What this checklist covers
The EV Parts Storage Checklist is a 15-point scorecard for HV parts storage, battery components, cable labelling, segregation, damage prevention, temperature control, and traceability. Each criterion is scored from 1 to 5 on what the auditor sees on the day, and every gap goes into an action plan with an owner and a close date.
AutoSmart tip: EV parts storage audits should verify that HV component labelling is sufficient to be understood by any staff member who might encounter the storage area — including emergency responders. A clearly marked HV warning on every stored battery component could be critical information for a first responder in an incident involving the storage area.
The checks
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HV component storage and labelling
- Are all high-voltage components (battery packs, HV cables, power electronics, inverters) stored in a clearly labelled, dedicated HV storage area, separate from standard parts storage?
- Is every stored HV component labelled with the part number, vehicle application, condition (new, used, remanufactured), and HV warning indicator?
- Are HV cables stored in a way that prevents connector damage — with protective caps fitted, cables coiled without sharp bends, and no heavy items placed on top?
- Are non-HV-certified staff prevented from accessing the HV parts storage area, with physical access control or a clear restricted- access designation enforced?
Battery parts and segregation
- Are battery modules and packs stored in their OEM-specified orientation — not inverted, tilted, or stacked beyond the manufacturer's permitted stack height?
- Are used or returned battery components stored separately from new parts, clearly labelled as 'Used — Awaiting Assessment' and not available for fitment without inspection?
- Are battery parts from different EV models stored separately and clearly identified by vehicle compatibility, to prevent incorrect fitment of a similar-looking but incompatible unit?
- Is a damaged or suspect HV battery component quarantined in a designated safe area — isolated from other parts, externally labelled, and assessed before any decision on use, return, or disposal?
Damage prevention and temperature control
- Is the HV parts storage area maintained within the temperature range specified by component manufacturers, with no HV parts stored in areas subject to extreme heat, cold, or humidity?
- Are battery packs stored at the OEM- recommended state of charge for storage periods, with charge level checked and maintained on the defined schedule?
- Is HV parts storage free from ignition sources, with appropriate fire suppression available and no flammable materials stored in the same area?
Traceability and governance
- Is a register maintained for all HV parts in storage, recording part number, serial number, vehicle VIN of origin (for used parts), storage date, condition, and charge level (for battery parts)?
- Is HV parts traceability sufficient to support a recall — allowing identification of all stored units from a specific batch or supplier if a safety notice is issued?
- Are HV parts disposal records maintained, confirming batteries and HV components were handled by a licensed recycler or returned to the OEM-designated recovery programme?
- Is the HV parts storage area included in the regular parts department audit cycle — not treated as an exception zone outside normal inventory and housekeeping standards?
How to run it
How the scoring works
Before the visit, fill in the dealer or centre, the auditor, the date and the audit cycle. Then score each of the 15 checks from 1 to 5 on what you see on the day, not on what the site aims for, and add them up out of 75.
- 1Not in place
- 2Attempted
- 3Defined
- 4Managed
- 5Fully sustained
- Green60–75 · 80–100%Compliant. Keep the standard.
- Amber38–59 · 50–79%Improvement needed: a structured action plan within 30 days.
- Red0–37 · Below 50%Priority intervention, escalated to regional management.
Then close every gap
Each gap goes into the action plan tracker and moves through four stages until the auditor closes it.
- 1PendingOwner and close date set
- 2In progressWork under way, evidence gathered
- 3CompletedEvidence submitted for review
- 4ApprovedVerified and closed by the auditor
