Why its important to implement
EV/Hybrid vehicles have high-voltage systems creating serious injury/death risks and expensive electrical damage. Pre-repair requirements and windscreen EV stickers essential for safety protocols.
EV Identification Sticker
Plus there should always be on the windscreen the sticker telling all that it's a EV and the pre disconnection has been preformed
High Voltage Danger
This situation even more important with the introduction to more and more EV and HEV entering body shops as the voltage on these vehicles increase the risk of serious injury or death in addition the expensive damage to batteries or of the electronic parts of the vehicles
Pre-Repair Requirements
For these reasons it is important that each Ev or HEV vehicle entering the workshop should have a vehicle repair method with the job card or each technician should have access to the BMS on a terminal in their work bay. At the very least each technician should be reminded of any pre-repair requirements specific to the vehicle being worked on
EV/HEV Safety Priority
There many different brands and models of vehicles and each have specific instructions for removing refitting each part of the vehicle. It is impossible for a technician even with much experience to know the safest and most efficient way to remove and refit every part
EV OEM Evidence Requirements
Evidence of the vehicle repair method being accessed by the technician is a requirement by some OEM's
Business Impact
Prevents catastrophic safety incidents, expensive electrical damage, and legal liability. Protects business viability through proper safety procedures and OEM compliance for certification maintenance.
Profit
If the business allows its technicians to work by trial and error on new model vehicles or vehicles not commonly worked on, they will experience longer repair times in all remove and refit areas, this costs the business revenue
Profit
If the business allows its technicians to work by trial and error on new model vehicles or vehicles not commonly worked on, they are at a higher risk of damaging parts and the business having to pay for them without charge out to the work provider
Key to key
Wasted productivity due to waiting for information to begin working on the vehicle will lengthen the time the job is in the shop
Throughput, general, body and paint productivity
If the business allows its technicians to work by trial and error on new model vehicles or vehicles not commonly worked on they experience longer repair times in all remove and refit areas, this mean lower throughputs
Customer satisfaction
If there is a claim against the business because a a vehicle was repaired incorrectly through incorrect welding processes or by using methods to repair vehicles that is not approved, for example mishandling of electrical systems causing expensive damage would lose its reputation with work providers and customers
Overall Business Impact
EV/Hybrid safety reminders are critical for preventing catastrophic consequences and maintaining business viability. High-voltage systems require specialized knowledge to prevent serious injury, death, and expensive electrical damage. Without proper pre-repair requirements and safety protocols, businesses face significant liability exposure, reputation damage, and potential closure. Proper EV/Hybrid procedures protect staff safety, prevent costly mistakes, and maintain OEM compliance essential for certification and customer confidence
action steps
Implement EV/HEV requirement reminders when entering workshop. Train in repair method access. Establish usage verification systems. Strong safety protocol enforcement.
Performance Monitoring and Enforcement
Strong internal warnings if policy not followed once established
Performance Monitoring and Enforcement
Regularly check that this is being carried out for every job, strong internal warnings if policy not followed once established
EV/Hybrid Safety Implementation
If the shop uses the OEM systems directly or a BMS for the technicians to access repair methods it must establish a way for the production manager to prove they were used
EV/Hybrid Safety Implementation
Implement and train the process of accessing repair methods and placing them with each job card
EV/Hybrid Safety Implementation
Implement and train a process for the production manager or VDA to remind staff of EV and HEV requirements check when they enter the work shop
Related tasks
Milestone:
04: Production Management Optimisation