What this checklist covers
The EV Service Workshop Checklist is a 15-point scorecard for EV service bays, high-voltage work areas, insulated tools, safety equipment, repair workflow, and quality control. 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 workshop safety cannot be treated as a standard workshop safety extension — the consequences of an HV isolation failure are fundamentally different from those of a conventional workshop accident. The minimum non-negotiable for every EV HV job is: certified technician, verified isolation documented on the job card, correct PPE worn and inspected. Auditors should verify all three against actual job cards, not only against posted procedures.
The checks
Tap Yes, No or Maybe to try it: your answers stay in this page and clear when you refresh. For a detailed walkthrough, download our PDF or book a demo.
EV service bays and HV work area
- Is a designated EV service bay clearly marked, with HV warning signage, restricted access during live HV work, and no non-HV-certified staff permitted to enter while HV work is in progress?
- Is the EV bay flooring non-conductive or insulated where required by the OEM's workshop safety specification for high-voltage work?
- Is the HV isolation point for the EV service bay clearly labelled and accessible without obstruction, allowing emergency de- energisation without delay?
- Are EV vehicles awaiting HV work clearly labelled with HV caution markers to prevent non-certified technicians from inadvertently accessing the high-voltage system?
Insulated tools and safety equipment
- Are all tools used in HV work rated for the voltage levels involved, with insulation class marked on each tool and tools inspected for insulation damage before each use?
- Are Class 0 (or higher, as required by the OEM) insulating gloves available in the HV work area, within their test validity period, stored in a protective case?
- Is a HV safety kit (insulating mat, HV barriers, warning signs, lockout/tagout equipment) available in the EV service area and confirmed as complete?
- Is HV PPE inspected before each use for signs of damage, puncture, or degradation — with damaged items removed from service immediately regardless of test validity date?
Repair workflow and technician allocation
- Are EV and HV jobs allocated exclusively to certified HV technicians, with the DMS or job allocation system preventing assignment to non-certified staff?
- Is the HV isolation procedure completed and documented before any work that requires accessing the high-voltage system, with isolation confirmation recorded on the job card?
- Is a second-person awareness protocol followed for live HV work — where a second trained person is aware of the work in progress and can act in an emergency?
Quality control and documentation
- Is a post-repair quality check completed after every EV HV system intervention, confirming the system has been correctly re-energised, all interlocks are restored, and no warning lights remain?
- Is HV work documented on the job card with specific reference to the isolation procedure followed, the system(s) accessed, and the re- energisation check completed?
- Is EV battery state-of-health (SoH) or equivalent diagnostic data recorded on the job card where a battery-related diagnosis or repair is performed?
- Are EV service quality incidents (HV near-miss, incorrect isolation, diagnostic error) logged and reviewed in a separate safety incident process — not absorbed into the standard comeback or complaint management process?
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
