The electric vehicle (EV) market is expected to achieve record numbers this year and for the foreseeable future. EV sales account for 8.9% of total auto sales, the highest percentage ever, and a full 1.1% year-over-year increase. Industry analysts believe EVs are poised to eclipse 10% percent of total auto sales in the United States.
This means that manufacturing processes will need to adapt as auto manufacturers work to scale their operations, enhance efficiency, and meet emerging safety standards.
Figure 1. As EV production scales, manufacturers are implementing advanced safety measures to address high-voltage systems, ergonomic risks, and automated machinery integration.
EV manufacturers are not just retooling to produce better products (though they are). They also can engineer safety into the production line, protecting and supporting their most valuable asset — their people (Figure 1).
The shift to EV manufacturing introduces several unique safety challenges that differ from typical automotive production. For example, high-voltage battery systems require specialized handling procedures to prevent electrical hazards, while thermal runaway risks necessitate advanced cooling and fire suppression measures.
Additionally, the integration of new materials, such as lightweight composites and advanced adhesives, presents distinct ergonomic and chemical exposure risks for workers. As automation increases, manufacturers must also ensure proper machine safety protocols and worker training to mitigate potential risks in highly automated production environments. Addressing these challenges is essential to maintaining a safe, efficient, scalable EV manufacturing process.
Here are three ways EV manufacturers can improve safety, efficiency, and employee satisfaction on the production line.
1. Investing in quality equipment
Automakers are investing billions in EV manufacturing, including significant contributions from conventional car makers and EV upstarts like Rivian, which is allocating massive funds to construct a new manufacturing facility in Georgia (Figure 2).
Much of this money will go toward big-ticket investments like advanced assembly robotics, battery module manufacturing lines, and facility expansions. However, even relatively small investments in quality equipment can have an external impact on production capacity, work quality, and total cost outcomes.
For example, Rivian’s Production Excellence Team faced a significant challenge with their Metrology Cell carts. Employees regularly moved 1,600-pound carts in and out of the Metrology Cell for scanning and measurement, requiring frequent, precise maneuvers.
However, the carts’ existing caster wheels generated high push forces, causing significant strain and increasing the risk of overexertion injuries. In this instance, a seemingly minor issue with caster wheels led to significant consequences for employees and the company.
Figure 2. Rivian’s investment in US manufacturing strengthens electric vehicle production, with aims to advance production safety.
The EV manufacturer invested in caster wheels tailored to specific use cases to address these issues, minimizing friction and eliminating wheel scrubbing. This reduced push force from 76 pounds to just 37.7 pounds, a 50% improvement that elevated safety for 92% of employees.
The lesson is simple: engineering safety starts with quality equipment that delivers the productivity and efficiency gains needed to provide a safe workplace for employees and an incredible product for customers.
2. Accounting for noise and ergonomics
Auto manufacturing facilities have two challenges that undermine workplace safety and long-term productivity: they are loud and require repetitive motion.
A study by the National Library of Medicine found that noise levels in auto manufacturing facilities often reach harmful levels, specifically impacting long-term employees exposed to loud noises over extended periods.
As the study explains, “Subjects with employment duration exceeding 10 years significantly developed hearing loss in either ear.”
That’s why The US Department of Labor requires employers to “measure noise levels; provide free annual hearing exams, hearing protection, and training; and conduct evaluations of the adequacy of the hearing protectors in use.”
EV manufacturers can address this regulatory requirement by reducing the overall volume of their facilities and providing noise protection equipment to all employees. For instance, minor adjustments, such as upgrading caster wheels, enhancing machine lubrication, and adding noise-dampening panels, can decrease noise levels and minimize the risk of hearing damage.
At the same time, EV manufacturers can address repetitive motion risks when redesigning their facilities for EV production.
This might include installing:
- Height-adjustable tables and workstations
- Tools with molded grips, lightweight materials, and vibration-dampening technology
- Cushioned floor mats at workstations reduce joint stress from prolonged standing
- Automated material handling systems to reduce manual lifting and repetitive strain injuries (Figure 3)
Figure 3. From noise reduction to ergonomic improvements, EV manufacturers are reengineering production lines to enhance worker safety and long-term operational efficiency.
In the long term, EV manufacturers can analyze production line data to identify ergonomic improvements based on worker habits and injury trends, making progressive improvements that support long-term employee safety and productivity.
3. Engineering for safety
The automotive industry has long been defined by expertise and high production capacity. However, EV manufacturing introduces a fundamentally different production process with unique risks and safety concerns.
To address these challenges, it’s essential companies take a proactive approach to safety, ensuring that employees are equipped with the necessary training and protocols specific to EV production. Strategically fostering a culture of safety that reflects these differences is essential to maintaining efficiency and worker protection.
This can be achieved in four stages:
- Conducting training sessions on safety protocols, equipment use, and emergency procedures
- Training employees on proper cart use, maintenance schedules, and material handling techniques
- Offering hands-on practice with tools and machinery for employee proficiency
- Maintaining documentation of training completion for each employee
A strong safety culture doesn’t develop by chance; it must be intentionally built and prioritized alongside other critical decisions in the transition to multifaceted automotive production.
Safety is a strategy
The EV sector may be experiencing a season of uncertainty, but one thing is sure: the automotive sector includes EVs.
As manufacturers refine their processes, retool facilities, and invest in new technologies, prioritizing safety becomes a strategic advantage. Investing in high-quality equipment, addressing noise and ergonomic challenges, and fostering a strong safety culture are essential to achieving both efficiency and long-term success.
This shift to EV manufacturing presents a unique opportunity to integrate advanced safety measures, automation, and ergonomic improvements from the start — resulting in safer, more efficient facilities that drive the production of higher-quality electric vehicles.
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