Certification concept for EV service technicians
Six stops a new technician passes before working near a high-voltage system alone: 18 competencies, each with a clear way to prove it.
Designed by Mariia Mukhina, Learning Designer
Where the high voltage is, and why "off" is not safe.
Labels every HV component and orange cable on a vehicle or diagram, no errors.
Explains shock, arc flash and stored energy in capacitors in own words.
Explains why a parked, switched-off vehicle is still energised.
The right protection and tools, checked before every job.
Chooses rated insulated gloves with protectors and eye/face protection; removes metal jewellery.
Checks rating and test date, inspects and air-tests before each use; rejects a faulty glove.
Confirms meter category and voltage rating, inspects leads and tool insulation.
Nobody walks in, nothing switches on by accident.
Places barriers and signage before starting; keeps the zone clear.
Parks, moves the key out of range, follows the manual for the 12 V system.
Locks and tags the isolation point and keeps their own key.
De-energise by the book, then verify before touching anything.
Completes every step in order, including the specified wait time.
Performs a live-dead-live test; does not touch until verified.
Records isolation status on the work order before work begins.
Recognise danger early, stop, and get help the right way.
Spots heat, smoke, hissing, swelling or odour; stops work and escalates.
Does not touch the casualty, isolates power, uses the rescue hook, calls for help.
Recognises a Level 2+ task and hands it over instead of attempting it.
The next person knows exactly what state the car is in.
Updates the status board and briefs the next technician at handover.
Re-energises per manual and completes the return-to-service check.
Logs a near-miss within the shift using the site process.
Awareness is taught and checked online. Doing is proven on the shop floor, against the same criteria shown at each stop.
Why HV safety matters and what the certificate unlocks.
HeyGen · 60 sStops 01 to 04, about 10 minutes each.
StorylineStop 05: wrong choices show consequences, not just "incorrect".
Storyline80% to pass; any missed SC question means a retake.
LMSMentor ticks each criterion yes or no; every SC item must be correct.
ChecklistValid 12 months, then a short refresher.
BadgeA new service technician may know cars well but have never worked near a high-voltage system. Before they work on an EV alone, the business needs proof that they can do it safely, not just a completed course.
I started with the job, not the content. I broke safe HV work down into what a technician must actually do and turned it into a competency map: 6 domains, 18 competencies, each with an observable criterion, a target level and an assessment method.
Competency map, certification path design, and this visual road map for learners and managers.
Task analysis and competency-based assessment design. Planned build: Articulate Storyline, HeyGen, LMS.
Validate procedures against the OEM service manual with a subject matter expert, then pilot the practical checklist with two mentors.