Smart Connectivity in Cable Manufacturing: Building a
Data-Driven Future

Turn line data into better margins, faster flow, and trusted product quality.
The wire & cable business runs on tight tolerances, volatile copper costs, and customer specs that don’t wait. Yet in most cable factories, critical data still lives in silos, on isolated machines, paper batch logs, stand-alone test benches, and disconnected ERP records. The result? Slow decisions, hidden scrap, reactive quality, and capital locked in WIP.

This ebook shows how to change that.

Instead of “bolting on sensors,” smart connectivity means building a digital foundation that unifies length, speed, material usage, quality gates, and production events across extrusion, stranding, insulation, testing, and shipment. When those signals flow into a connected layer and onward into an industry-specific MES that talks to ERP, you get something far more powerful than data: actionable control.

With this Ebook, gain deep insights on how to:
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➢ Preserve Margins with Real-Time Cost Control
Learn how to connect yield and scrap data to pinpoint material loss, so you can make smarter decisions with expensive inputs like copper and polymers, and protect profitability on every reel.
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➢ Build Trust Through Meter-Level Traceability
Discover how to implement end-to-end traceability, down to the meter, giving your customers proof of quality, improving compliance, and reducing risk during audits or product recalls.
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➢ Maximize What You Have Before You Buy More
Understand, how to leverage performance data (OEE, line speed, length) to decide whether you truly need to invest in new lines or if smarter operations can unlock hidden capacity.

➢ Integrate the Old with the New; Seamlessly
Get practical strategies for connecting legacy and modern machines using interoperable protocols and modular architecture, so your smart factory evolves without costly overhauls.

➢  Turn Lagging Reports into Instant Actions
Explore how real-time visibility across maintenance, quality, planning, and customer service reduces delays, improves responsiveness, and eliminates surprises at end-of-shift reviews.

What this ebook delivers
A practical, staged playbook built for wire& cable factories, showing where to start (high-impact lines), how to scale with modular architecture, which KPIs drive real business value, and how an wire and cable specific MES turns connectivity into measurable operational gains.