Product Overview

Summary: This SOP sets out a controlled, WHS-focused process for performing software updates on electric vehicles in a workplace setting. It helps organisations manage cyber, electrical and operational safety risks while keeping EV fleets compliant, reliable and aligned with manufacturer and Australian regulatory requirements.

As electric vehicles become standard across Australian fleets, software updates are no longer an occasional, simple task—they are a critical safety and performance function. Poorly managed updates can introduce operational faults, disable key safety systems, expose vehicles to cybersecurity threats, or leave your organisation non-compliant with manufacturer guidance and WHS obligations. This Safe Operating Procedure provides a clear, step-by-step method for planning, authorising, executing and verifying EV software updates in a way that protects workers, passengers, assets and data.

The procedure covers both over‑the‑air (OTA) and workshop-based updates, integrating WHS risk management with IT security and operational controls. It defines who may initiate updates, how vehicles are isolated and made safe, how data and configuration are backed up, and how to test and sign off vehicles before they return to service. By implementing this SOP, businesses can standardise their approach across multiple sites, demonstrate due diligence under Australian WHS law, and reduce downtime, incidents and costly post-update troubleshooting.

Designed for the Australian context, this document supports organisations operating light and heavy EV fleets, pool vehicles, service vans and specialist plant. It complements existing vehicle maintenance schedules, electrical safety procedures and information security policies, giving you a practical, defensible framework for managing EV software changes from both a safety and governance perspective.

Key Benefits

• Ensure EV software updates are performed safely, consistently and in line with manufacturer and WHS requirements.
• Reduce the risk of software-related faults impacting critical safety systems such as braking, stability control and battery management.
• Strengthen cyber resilience by controlling access, authentication and logging for over-the-air and connected updates.
• Minimise vehicle downtime through planned, documented update windows and clear return-to-service checks.
• Demonstrate due diligence to regulators, insurers and clients through a documented, auditable update protocol.

Who is this for?

• Fleet Managers
• Workshop Managers
• Automotive Technicians
• Electric Vehicle (EV) Specialists
• WHS Managers and Advisors
• IT and Cybersecurity Managers
• Facilities and Asset Managers
• Transport and Logistics Coordinators
• Public Sector Fleet Coordinators
• Sustainability and ESG Managers

Hazards Addressed

• Unintended deactivation or malfunction of safety-critical systems (e.g. ABS, traction control, ADAS) following updates
• Electrical hazards during workshop-based updates, including exposure to high-voltage components if isolation is not correctly applied
• Vehicle movement hazards in workshops or depots during update and post-update testing activities
• Cybersecurity breaches via compromised update channels, unauthorised access or insecure network connections
• Data integrity and privacy risks relating to vehicle telemetry, location data and user information
• Manual handling and ergonomic risks associated with connecting diagnostic tools, charging equipment and test devices
• Fire risk associated with high-voltage battery systems if updates affect thermal management or charging behaviour

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (EV Systems, OTA Updates, High Voltage, ADAS, etc.)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Manufacturer Requirements
• 5.0 Pre-Update Planning and Risk Assessment
• 6.0 Vehicle Identification, Verification and Update Eligibility
• 7.0 Safety Preparations and Isolation Procedures for EVs
• 8.0 Network, Cybersecurity and Access Control Requirements
• 9.0 Over-the-Air (OTA) Software Update Procedure
• 10.0 Workshop-Based and Diagnostic-Tool Update Procedure
• 11.0 Data Backup, Configuration Management and Version Control
• 12.0 Post-Update Functional and Safety System Testing
• 13.0 Return-to-Service Criteria and Authorisation
• 14.0 Incident, Fault and Rollback Management
• 15.0 Documentation, Recordkeeping and Audit Trail
• 16.0 Training, Competency and Supervision Requirements
• 17.0 Communication with Drivers, Operators and Stakeholders
• 18.0 Continuous Improvement, Review and Change Management

Legislation & References

• Model Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS legislation
• Model Work Health and Safety Regulations 2011
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Electrical Risks in the Workplace
• AS/NZS 5732: Electric vehicle operations – Maintenance and repair (where applicable or as emerging guidance)
• AS/NZS 3000: Electrical installations (Wiring Rules) – for associated electrical infrastructure and charging systems
• AS ISO 39001: Road traffic safety (RTS) management systems
• AS ISO/IEC 27001: Information security management – for integration with organisational IT security controls
• Manufacturer-specific EV service and software update bulletins and technical instructions