This section provides general information which can help to reduce the physical impact from the activities carried out in Service Centers.

In electric vehicle maintenance, the risks come not only from heavy physical effort but also from prolonged and precise postures. These repeated movements and awkward positions can cause back, neck, shoulder, and wrist pain. Prevent most common injury types due to poor ergonomics:

• Shoulder Overuse & Strain
• Wrist & Hand Disorders
• Knee Stress Injuries
• Neck Injury
• Elbow Stress Injuries
• Lower Back Strain & Injury

Prolonged or Awkward Posture

• Adjust workstation height and layout to allow comfortable, neutral postures - vehicle lifts included.
• Encourage frequent posture changes and avoid staying in the same position too long.

Manual Handling of Heavy or Bulky Loads

• Employ equipment like trolleys, hoists, pallet jacks, or forklifts to reduce manual lifting.
• Encourage lifting heavy or bulky items with the help of a partner.
• Avoid lifting loads that exceed recommended weight limits for a single person.
• Arrange workstations to minimize unnecessary repetitive movements and awkward reaches.

Slippery, Cluttered, Hard or Poorly Lit Floors

• Regularly clean spills and remove debris to prevent slips and trips.
• Install non-slip mats or apply anti-slip treatments on slippery surfaces.
• Use clear signage or floor markings to highlight slippery zones or obstacles.
• Keep tools, materials, and equipment properly stored to avoid cluttered walkways.
• Ensure adequate lighting in all work areas, especially near potential hazards.

Poorly Organized or Cramped Workspace

• Design the workspace to allow safe, efficient movement and access to tools and materials.
• Remove unnecessary items and store tools/equipment in designated locations.
• Ensure walkways and emergency exits are always free of obstacles.

Using Tools and Equipment, Vibration

• Take short breaks when using vibrating tools.
• Hold tools with your whole hand and not just your fingers.
• Keep wrists in neutral position.

Pushing and Pulling Loads

• Push rather than pull.
• Keep your elbows close to your body.
• Make sure floor surfaces are clean and dry before moving anything.
• Start slowly to avoid sudden jerks and resistance.

Working Above Shoulder Level

• Use adjustable lifts or platforms to bring the work closer to waist level.
• Employ tool balancers or extensions to reduce arm strain.
• Take regular breaks and vary tasks to avoid prolonged overhead reaching.
• Use team lifts or mechanical aids for heavy components above shoulder height.
• Train technicians on proper overhead reaching techniques and posture

Working in a Squatting Position

• Use height-adjustable creepers and stools or knee pads to reduce pressure on knees and legs.
• Rotate tasks frequently to avoid prolonged squatting.
• Encourage technicians to stand up and stretch regularly.
• Design workstations to allow sitting or use of supportive seats when possible.
• Provide training on safe squatting techniques and posture.

Kneeling Operations

• Keep your back straight and avoid twisting while kneeling.
• Take frequent breaks to stand, stretch, or walk.
• Use Lifts when it’s possible.

Tire Handling

• Stand close to the tire to avoid extended reach.
• Keep tires between your feet before lifting.
• Keep a neutral back: bend at the hips and knees, not the waist.
• Keep elbows close to the body and avoid overhead lifts when possible.
• Use a smooth, controlled motion.
• Use lift assists or team lifts for heavy/awkward tires.
• Take micro-breaks to reduce shoulder and back strain.

Glass Changes

• Keep work at elbow height to avoid reaching or bending.
• Hold glue gun with relaxed shoulders and straight wrists.
• Keep elbows close to the body to avoid extended reaching.
• Use a lightweight, low-trigger-force gun.
• Take short breaks to rest shoulder, forearm, and hand muscles.
• Vary tasks or alternate hands when possible.

Underbody Work

• Ensure vehicle is raised high enough to reduce overhead reaching.
• Use an adjustable stool or creeper seat to work at comfortable height.
• Keep arms below shoulder level whenever possible; alternate tasks to avoid fatigue.
• Use arm supports or tools to reduce sustained overhead effort.
• Rise from seated position using leg strength, not by twisting the knees.