Case Study: Emergency One controls wire-harness complexity and slashes delivery lead times with Zuken's E³.series

Emergency One controls wire harness design complexity and slashes delivery lead times with standardized design and manufacturing process

Emergency One, a Scotland‑based specialist fire and emergency vehicle manufacturer, was struggling with extreme electrical complexity—each installation typically exceeds 1,000 wires and uses multiple 154‑way controllers—plus heavy customization, inability to test and verify designs early, and a limited pool of specialist electricians. To tackle these challenges they adopted Zuken’s E³.series (including E³.cable and E³.formboard) to create standardized, document‑rich electrical designs.

Using Zuken’s E³.series, Emergency One implemented modular, parameterized harness templates, on‑screen test/verification and detailed formboard outputs for manufacturers, which removed installation bottlenecks and cut reliance on niche skills. The result was a standardized design and manufacturing process that delivered cost savings and reliability benefits, slashed delivery lead times, produced about 90% common wiring across builds, reduced harness problems and lowered customer‑support and time‑to‑market impacts.

Emergency One

Graeme Shields

Design Manager