The Victorian State Emergency Service (VICSES) has been recognised at the IPWEA Fleet Conference with the 2025 Fleet Innovation Award for its ground-breaking work in developing the Next Generation Heavy Rescue Truck (HRT). This achievement represents a major step forward in fleet design and management for emergency services in Australia, showcasing best practice, continuous improvement, and innovation that will benefit both volunteers and the communities they serve.
What Problem Was VICSES Trying to Solve?
VICSES identified significant shortcomings in its existing heavy rescue truck fleet, which had been procured through supplier-led processes. The older vehicles were plagued by reliability and durability issues, with limited practical testing leading to frequent maintenance problems. Volunteers reported ergonomic challenges, cramped workspaces, and insufficient storage for critical tools. The lighting systems were outdated, hindering operations during night-time rescues and poor visibility conditions.
Additionally, the industry’s transition toward battery-powered tools and reduced reliance on complex electrical systems was not supported by the existing fleet design. The supplier-owned designs also restricted VICSES’ ability to scale procurement or adapt vehicles for evolving operational needs. These limitations directly impacted the safety, efficiency, and morale of volunteers responding to emergencies in challenging environments.
The Innovative Solution
Instead of persisting with supplier-dependent procurement, VICSES took a bold, forward-thinking approach by taking ownership of the entire design process. They established an engagement framework that brought together in-house experts, external specialists, engineers, and most importantly, frontline volunteers.
Key innovations in the Next Generation Heavy Rescue Truck design included:
- Finite Element Analysis (FEA): Used to model and predict stress and fatigue performance, ensuring that the truck’s structural integrity would withstand harsh operational environments.
- 3D Scanning: Enabled precise modelling of the chassis and body to support long-term serviceability and potential transfers of service bodies to new cab chassis.
- Durability Testing: Conducted in multiple phases to ensure that the vehicles would meet or exceed lifespan expectations and performance standards.
- Ergonomic Consultation: For the first time, VICSES engaged an ergonomist to address issues such as tool placement, storage access, and ease of use, taking into account the diverse needs of volunteers.
- Advanced Lighting and Safety Features: The trucks were fitted with LED scene lights, integrated locker lighting, and automatic mains power inlets to protect volunteers from potential hazards.
- Battery-Operated Tools: Reducing reliance on complex and failure-prone electrical systems, while also cutting down on noise and emissions.
- Volunteer Welfare Considerations: The trucks feature amenities like a fridge/freezer and hot water system to support volunteers during extended operations.
Measuring Success
The success of the Next Generation HRT is measured against several key indicators:
- Return on Investment: The upfront investment is expected to be offset by significantly lower maintenance costs, reduced operational downtime, and longer vehicle lifespan.
- Production Flexibility: By owning the design, VICSES can engage multiple builders, accelerating production without compromising quality.
- Operational Efficiency: Improved tool storage, an integrated workbench, and faster equipment access are expected to result in quicker, more effective responses.
- Volunteer Safety and Wellbeing: The ergonomic improvements, advanced lighting, and thoughtful design all contribute to reducing injury risk and fatigue for volunteers.
- Service Delivery: The truck’s larger storage capacity and adaptability allow for broader equipment carriage, supporting more effective community outcomes.
Project Timeline and Development Stages
The development of the Next Generation HRT began in 2019 with a collaborative workshop involving over 20 volunteers, engineers, and external experts. This initial phase focused on gathering insights from frontline responders and defining the design principles of the new vehicle.
Over the next five years, VICSES moved through concept development, engineering analysis, prototype construction, and rigorous testing phases. In 2024, the prototype vehicle underwent a state-wide roadshow, collecting feedback from volunteers across Victoria. The feedback from this consultation period directly influenced final design adjustments.
The second prototype is currently under construction, with the full rollout of the new fleet expected to be completed by mid-2025.
Key Learnings from the Project
One of the most significant lessons from this project has been the power of collaborative, user-centred design. By placing volunteers at the heart of the development process and integrating cross-functional expertise, VICSES created a vehicle that truly meets operational requirements.
Additionally, retaining design ownership has proven critical. It allows VICSES to maintain flexibility, ensure quality, and incorporate future technological advancements. The project also highlighted the importance of gathering real-world data during the testing phase, leading to more informed decisions and continual fleet improvement.
Another takeaway is the potential value of emerging technologies such as predictive maintenance powered by artificial intelligence. VICSES has identified this as a future opportunity to enhance fleet performance and lifecycle management.
A Framework for the Future
The VICSES Next Generation Heavy Rescue Truck project demonstrates what can be achieved when an organisation steps back from traditional procurement processes and takes a holistic, best-practice approach to fleet management. This innovation not only solves immediate operational challenges but also positions VICSES to adapt and thrive in a rapidly changing environment.
There is growing interest across the broader emergency services sector in VICSES’ approach, particularly following its presentation at the National Council for Fire and Emergency Services Fleet Technical Group meeting.
Industry Recognition and Final Thoughts
The judges commended VICSES for refusing to simply repeat past practices. Instead, they took the opportunity to start from scratch, design with the end user in mind, and deliver a vehicle that sets new standards for safety, functionality, and innovation.
As Matthew Rankin, VICSES Whitehorse Deputy Controller and Fleet Working Group member, stated: “The Next Generation HRT is leaps and bounds ahead of previous generations. It’s the most modern, technology-enabled, capable, and flexible truck VICSES has built and represents a significant achievement for volunteers.”
The 2025 Fleet Innovation Award is well-deserved recognition of VICSES’ commitment to continuous improvement and best practice fleet management. More importantly, it’s a win for the dedicated volunteers and communities that rely on these life-saving vehicles every day.
