One system from rod coil to labelled drum.
Run cable and wire enquiries, metal-linked quotations, rod receipt, drawing, stranding, extrusion, armouring, drum winding, testing and dispatch from one record. Each drum carries its metal weight, compound lot, test results and customer order. Planners see machine loads, stores see rod and compound stock, and the test room records its readings against the drum.
- Cable constructions, die sets and compound lots entered the way the plant runs them
- Rod stock, open orders and drum balances brought over
- Later construction or test sheet changes done by GullySystem staff on request
Cable and wire plants get one place, shaped by GullySystem, for quotations, rod receipt, wire drawing, stranding, extrusion, drum winding, testing and dispatch together. Each drum record carries metal weight, compound lot, test results and the customer order it serves. Scrap and remnant lengths are tracked as stock.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Enquiry and quotation
The buyer asks for a cable construction, length and delivery date. The quotation prices conductor weight at the current metal rate plus insulation and processing.
- 2
Order and drum plan
The confirmed order is split into drum lengths and assigned to lines. Required rod, compound and masterbatch are checked against stock.
- 3
Drawing and stranding
Rod coils are drawn to size and annealed, then stranded. Weight, die set and lay length are logged for the run.
- 4
Extrusion and sheathing
The extruder run records compound lot, colour and core diameter. Cores are laid up, armoured where required, and sheathed.
- 5
Testing and drum labelling
Each drum is spark tested and measured for conductor resistance. A label carries drum number, length and order.
- 6
Dispatch and invoice
Each drum is packed to its order line, the dispatch papers leave with the truck, and billing uses either the copper rate of the day or the fixed rate settled earlier.
What is inside.
Every module can be switched on, left out or changed to match how your team already works.
The business modules it is built from.
Each one is also available on its own, or inside a system built for you.
- Production Planning
Orders are split into drum lengths and placed on drawing, stranding and extrusion lines according to machine availability and the dispatch dates promised.
- Bill of Materials
Each construction lists conductor wire, insulation compound, masterbatch, armour and sheath, so the planner knows the weight of every material per metre.
- Batch and Serial Tracking
Every drum carries a number that links to the rod coil, the compound lot and the test entries behind it.
- Quality Control
Spark test, conductor resistance and length readings are entered per drum, and a failed drum is held out of dispatch.
- Quote & Proposal Management
A cable quotation multiplies conductor weight by the day’s metal rate and adds insulation and processing, keeping each revision.
- Stock Tracking and Alerts
Rod coils, compound and masterbatch are tracked by lot and weight, and a reorder level warns before a line stops.
- Work Order Management
An extruder work order carries compound, colour and core diameter, and the operator closes it with the weight produced.
- Goods Receipt (GRN)
Rod coils are received by weight against the supplier certificate, and a mismatch with the delivery note is noted at the gate.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For plant managers
See line loads, metal consumed, scrap by stage and drums waiting for test.
For planners
Split orders into drums, assign lines and check rod and compound stock before promising dates.
For machine operators
Log die changes, bobbin weights and extruder settings at the machine.
For the test room
Enter spark, resistance and length readings against each drum.
For sales and dispatch
Quote from the current metal rate, offer remnant lengths and prepare packing lists.
The numbers the owner asks for.
- Metal weight in and out by stage and by run
- Scrap copper and aluminium booked to stock
- Drums by test status and customer order
- Compound and masterbatch lots used per extruder run
- Remnant lengths available by size
- Quotations won and lost with the metal rate used
Who this is built for.
- Makers of building wire and flexible cable
- Plants that draw copper or aluminium wire and sell it as coil
- Manufacturers of armoured power cable and control cable
- Works with extrusion lines for PVC or cross-linked polyethylene insulation
- Cable makers who sell by drum and by cut length
When it is not the right choice.
- A trader who cuts and sells cable bought from a maker needs trading software, not manufacturing.
- Makers of switchboards will find Switchgear Manufacturer Management Software closer.
Adapted to your business before it goes live.
You are not handed a login and left to it. The product is set up around your records, your people and the tools you already use.
Works alongside
- Accounting export
- Label printer
- Weighing scale
Questions owners ask before a demo.
Can a quotation follow the metal market?
Yes. The conductor weight is multiplied by the current rate you set, then processing and insulation are added. Older quotations keep the rate they were priced on.
How are drawing and stranding losses recorded?
The operator enters weight in and weight out for each run. The difference is shown as scrap and annealing loss, and scrap is booked back to metal stock.
Can I trace a drum to its rod coil?
Yes. A drum record links to the stranding run, the die set, the rod coil and the compound lot used on the extruder.
Does it handle armoured and multicore cable?
Yes. Each construction lists cores, armour type and sheath. Laid-up cores and armoured lengths are tracked as intermediate stock.
What tests can be stored?
Spark test, conductor resistance and length checks are stored per drum with operator and instrument. Limits are agreed with your own quality staff.
How do remnant lengths get sold?
Short drums left from cut orders are listed by size and length. A salesperson can reserve one against a new order from the same list.
Can weighing scales feed the system?
Sometimes. Where the scale allows an export or manual entry, its weights can feed the drum and run records. This is checked during implementation.
What drives the cost?
The quote grows with the extrusion lines, the people logging in and the cable types in your range. A sample drum is shown first, and the quote then arrives in writing.
Who owns the production records?
You do. The format in which drum, run and test history can be exported is written into the agreement.
Is there a fixed way to start?
No fixed order exists, though most plants begin with rod stock and drum labelling, then add extrusion records. The first workshop settles the sequence for your plant.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Cable and Wire Manufacturer Management Software with your own data.
Tell us how you run things today. We’ll show you the parts that matter to you and say plainly what would need changing.
- No obligation
- A reply within one business day
- Your details stay private
Start with your requirements
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