Manage drawing → stranding → insulation → sheathing with dual-UOM inventory (meters and kg), returnable drums, and BIS certificate traceability - in one cloud system.
Tally and BUSY handle accounting. SAP and Microsoft Dynamics need 4-month implementations. Neither is built for these specific wire & cable manufacturers pain points:
Conductor inwards is in kg; cable output is in meters per drum; customer dispatch is in length OR drum count. Without dual-UOM at the system level, every conversion is manual and error-prone.
LME copper moves daily; aluminium follows. If your quotes use yesterday's rate, you bleed margin on rising days and lose orders on falling days. You need real-time rate-linked costing.
Steel and wooden drums are returnable assets. Track which drums went to which customer, when they're due back, and the deposit ledger. Lost drums = ₹5,000-₹50,000 each.
Drawing wastage (chips), insulation wastage (PVC compound), and extrusion wastage are all separate. Without per-stage capture, you can't isolate where margin is leaking.
Cables under IS 694 / IS 7098 / IS 1554 require BIS certification per type. Customers demand the BIS test certificate per dispatch. Without a system linking dispatch to BIS test report, every email request becomes a file-hunt.
Some customers want 100m drums; others want 250m or 500m. Production lots must be planned to minimize end-cut wastage. Without an MRP-aware cutting plan, end-of-lot scrap eats 3-7% of output.
Here is exactly what we will show you in a 30-minute demo. Every screen uses real industry workflows, not generic sample data:
Copper rod is stocked in kg. As you draw it to a specific gauge, the system calculates equivalent length (meters) using density × cross-section. Stock view shows both units. Reorder triggers on kg; production planning uses meters.
Cable BOM is layered: conductor (kg per meter), insulation (PVC / XLPE in kg per meter), inner sheath, armour (where applicable), outer sheath, drum. Each layer's rate updates independently; cable cost rolls up automatically.
Production order routes through machines in sequence. Each stage captures input qty, output qty, scrap qty, operator, machine. Real-time WIP shows: 8,400m on extruder #3, 12,000m awaiting sheathing, 6,200m on drum-up.
Drawing chips, insulation flash, extrusion start-up scrap - each has a wastage code. Dashboard breaks down monthly wastage by stage and by cable type. Spot the leak; fix the leak.
Each drum has a unique ID. Issued to customer on dispatch with deposit. Returned drums are inwarded; deposit released. Drums not returned in 90 days auto-flagged with customer ledger entry.
Cable type-tested once per period at BIS-recognized lab. Test certificate stored in system. Every dispatch invoice can attach the relevant BIS TC for the cable type. Customer query → 10-second lookup.
MRP looks at all open orders for 1.5 sqmm flexible cable (200m, 250m, 300m, 500m orders). System suggests the production lot length that minimizes end-cut wastage.
Cable dispatch needs Part B vehicle + weight. System auto-calculates total dispatch weight from drum weights and generates EWB with one click.
Out-of-the-box features (no custom development needed):
Stock in kg, produce in meters, dispatch in either - all from one item master.
Drawing → stranding → insulation → laying → sheathing → drum-up as one routing.
Drum issue, return, deposit, ageing - all as a sub-ledger.
Test certificates linked to cable types; auto-attached to dispatch documents.
Capture wastage at every stage; trend dashboard for leak detection.
Hook in daily LME rate via API or manual entry; quotations always current.
Indian regulatory requirements handled natively:
A wire and cable manufacturer in Chennai
180 employees, ₹65 cr turnover, 240 active cable types
"Drum tracking alone saved us about ₹14 lakh in 18 months - drums we'd written off as lost turned out to be sitting at three customer warehouses. We just had to ask. The system told us who, when, and how many."Measured outcomes
Yes - dual UOM is native at item-master level. Stock can be tracked, costed, and dispatched in either unit, with auto-conversion based on conductor density and cross-section.
Each drum is an item in the system with a unique ID. On dispatch, drum is issued to customer with a deposit entry. On return, deposit is released. Drums not returned in N days (configurable) appear on an ageing report with customer details.
Yes. We can ingest daily copper/aluminium rates via API (manual entry also supported). All BOM costs and quotations auto-update against the latest rate.
Test certificates are uploaded against the cable type master. When a dispatch is created for that cable type, the relevant BIS TC is auto-attached to the dispatch document and customer invoice email.
1-2 weeks for a single-location 100-200 employee cable unit. Master data import (cable types, conductor sizes, drum sizes) typically takes 3-5 days, then 5 days of parallel run before sunset of the old system.
BOM with multi-stage routing, dual UOM inventory, returnable drum tracking, BIS certificate library, wastage capture per stage, production scheduling with cutting-plan optimization, GST invoicing, e-way bill integration, ITC-04 (if you outsource drawing).
Free 30-minute personalized demo using your actual products, BOMs, and pain points. Scheduled within 24 hours.