ERPDrive for Wire & Cable Manufacturers
Manage drawing → stranding → insulation → sheathing with dual-UOM inventory (meters and kg), returnable drums, and BIS certificate traceability - in one cloud system.
The pain points generic ERP doesn't solve
Tally and BUSY handle accounting. SAP and Microsoft Dynamics need 4-month implementations. Neither is built for these specific wire & cable manufacturers pain points:
Dual unit-of-measure (meters + kg)
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.
Copper and aluminium rate volatility (hourly)
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.
Returnable drum management
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.
Wastage capture per process stage
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.
BIS certification + cable-type traceability
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.
Standard length cuts vs custom lengths
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.
The ERPDrive demo flow for your factory
Here is exactly what we will show you in a 30-minute demo. Every screen uses real industry workflows, not generic sample data:
- Conductor inventory in kg AND meters
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.
- BOM with conductor + insulation + sheath + drum
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 sequence (draw → strand → insulate → lay-up → sheath)
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.
- Wastage capture per stage
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.
- Returnable drum tracking
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.
- BIS certificate against dispatch
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.
- Cutting plan optimization
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.
- E-way bill with cable load weight
Cable dispatch needs Part B vehicle + weight. System auto-calculates total dispatch weight from drum weights and generates EWB with one click.
Modules tailored for wire & cable manufacturers
Out-of-the-box features (no custom development needed):
Dual UOM at item level
Stock in kg, produce in meters, dispatch in either - all from one item master.
Multi-stage routing BOM
Drawing → stranding → insulation → laying → sheathing → drum-up as one routing.
Returnable packaging
Drum issue, return, deposit, ageing - all as a sub-ledger.
BIS certificate library
Test certificates linked to cable types; auto-attached to dispatch documents.
Wastage by stage and reason
Capture wastage at every stage; trend dashboard for leak detection.
LME-rate plug-in for copper/aluminium
Hook in daily LME rate via API or manual entry; quotations always current.
GST and compliance
Indian regulatory requirements handled natively:
Customer story
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
- Drum write-off dropped from ₹14 lakh/year to ₹2 lakh/year
- Wastage at extrusion stage down 22% (visibility led to fix)
- BIS certificate query response time: 1 day → 30 seconds
Pricing for your size
Frequently asked questions
Does ERPDrive support both kg and meter UOM on the same item?
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.
How does drum tracking work?
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.
Can ERPDrive integrate with LME rate feed?
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.
How is BIS certificate stored and retrieved?
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.
How long does implementation take for a cable unit?
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.
What modules does ERPDrive include for cable manufacturers?
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).
See ERPDrive for your wire & cable manufacturers
Free 30-minute personalized demo using your actual products, BOMs, and pain points. Scheduled within 24 hours.