut off engines and disable airbags, power steering and power brakes.
Colorado Congresswoman Diana DeGette cited a 2005 GM document that she said showed a cost of 57 cents per fix.
DeGette did not release the document, and Reuters was unable to get a copy. However, Reuters obtained what appeared to be a separate document, a series of 2005 e-mails between GM engineers debating whether to make a change to the ignition switch. The change would have cost an extra 90 cents per unit and additional tooling costs of US$400,000, one e-mail showed. Those tooling costs are amortized over several years.
Barra said she found the concept of turning down the change because of tooling costs “very disturbing. That is not the way we do business in the New GM.”
In the e-mail exchange, one of the engineers, John Hendler, said his team was prepared to continue using a switch that was made by Delphi Automotive and approved by GM, even though Delphi told the automaker in early 2002 that the switch did not meet GM’s performance specifications.
Hendler said the cars, including the Chevrolet Cobalt and Saturn Ion, which were recalled this year, would continue using the old switch “until the piece cost can be eliminated or significantly reduced,” and targeted a new switch for 2009 models.
Another GM executive, Lori Queen, who had responsibility for the development of GM’s small cars, responded, “I’m not sure it’s OK to wait.” She did not explain herself in the e-mail.
A GM spokesman said the company was still investigating the recall and would review all relevant documents.
Representatives repeatedly questioned Barra about GM’s weighing of costs even in safety situations. Barra said that was no longer the case, and that the company since its 2009 bankruptcy was changing from a “cost culture” to one focused on customers.
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