Why cable manufacturers need dedicated wire and cable ERP software
In a cable plant, copper or aluminium is most of the cost and the price moves every day. Metal is bought in kg, conductors are drawn and stranded in kg, insulation compound is applied in kg, and finished cable is sold in metres on drums or in coils. Each cable construction, size and core count is a separate item, and a few grams of extra conductor per metre add up to real money across a large order.
Wire and cable ERP software keeps metal and metres in balance. DotOne, which we implement, records each process stage, holds stock drum by drum, applies metal price variation in quotations and invoices, and connects it all to GST, e-way bill and costing.
The cable process, stage by stage in the ERP
Each stage records input, output and scrap so that metal yield is measured where it happens.
Rod receipt and drawing
Copper or aluminium rod is received by coil weight and lot. Drawing machine runs record input rod, output wire by size in kg, and drawing scrap, with annealing where applicable.
Bunching and stranding
Wires are bunched or stranded into conductors by construction, such as number of wires and wire diameter. Output is recorded on bobbins or drums in kg and metres.
Insulation, laying up and sheathing
Extrusion lines apply PVC, XLPE or other compounds. The ERP records compound consumed, conductor used and insulated core produced, then laying up of cores, armouring where needed, and the outer sheath.
Testing, cutting and packing
Finished cable is tested, cut to drum or coil lengths, and packed. Each drum or coil gets its own number, length, gross and net weight, and test reference.
Drum and coil-wise stock in metres
Cable cannot be managed as a single stock total. A customer asking for 500 metres needs to know whether one drum holds it, or whether it must be cut from a longer drum leaving a short end. The ERP holds every drum and coil as a separate stock unit with length and weight.
- Drum-wise stock by cable type, size and core count with length available.
- Cutting of drums into ordered lengths with the balance kept as a new drum or cut piece.
- Short length and cut piece stock tracked separately for clearance sales.
- Empty drum stock, drum deposits and returnable drums tracked by party.
- Coil stock for house wires in standard lengths such as 90 metres.
Stock locations and bins are configured through our warehouse management software.
Metal price variation in quotes and billing
Many cable orders, especially for utilities, projects and tenders, are priced with a metal price variation clause. The ERP stores the base metal price used in the quotation and the metal content per km for each item, and calculates the variation on the invoice from the agreed reference price for the billing period.
For dealer and trade sales, price lists can be revised quickly when copper or aluminium moves, and the system can show margin at current metal rates rather than at the rate the stock was bought.
Metal yield, scrap and job work
Copper and aluminium scrap has a high value, so it is stock, not waste. Drawing scrap, conductor offcuts and insulated scrap are booked by stage and reason, and the ERP shows metal yield by machine and shift. Overweight conductor, where actual metal per km runs above the design value, is reported against standard.
Where drawing, annealing or insulation is done by a job worker, metal sent out is tracked as stock at that vendor, and returns are reconciled against allowed process loss with ITC-04 data available. The flow is explained on the job work software page.
Cable costing, testing and dispatch
Cost per metre is built from actual metal per km, insulation and sheath compound, armour, power, labour and scrap loss, so management can see margin by construction and customer. See costing software for details. Routine and type test results are recorded against drums through quality management software, and test certificates can be printed with the dispatch.
Dispatch documents list drum numbers, lengths and weights, and the GST e-invoice and e-way bill are generated from the same document.
What is the best ERP for wire and cable manufacturers?
Test any cable ERP software on your own constructions and orders. Ask the vendor to show:
- Metal tracked in kg through drawing, stranding and insulation.
- Drum and coil-wise stock with cutting and short lengths.
- Metal price variation calculation on invoices.
- Metal yield and overweight conductor reports.
- Test records linked to drum numbers.
- E-invoice and e-way bill from the dispatch document.
Our how to choose ERP software guide lists more questions for a demo.
