High Voltage EV Safety Checklist

This comprehensive high voltage ev safety checklist helps teams maintain regulatory compliance and operational control against OSHA 29 CFR 1910, NFPA 70E, and related requirements. Designed for Plant Supervisor / EHS / Quality Lead, complete all sections, capture evidence, and log corrective actions to reduce risk and improve readiness.

  • Industry: Automotive
  • Frequency: Weekly
  • Estimated Time: 20-35 minutes
  • Role: Plant Supervisor / EHS / Quality Lead
  • Total Items: 35
  • Compliance: OSHA 29 CFR 1910, NFPA 70E, IATF 16949, ISO 45001

Pre-Start & Documentation

Verify the shift starts with required permits, procedures, and records in place.

  • SOPs and work instructions available at point of use?
  • Latest risk assessment/JSA reviewed with team?
  • Required permits validated (hot work, LOTO, confined space) if applicable?
  • Previous shift issues reviewed and assigned?
  • Notes / exceptions

Machine Guarding & Safe Operation

Confirm safeguarding and safe operating controls per machinery safety standards.

  • Machine guards installed, intact, and not bypassed?
  • Emergency stops tested and accessible?
  • Interlocks/light curtains functional where present?
  • Lockout points labeled and accessible?
  • Photo evidence of guarding

Process Quality & Traceability

Verify critical quality checks, process parameters, and traceability controls.

  • Critical-to-quality checks completed at required frequency?
  • Gauges/fixtures within calibration date?
  • Traceability labels present and correct (lot/serial/date)?
  • Nonconforming material identified and segregated?
  • Record key readings (torque/press force/paint thickness)

Chemical Handling & WHMIS

Check hazardous products management, labeling, and SDS access.

  • All chemical containers labeled and in good condition?
  • SDS accessible for all chemicals in use?
  • Secondary containment used where required?
  • Spill kit stocked and available in area?
  • Notes on chemical issues

Preventive Maintenance & LOTO

Confirm maintenance readiness, planned work, and isolation controls.

  • PM schedule up to date for critical assets?
  • LOTO procedure available and followed for servicing?
  • Tools and parts stored safely (no trip hazards)?
  • Compressed air/hydraulic lines inspected for leaks?
  • Corrective actions assigned for any defects?

Ergonomics & Manual Handling

Reduce MSD risk by checking lifts, reaches, and workstation setup.

  • Lifts within limits or mechanical assist used?
  • Workstation height and reach zones acceptable?
  • Job rotation/breaks applied per plan?
  • PPE available and used (gloves, eye/ear)?
  • Photo of workstation setup

Emergency Preparedness & Reporting

Ensure emergency equipment is ready and incidents are reported correctly.

  • Fire exits/routes clear and illuminated?
  • First aid kit and AED accessible (if applicable)?
  • Incident/near-miss reporting process posted and understood?
  • Emergency contacts and muster points posted?
  • Corrective action summary

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Why Use This High Voltage EV Safety Checklist?

This high voltage ev safety checklist helps automotive teams maintain compliance and operational excellence. Designed for plant supervisor / ehs / quality lead professionals, this checklist covers 35 critical inspection points across 7 sections. Recommended frequency: weekly.

Ensures compliance with OSHA 29 CFR 1910, NFPA 70E, IATF 16949, ISO 45001. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the High Voltage EV Safety Checklist cover?

This checklist covers 35 inspection items across 7 sections: Pre-Start & Documentation, Machine Guarding & Safe Operation, Process Quality & Traceability, Chemical Handling & WHMIS, Preventive Maintenance & LOTO, Ergonomics & Manual Handling, Emergency Preparedness & Reporting. It is designed for automotive operations and compliance.

How often should this checklist be completed?

This checklist should be completed weekly. Each completion takes approximately 20-35 minutes.

Who should use this High Voltage EV Safety Checklist?

This checklist is designed for Plant Supervisor / EHS / Quality Lead professionals in the automotive industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

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