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Wire Harness Manufacturing Software

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Harness Builder for E3.series

Harness Builder for E3.series supports the custom wire and cable harness market. This E3.series integrated module is purpose-built for harness manufacturers. Harness manufacturers are empowered to create accurate quotations/estimates, full nail board/pegboard documentation, drive testing, digital assembly, and automated wire preparation machines.

Quickly document a complete harness from drawings or wirelist. Manage datasheets and additional manufacturing instructions. Efficiently manage design variations with Dash number harness variables. Automatically drive pricing information, lead time, and assembly time calculations from design elements.

Harness Builder for E3.series

Automate harness support and documentation

Quickly generate accurate B.O.M., Wire lists, and cost estimates

Communicate with testing, wire processing, and automated assembly machines

Quickly produce manufacturing work instructions

Harness Builder 2021 - What's New

Harness Builder 2021 for E3.series introduces enhancements to augment, automate and improve wire harness design modularization and manufacturing documentation. In 2021, our user base is driving the majority of the features and updates to improve productivity in all areas of the design process.

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Automate Wire Harness Design and Testing

Import from/to wiring lists directly and load parts, wires, and cables directly from the library. Automatically manage connector pin terminal selection based on wire size and connector type. Auto place labels, wire protection, tapes, and other accessories to further enhance the production quality of the harness. Create and drive test plans for automated harness testing machines from leading providers like Cirris, DIT-MCO, Dynalabs, CamiResearch, Nexeya, CKT Technologies, and more.

Intelligent Cost Estimates and B.O.M

Harness Builder for E3.series creates time and cost estimates for a harness driven by selecting and placing connectors, terminals, wires, and cables. User-defined excel templates enable precise control over reporting formats and content. Automated B.O.M. driven by project data tracks all parts, wires, labels, splices, connector terminals, and accessories. The dash number function tracks multiple B.O.Ms options using the variable wire harness configurations set in the project, along with a summary of all possibilities.

Comprehensive Intelligent Library

Harness Builder for E3.series comes with component libraries containing thousands of detailed components to simplify the design process. The intelligent parts help automate wire sizing, reduce connectivity errors, and optimize terminal selection. The configurable parts library connects engineering with upstream and downstream business units. The centralized design library helps standardize parts and design practices across users and teams

Enhanced Manufacturing Automation

Harness Builder for E3.series transforms manufacturing and assembly processes with the help of intelligent harness design data. The accurate digital data drives highly automated wire cutting and processing machines from vendors like Schleuniger, Komax, and Argus. Configurable output formats connect to leading labeling, marking, and other printing options for wires and devices. Quickly power next-generation augmented smart assembly-aids like ‘ProjectionWorks’ to enable the digital transformation of the manufacturing process.

Detailed Wiring Documentation

Automatically generate a complete configuration Wire Run List (W.R.L.) driven by the project data. Various types of details, both explicit and implicit, are captured to maintain an up-to-date count of parts inside the project. The application captures insertion lengths at the connector and termination level to improve the accuracy of wire length calculations across the wire harness. The accuracy of wiring data enables wire processing and testing machines to improve quality, reduce effort, and implement design standards.

Assembly and manufacturing Instructions

Simplify the time-consuming process of creating work instruction using the engineering data in harness builder for E3.series. Create, release, and manage work instruction packages to define the harness building process. Pre-built customizable work instruction templates ensure consistency across projects. Auto-actions trigger repeatable custom automation routines to assemble relevant assembly instructions. The combination of comprehensive reports and configurable reports improves quality and increases productivity.

Features and Benefits

Comprehensive Smart Library Accurate Quotes and Bills of Materials Capture Wiring Details and Testing Improve Harness Documentation Quality Automate harness detailing Enhance manufacturing automation

Comprehensive Smart Library


  • Harness Builder for E3.series comes with a comprehensive set of component libraries containing thousands of components.
  • The library parts provide focused harness manufacturing details like loading views, pin terminal details, mating connectors and more.
  • The intelligent parts make it possible for a layout builder to select and match wire sizing and optimize terminal selection.
  • The harness bundle diameter can drive the selection of labels, sleeves, and cable protection from the library.
  • Automatic creation of connector tables, manufacturing, and displayed wire lengths are enabled while applying logical stretching and compression routines.
  • The consistency of data is the cornerstone of all E3.series design solutions. Schematic, formboard, and other documentation views are always in sync.

E3.series Harness Builder Database - Zuken

Accurate Quotes and Bills of Materials


Capture parts and accessories:

  • Automatically generate a complete B.O.M driven by the project data. Various types of details, both explicit and implicit, are captured to maintain an up-to-date count of parts inside the project. The B.O.M automatically tracks components, wires, cable, looming parts, labels, splices, and other miscellaneous parts.

Display on the Formboard drawing:

  • The B.O.M on a drawing sheet is formatted and configured as per user requirements. The application details the item’s numbers in balloons automatically across the drawing and is in sync with the on-sheet B.O.M.

Configurable user-defined report:

  • A user-defined excel template enables precise control over the format and content of the report for downstream consumption. The wires, cables, labels, and loom are quantified based on length to provide accurate results. The link between the B.O.M and wire reports helps to maintain precise wire length and termination details.

Detailed parts data:

  • Additional parts to the connectors are associated and easy to add to the B.O.M. without searching through O.E.M. or supplier documentation for part numbers. Elements hyperlink to PDF documents for information about sizing and terminal insertion.

Dash Number configuration:

  • The dash number function creates multiple reports driven by the configuration options for the wire harness along with a summary of all options.

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Capture Wiring Details and Testing


Wiring Reports:

  • Automatically generate a complete configuration Wire Run List (WRL) driven by the project data. Various types of details, both explicit and implicit, are captured to maintain an up-to-date count of parts inside the project. The B.O.M automatically tracks components, wires, cable, looming parts, labels, splices, and other miscellaneous parts.

Display and Share on Formboard:

  • The WRL on a drawing sheet is formatted and configured as per user requirements. User-defined templates enable precise control over the format and content of the report for downstream consumption. The wires, seals, caps, and wire terminations are tracked and updated in the wire run lists. The link between the B.O.M and wire reports helps to maintain precise wire length and termination details. The combination of on-sheet and Excel reports bring versatility and robustness to the reporting process.

Accurate lengths to drive manufacturing:

  • The application captures insertion lengths at the connector and termination level to improve the accuracy of wire length calculations across the wire harness. The accuracy of wiring data enables the use of wire processing and testing machines to improve quality, reduce effort, and implement design standards.

Automated Harness Testing

Easily drive automated harness testing machines directly from the design details. The export options for Cirris, DIT-MCO, Dynalabs, CamiResearch, Nexeya, CKT Technologies, and more. provide an easy path to improved quality and time savings.

Key Features

  • Create on-sheet wire run lists with termination details
  • User-defined options for sequence and terminations of wires
  • Capture wiring details like insertion length at connector and pin-level to accurately calculate wire lengths
  • Excel output to drive multiple downstream processes
  • Drive wire processing and testing machines to improve quality and reduce the effort

Zuken E3.series Harness Builder Harness Testing V2

Improve Harness Documentation Quality


Splice Documentation for Sonic Welders

  • Splicing is recognized as an integral part of the harness and manufacture creation. Harness Builder for E3.series will provide direct output, including barcodes for the ultrasonic welders. Left and right side welds are thoroughly detailed with the correct size heat-shrink selected for the fabricated weld.

Wire color details on connector views

  • Documenting a harness with the color of the wire connected to a pin is beneficial in increasing wiring efficiency. Both the loading views and table views of the harness can display the wire colors on the pins. Display additional details using configurable wire attributes to boost downstream processes.

IPC Wire A-620 Wire Tolerancing Standards

  • Harness tolerancing blocks were placed on a formboard to follow the IPC wire A-620 standard. The standard adjusts the size of the wire to increase on a sliding scale based on the routed length.
  • The tolerance setting options can be in imperial units, metric units, or a percentage. These settings are read from the drawing, therefore, configurable for individual harnesses.

Formboard Copilot

  • Formboard Co-pilot is a drafting tool to simplify creating a harness on a size-constrained formboard.
  • The exact length of branches and trunks is always a challenge to manage perfectly the first time around wrapping a harness around a size constrained formboard when the length is known in advance.

Zuken E3.series Harness Builder: Wiring V2

Automate harness detailing


Cable protection and coverings

  • The application automatically calculates bundle diameter for parts selection. The coverage and slack calculation is configurable for multiple applications. Automatically apply across the entire harness or selected segments. Reports capture part numbers and details for use in assembly and manufacturing processes

Label Placement

  • The automatic label placement saves time and standardizes harness designs across projects effectively. The labels are for standard devices and connectors. The label placement option is highly configurable to handle the labels as independent parts or additional parts of the devices and connectors. Furthermore, automatically assign heat shrinks to device and connector terminations. The versatile solution provides complete auto place options as well as an individual placement option.

Tape Placement

  • Tape or other accessories are placed automatically on the entire harness or selected branches. The calculation for the bundle diameter is automatic, and an appropriate tape is selected. The Tape placement is configurable with offset, centering, and other selection standards to match various process requirements.

Zuken E3.series Harness Builder: Harness Detailing

Enhance manufacturing automation


Harness Builder for E3.series is loaded with a list of direct import and export functions. The intelligent harness data digitally drives a variety of automated manufacturing and assembly platforms. The connectivity with 3rd party platforms creates a harness manufacturing ecosystem to improve quality and efficiency.

Automatic Wire Processing machines:

  • Drive highly automated wire cutting and processing machines from vendors as Schleuniger, Komax, and Argus using direct outputs from Harness Builder for E3.series

Automatic Labelling:

  • Automatically print labels using popular machines from Brady, Brother, and Hewlett Packard. The output and user formats are easy to create and deploy. Additionally, several laser marking, labeling, and other printing options are readily available to drive manufacturing automation.

Augmented Reality Assembly Solutions:

  • Manufacturing assembly aids like ‘Projection Works’ are driven directly from the harness assembly to enable smart manufacturing processes.

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Got a Question? - Contact Zuken today

For more information on how Zuken can help your design process, contact Zuken today.
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