Product Overview

Summary: This SOP provides a structured, WHS-aligned approach to managing employee health and wellness in electric vehicle (EV) facilities, where unique physical, chemical and psychosocial risks converge. It supports Australian businesses to proactively protect workers, reduce health-related disruptions, and foster a sustainable, high-performance workforce in a rapidly evolving industry.

Electric vehicle facilities combine traditional workshop risks with emerging hazards from high-voltage systems, battery chemistry, fast-charging infrastructure and evolving work patterns. This SOP translates those complexities into a practical, health- and wellness-centred framework that integrates WHS obligations with contemporary wellbeing initiatives. It covers physical health (ergonomics, fatigue, heat, noise, exposure to battery chemicals), mental health (stress, shift work, change fatigue) and broader wellness measures tailored to EV design, manufacturing, maintenance and charging environments.

By implementing this procedure, organisations can move beyond ad-hoc wellness programs and establish a consistent, defensible system for supporting employee health across the full lifecycle of EV operations. The SOP sets out clear responsibilities, risk assessment processes, health monitoring strategies, early intervention and reporting pathways, and links to Employee Assistance Programs (EAPs) and external health providers. It helps businesses meet their primary duty of care under Australian WHS legislation, reduce absenteeism and turnover, and position themselves as employers of choice in the competitive EV sector.

The document is designed for practical use on the ground: it aligns health and wellness initiatives with day-to-day tasks such as high-voltage work, battery handling, workshop activities, warehouse operations and field servicing. It provides step-by-step guidance on integrating wellness considerations into toolbox talks, pre-starts, training, rostering, job design and incident investigations, ensuring that health and wellness are embedded into how work is planned and performed—not treated as an optional add-on.

Key Benefits

• Ensure compliance with Australian WHS laws by systematically addressing both physical and psychological health risks in EV facilities.
• Reduce absenteeism, presenteeism and turnover through structured early intervention, support pathways and wellness initiatives.
• Strengthen workforce resilience by embedding mental health, fatigue and stress management into daily EV operations and supervision practices.
• Standardise health and wellness practices across multiple EV sites, shifts and teams, improving consistency and accountability.
• Enhance employer brand and worker engagement by demonstrating a genuine, documented commitment to employee wellbeing in a high-tech industry.

Who is this for?

• WHS Managers
• Health and Safety Representatives (HSRs)
• EV Facility Managers
• Operations Managers
• Human Resources Managers
• People and Culture Managers
• Workshop Supervisors
• Battery Manufacturing and Assembly Supervisors
• Maintenance Managers
• Return-to-Work Coordinators
• Occupational Health Nurses
• In-house Rehabilitation and Injury Management Coordinators

Hazards Addressed

• Exposure to hazardous substances associated with batteries (electrolytes, fumes, off-gassing during failures or thermal events)
• Musculoskeletal disorders from repetitive tasks, awkward postures and manual handling of EV components and battery packs
• Fatigue from shift work, extended hours, call-outs and irregular maintenance schedules
• Heat stress in workshops, charging areas or battery rooms with limited ventilation or high ambient temperatures
• Noise exposure from plant, equipment, ventilation systems and workshop operations
• Psychological hazards including high workload, tight deadlines, rapid technological change and role ambiguity
• Stress and anxiety related to high-voltage work, perceived risk of electric shock, and incident exposure
• Sedentary work risks for design, engineering, monitoring and control room staff
• Eye strain and discomfort from prolonged screen use, diagnostics and monitoring systems
• Occupational violence or aggression from customers or members of the public in EV service or charging environments

Included Sections

• 1.0 Purpose, Scope and Objectives
• 2.0 Definitions and Key Terms (EV-Specific Health and Wellness Concepts)
• 3.0 Roles, Responsibilities and Consultation (Officers, Managers, HSRs, Workers)
• 4.0 Overview of Health and Wellness in Electric Vehicle Facilities
• 5.0 Risk Management Process for Health and Wellness Hazards
• 6.0 Physical Health Management in EV Facilities
• 6.1 Ergonomics and Manual Handling of EV Components and Battery Packs
• 6.2 Noise, Heat and Environmental Conditions in Workshops and Charging Areas
• 6.3 Sedentary Work and Screen-Based Task Management
• 6.4 Health Monitoring and Fitness for Work Considerations
• 7.0 Psychological Health and Psychosocial Hazard Management
• 7.1 Identifying Psychosocial Risks in EV Operations
• 7.2 Workload, Shift Work and Fatigue Management
• 7.3 Managing Stress Linked to High-Voltage and Battery-Related Tasks
• 7.4 Support Pathways, EAP and Confidential Reporting
• 8.0 Wellness Programs and Preventive Initiatives
• 8.1 Site-Based Wellness Activities and Resources
• 8.2 Integration of Wellness into Toolbox Talks and Pre-Starts
• 8.3 Health Promotion, Education and Training for EV Workers
• 9.0 Early Intervention, Incident Response and Return-to-Work
• 9.1 Reporting Health and Wellness Concerns
• 9.2 Responding to Health-Related Incidents and Near Misses
• 9.3 Rehabilitation, Return-to-Work and Suitable Duties in EV Settings
• 10.0 Communication, Consultation and Worker Engagement
• 11.0 Training, Competency and Induction Requirements
• 12.0 Recordkeeping, Confidentiality and Privacy Considerations
• 13.0 Performance Monitoring, Review and Continuous Improvement
• 14.0 References, Legislation and Applicable Standards
• 15.0 Appendices – Sample Checklists, Health and Wellness Plans, Toolbox Talk Templates

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• Safe Work Australia – Code of Practice: Managing the Risk of Psychosocial Hazards at Work
• Safe Work Australia – Guide: Work-related Psychological Health and Safety
• Safe Work Australia – Guide: Managing the Risks of Working in Heat
• AS/NZS 45001:2018 Occupational health and safety management systems
• AS/NZS 4801:2001 Occupational health and safety management systems (superseded but still referenced in some organisations)
• AS/NZS 1269 Occupational noise management (series)
• AS/NZS 1680 Interior lighting and the visual environment (series) – for office and control room environments
• Any applicable state-based Codes of Practice relating to Hazardous Chemicals and Manual Tasks