In a troubling revelation about one of America’s most promising electric vehicle manufacturers, a detailed investigation has uncovered serious workplace safety concerns at Rivian’s manufacturing facility in Normal, Illinois. The investigation, published by Bloomberg News, paints a concerning picture of a company racing to produce luxury EVs and Amazon delivery vans while potentially compromising worker safety.

A History of Rapid Growth and Recent Stumbles

Rivian’s journey from a startup in 2009 to an EV powerhouse has been remarkable. After raising $450 million in private capital in 2017, the company purchased a former Mitsubishi plant in Normal, Illinois, for just $16 million. Their trajectory soared when they secured a massive deal with Amazon for 100,000 delivery vehicles, leading to a spectacular IPO in 2021 that briefly valued the company at $150 billion – double Ford’s market value at the time.

But the shine has worn off. The company’s now losing approximately $30,000 on each R1 model produced, and their stock has plunged 90% from its peak. Recent production estimates have been slashed by 18%, with the company now expecting to produce only 49,000 vehicles for the North American market due to supplier issues.

Mounting Safety Concerns Draw Regulatory Attention

The safety record at Rivian’s plant has become increasingly concerning. With 16 serious OSHA violations in just 21 months – more than any other automaker – the facility has drawn scrutiny from regulators and labor advocates alike. Former OSHA chief of staff Deborah Berkowitz called the volume of complaints, citations, and serious injuries “red flags.”

Workers have reported numerous serious incidents. In February 2023, an employee at the paint shop’s entrance suffered a severe back laceration requiring surgery. Two months later, another worker lost a finger when struck by a control handle while working on an electric delivery van. The following month brought perhaps the most serious incident: a worker’s skull was fractured in a fall.

The Human Cost of Rapid Production

The case of Addison Zwanzig, a 20-year-old worker who joined Rivian in July 2023, exemplifies the human impact of these safety issues. Initially thrilled at the opportunity to work in high-tech manufacturing and earn enough to move out of her family home, Zwanzig was assigned to the paint room at $23 per hour plus benefits. Her protection consisted of only a polyester suit, rubber gloves, and plastic goggles.

Within weeks, she developed serious symptoms, including dizziness and nausea. Her complaints of vomiting with a distinctive “Rivian blue” tinge were initially dismissed, and her requests for proper respiratory protection were denied. After being transferred to a different role, she was asked to perform tasks that contradicted safety training, including climbing on vehicles still on the production line.

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Infrastructure and Oversight Issues

The problems extend beyond individual incidents. Jacqueline Hamilton, a 28-year-old worker in the battery section, reported that the roof leaks during heavy rains, with only tarps protecting high-voltage electrical equipment. The situation has created potential deadly hazards, though Rivian maintains workers were never in danger.

OSHA investigations have revealed other systematic issues. The company received citations for failing to provide proper medical evaluations for respirator use, leaving fire alarms obstructed, and not marking emergency exit paths. Perhaps most telling was the discovery that “bulldozing” empty carts with forklifts was an accepted practice, despite its clear safety risks.

Future Plans Amid Current Struggles

Despite these challenges, Rivian continues to push forward with ambitious expansion plans. The company aims to increase its workforce beyond its current 8,000 employees as it prepares for the 2026 launch of the R2, a sport utility vehicle targeted at $45,000. They’ve secured up to $827 million in incentives from Illinois and committed to a $5 billion factory investment in Georgia that could bring in up to $1.5 billion in state incentives.

Union Efforts and Worker Response

The United Auto Workers has been attempting to organize Rivian’s workforce, with several employees becoming active in union efforts. Renee Leonard, a worker since June 2022, highlighted the inconsistent policies between managers, stating, “You have no idea what a policy is from day to day or from manager to manager.”

EVXL’s Take

The situation at Rivian represents a critical juncture in the evolution of America’s EV industry. While Rivian has shown promise in developing innovative electric vehicles and creating manufacturing jobs, the company’s growing pains highlight the challenges of scaling up EV production while maintaining worker safety. The upcoming R2 model could be a game-changer for making EVs more accessible, but the company must first address its safety culture and workplace conditions. The success of new EV manufacturers isn’t just about technological innovation – it’s about building sustainable, safe workplaces that can support the long-term growth of the industry.

What do you think about the balance between rapid EV production and worker safety? Share your thoughts in the comments below.