Product Overview

Summary: This SOP sets out a clear, step-by-step framework for managing health and safety risks in electric vehicle (EV) production environments. It helps Australian manufacturers control high‑voltage, battery, chemical, ergonomic and plant-related hazards while demonstrating robust compliance with WHS obligations across design, assembly, testing and rework operations.

Electric vehicle production combines traditional manufacturing risks with complex electrical, battery and chemical hazards that must be tightly controlled to protect workers and meet Australian WHS requirements. From handling high‑voltage components and lithium‑ion battery packs to managing automated plant, robotics and manual assembly lines, the risk profile is significantly different from conventional automotive manufacturing. This SOP provides a structured, practical framework for planning, conducting and supervising EV production tasks safely, ensuring that high‑risk activities are carried out in a consistent, documented and defensible way.

The procedure covers the full lifecycle of EV production activities, including receipt and storage of cells and modules, battery pack assembly, integration of high‑voltage systems, commissioning, testing, rework, and de‑energisation for maintenance. It sets out how to identify and control hazards such as electric shock, thermal runaway, arc flash, chemical exposure, fire, crush and ergonomic risks, while embedding lockout/tagout, isolation, PPE, housekeeping and emergency response into daily operations. By adopting this SOP, organisations can strengthen their due diligence, streamline training for new and existing workers, reduce incident rates, and align their EV production lines with best practice and contemporary Australian WHS standards.

Key Benefits

• Ensure consistent control of high‑voltage and battery-related risks across all EV production activities.
• Reduce the likelihood of electric shock, thermal runaway events, fires and serious injuries in the workplace.
• Demonstrate compliance with Australian WHS legislation, electrical safety requirements and relevant standards.
• Standardise training and induction for production, maintenance and engineering teams on EV‑specific hazards.
• Improve operational reliability by embedding safe isolation, testing and verification into production workflows.

Who is this for?

• EV Production Managers
• Manufacturing Operations Managers
• WHS Managers and Advisors
• Plant and Factory Supervisors
• Electrical Engineers
• Battery Assembly Team Leaders
• Maintenance Supervisors
• Health and Safety Representatives (HSRs)
• Process Improvement Engineers
• Quality Assurance Managers

Hazards Addressed

• Electric shock and electrocution from high‑voltage systems and components
• Arc flash and arc blast during testing, commissioning or fault conditions
• Thermal runaway of lithium‑ion batteries leading to fire, explosion or toxic off‑gassing
• Exposure to hazardous chemicals, electrolytes and fumes from batteries and associated processes
• Burns from hot components, charging systems and thermal management equipment
• Mechanical entanglement, crushing and impact from conveyors, robotics and automated plant
• Manual handling injuries from lifting and moving heavy battery packs and driveline components
• Slips, trips and falls due to poor housekeeping, cabling, tools and components on walkways
• Noise-induced hearing loss from production machinery and test equipment
• Eye injuries from flying particles, sparks or battery venting events
• Ergonomic strain from repetitive assembly tasks and awkward postures
• Fire and explosion risks in battery storage, charging and testing areas
• Exposure to hazardous gases and smoke during battery failure or fire events

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and EV-Specific Terminology
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification for EV Production Activities
• 6.0 Risk Assessment and Control Hierarchy
• 7.0 High-Voltage Systems: Isolation, Lockout/Tagout and Verification of De-energisation
• 8.0 Lithium-Ion Battery Handling, Storage and Assembly Requirements
• 9.0 Safe Operation of Plant, Robotics and Automated Systems
• 10.0 Manual Handling and Ergonomic Controls for EV Components
• 11.0 Personal Protective Equipment (PPE) Selection, Use and Maintenance
• 12.0 Housekeeping, Traffic Management and Work Area Layout
• 13.0 Pre-Start Checks, Permits and Authorisations for High-Risk Tasks
• 14.0 Safe Work Steps for EV Assembly, Testing, Rework and Commissioning
• 15.0 Managing Hazardous Chemicals, Fumes and Ventilation in EV Production
• 16.0 Battery Thermal Runaway, Fire and Explosion Prevention Measures
• 17.0 Emergency Response: Electric Shock, Battery Failure, Fire and Chemical Exposure
• 18.0 Incident Reporting, Investigation and Corrective Actions
• 19.0 Training, Induction and Competency Verification for EV Production Staff
• 20.0 Inspection, Maintenance and Review of Controls and SOP Effectiveness
• 21.0 Document Control, Version History and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing Electrical Risks in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• AS/NZS 3000: Electrical installations (Wiring Rules)
• AS/NZS 4836: Safe working on or near low-voltage electrical installations and equipment
• AS IEC 62133 series: Safety requirements for portable sealed secondary cells and batteries (as applicable to battery modules)
• AS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use
• AS 1940: The storage and handling of flammable and combustible liquids (where applicable to battery electrolytes and solvents)