The thesis describes the diagnosis, testing and calibration activities to be performed for the correct evaluation and estimation of the plant process readiness of a novel BEV to be produced in automotive mass volumes. These activities are aimed at the analysis and management of the possible failures and risk situations that could occur in the final vehicle development phase and are performed through specific and innovative methods and procedures derived from the ICEV development experience and modified according to the specificities of a pure e-propulsion system based vehicle fed by a HV battery with Li-ion cells. The defined methodology has been applied for its validation to the new Fiat 500 electric to be produced at the FCA Mirafiori Plant.