How to Maintain Fleet Uptime While Transitioning from ICE to EV

Electrifying your fleet is one of the most transformative steps your business can take. But for many fleet managers, the path from internal combustion engine (ICE) vehicles to electric vehicles (EVs) isn’t paved with just lower emissions and fuel savings—it’s filled with uncertainty around uptime, infrastructure, and operational disruption.

In mixed fleets especially, maintaining high vehicle uptime during electrification is both a major challenge and a strategic opportunity. The goal? Ensure every vehicle, whether ICE or EV, is on the road when it needs to be.

This guide breaks down how to sustain (and even improve) uptime during your fleet's transition from ICE to EV. With lessons from industry leaders like DHL, actionable strategies, and data-backed best practices, we’ll help you manage the shift smoothly and smartly.

Why Fleet Uptime Matters More During the ICE-to-EV Shift

Fleet uptime—the amount of time a vehicle is available and operating as expected—directly impacts logistics, revenue, and customer satisfaction. But electrification changes the rules:

• EVs introduce new variables like charging time, charging availability, battery range, and how weather can affect battery performance.

• Infrastructure planning becomes as critical as vehicle selection.

• Mixed fleets (ICE + EV) require different maintenance cycles, performance metrics, and downtime strategies.

  
  

In short, uptime becomes harder to manage, unless you adapt proactively.

1. Assess Fleet Readiness with a Data-Driven Approach

Not all vehicles should be electrified at once. Start with a strategic audit:

- Analyze Usage Patterns

Look at your existing telematics or trip logs. Identify:

• Vehicles with high fuel consumption but which don’t travel very far each day (ideal EV candidates)

• Routes with consistent stop-start activity (where EVs excel)

• Assets that return to base daily (easier overnight charging)

  
  

- Set Electrification Priorities

Don’t electrify the most complex routes first. Use a phased rollout to test and adapt.

Tip: Tools like EVE’s platform help automate this analysis and guide which vehicles to replace first.

2. Avoid Downtime by Planning Charging Infrastructure Strategically

Charging logistics can make or break EV uptime. Avoid the common trap of installing chargers only where it’s convenient.

-   Map Out Real Charging Needs

• Depot-based overnight charging for predictable daily routes

• DC fast charging near high-mileage hubs

• Integration with public charging networks

  
  

-  Standardize Your Charging Playbook

Learn from DHL’s award-winning fleet program where charging infrastructure is meticulously planned and monitored.

"Charging infrastructure determines the uptime of the network."

– Marijn Slabbekoorn, DHL Express Europe

A well-planned infrastructure strategy prevents grid bottlenecks and ensures consistent charging availability, essential for uptime.

3. Dual Maintenance Protocols: Don’t Treat EVs Like ICE Vehicles

ICE and EV vehicles have fundamentally different maintenance needs:

• ICEs: oil changes, engine diagnostics, exhaust systems

• EVs: battery health, software updates, electrical system checks

  
  

Create separate service schedules. Consider hiring EV-certified technicians or partnering with service providers who specialize in EVs.

DHL uses predictive maintenance enabled by telematics to reach near "zero downtime." Their EVs are kept for six years, beyond typical ICE lease cycles source.

4. Use Smart Software to Track Uptime Across a Mixed Fleet

Relying on spreadsheets or legacy fleet systems will hurt you in a dual-fuel environment. You need a unified view of both ICE and EV metrics:

• Real-time fuel and energy usage

• Charging and fueling downtime

• Maintenance alerts across vehicle types

• TCO comparisons between ICE and EV

  
  

EVE’s fleet management software centralizes all of this, giving you better visibility and decision-making power.

5. Train Drivers to Minimize Downtime

Drivers are the first line of defense in uptime management. But switching to EVs requires:

• New habits: avoiding high-speed acceleration, maximizing regenerative braking, optimizing charging stops

• Range confidence: knowing how far they can go without playing it too safe

• Routine reporting: quickly flagging battery or charging issues

  
  

DHL's Example:

DHL ran driver education programs with safety, energy use, and performance at the core. Over 50% of their company drivers now choose EVs voluntarily.

6. Build Contingency Plans to Minimize Disruption

Even with the best planning, things go wrong. Successful fleets plan ahead for backups and unexpected problems during their rollout.

• Have backup ICE vehicles for essential long-haul routes

• Maintain access to public fast chargers near key routes

• Set protocols for charging failures or out-of-service EVs

  
  

Tip: DHL monitors chargers across Europe, with contractors on call to fix faults quickly. This ensures their electric fleet doesn’t sit idle.

Real-World Impact: DHL’s Electrification Case Study

DHL Express Europe is electrifying 75% of its fleet by 2030. As of now, 25% of its 14,500 light commercial vehicles are already electric.

• Uptime remains high thanks to predictive maintenance via telematics.

• TCO is lower for EVs than diesel, due to optimized routing and cheaper overnight charging.

• Charging is 100% renewable, with solar and storage supplementing the grid.

• EVs are now retained longer, proving durable and cost-effective in daily use.

  
  

"Electric vehicles are cheaper for us in Europe than diesel vans from a TCO perspective."

— Marijn Slabbekoorn, DHL Express Europe

DHL’s strategy shows that fleet uptime doesn’t have to drop during electrification. In fact, with the right tools, it can improve.

Final Thoughts

Electrifying your fleet doesn’t have to mean trading efficiency for sustainability. With the right data, software, and strategy, you can maintain or even improve uptime during the transition from ICE to EV.

FAQs: Maintaining Fleet Uptime During EV Transition

1. What is fleet uptime?

Fleet uptime refers to the amount of time vehicles are available and operational. Higher uptime = better delivery performance and cost-efficiency.

2. How do EVs affect fleet uptime?

EVs have fewer moving parts and require less maintenance but need well-planned charging. Without smart infrastructure, downtime can increase.

3. How do you monitor uptime in a mixed fleet?

Use unified fleet management software that tracks both ICE and EV vehicles for usage, maintenance, and downtime.

4. Is EV downtime worse in winter?

Yes. Cold temperatures can reduce battery range and increase charging time. Planning for seasonal variations is key.

5. Can EVs be used for long-haul routes?

Some EVs can, but most long-haul routes still rely on ICEs. A phased electrification strategy helps ensure uptime while expanding range capability.