Introduction and Industry Context
The cable manufacturing industry spans electrical cables, power cables, telecom cables, fiber optics, and industrial wiring—each requiring precise coordination of multi-stage production processes, material planning, quality control, compliance, and customer management. Cable manufacturers must manage complex production lifecycles, technical specifications, quality records, machine scheduling, and high-cost raw materials such as copper, aluminum, and insulation compounds.
Traditional systems often create data silos—separating production, costing, inventory, and customer interactions—leading to scrap generation, quality failures, delayed dispatches, and inaccurate costing.
SAP Business One provides a unified ERP platform integrating production planning, BoM management, quality control, inventory, financials, CRM, vendor management, and traceability to deliver seamless operations and real-time visibility across the cable manufacturing lifecycle.
Key Challenges
- Multi-Stage Production Complexity
- Lack of Real-Time WIP & Material Consumption Visibility
- Manual Quality Testing & Documentation
- Costing Deviations Due to Copper/PVC Price Fluctuations
- Scrap & Rework Control Challenges
- Inconsistent Batch/Drum-Level Traceability
Our Solutions
- Advanced BoM & Routing Control
- Real-Time Production & WIP Oversight
- Automated Quality Testing & Documentation
- Accurate Costing & Consumption Tracking
- Scrap, Rework & Yield Management
- Batch, Coil & Drum-Level Traceability
Implementation Approach
- Discovery: Workshops with production managers, QA teams, procurement, sales, and finance to map cable production stages, QC checkpoints, BoMs, machine processes, and traceability requirements.
- Configuration: Custom SAP Business One modules aligned with cable manufacturing workflows—multi-stage production, test report automation, batch/drum numbering, costing models, and scrap handling.
- Integration: Connections with MES/PLC systems, weighing scales, barcode/RFID scanners, and laboratory testing equipment for automated QC capture.
- Training & Support: End-user training with continuous support for new cable variants, production expansions, and updated compliance standards.
Results & Business Impact (90 days)
| Metric | Improvement | Baseline | Post-Implementation |
|---|---|---|---|
| Material Cost Accuracy | 30% improvement | 65% accuracy | 85% accuracy |
| Production Planning Efficiency | 40% faster | 5 hours/day | 3 hours/day |
| Scrap Reductione | 18% reduction | 12% scrap | 9.8% scrap |
Why Clockwork Business Solutions?
Clockwork’s deep expertise in SAP Business One and extensive background in cable manufacturing environments make it the ideal partner for this transformation:
- Domain-Specific Customizations
- MES/PLC Integration
- End-to-End Batch & Drum Traceability
- Scalable Architecture
Clockwork’s industry-focused ERP deployments ensure stronger production control, lower wastage, accurate costing, and enhanced operational efficiency.
Conclusion
SAP Business One transforms cable manufacturing operations by integrating production management, quality control, costing, sales, finance, and traceability into one unified platform. This integrated approach drives higher productivity, improved profitability, and complete operational transparency—empowering manufacturers to deliver better quality, reduce scrap, and scale with confidence.