In the cable industry, manufacturing processes and MES (Manufacturing Execution Systems) are critical to improve the efficiency and quality of production processes. Cable production involves a series of complex processes that often require high precision and quality. MES systems are used to monitor, control and optimize these processes.
Production Processes in the Cable Industry
Raw Material Preparation: Cable production starts with the supply of conductive materials such as copper and aluminum as well as insulating materials such as plastic and rubber. These materials are subjected to quality control processes to ensure their suitability for production. High quality raw materials directly affect the performance and reliability of the final product.
Wire Drawing: After raw material preparation, copper or aluminum rods are transformed into thin wires of various diameters. The drawing machines used in this process ensure that the metal has a fine and homogeneous structure. After the wire drawing process is completed, the wires are cooled and the dirt and oxides are removed from their surfaces.
Wire Bending: In cable production, thin wires are brought together in certain arrangements to form multi-stranded structures and twisted to form multi-stranded cables. This process increases the flexibility and durability of the cable.
Insulation: After wire stranding, insulation material is coated around the conductor wire. This is usually done by a process called extrusion. In the extrusion process, the insulating material on the wire is homogeneously distributed and then the insulated cables are cooled and cut to the appropriate dimensions.
Stranded Wire Groups (Cable Grouping): The insulated wires are twisted and wound, arranged in specific groups. This process allows the cable to be used in different applications and improves its electrical properties.
Outer Sheath Coating: A protective outer sheath is coated around the cable assemblies. This is again done by extrusion. The outer sheath coating protects the cable against physical damage and environmental factors. After coating, the cables are cooled and cut.
Testing and Quality Control: At each stage of the production process, quality control and testing is carried out. Cables are subjected to electrical tests such as conductivity and insulation resistance. Mechanical tests such as tensile strength and bending strength are also performed. These tests guarantee the high quality and conformity of the cable to international standards.
Packaging and Storage: Finally, cables that have successfully passed the quality control and tests are properly packaged and made ready for shipment. They are regularly inspected in storage areas before shipment.
Data Tracked by MES Systems and Customizations
Production Planning and Tracking: MES systems monitor the details and timelines of production orders. The work orders set for each production batch are optimized by the system and completed on time. This increases the efficiency of the production line and prevents wasted time.
Material and Inventory Management: Tracks the entry and exit movements of raw material, semi-finished and finished product stocks. Stock levels are regularly updated by monitoring material consumption and supply chain data. In this way, material flow is streamlined and inventory costs are reduced.
Quality Control and Traceability: Quality control data and test results collected during production stages are recorded by MES systems. By ensuring the traceability of each production batch, it is possible to trace back the products and intervene quickly in possible recall processes.
Machine and Equipment Management: The status of production machines, failure records and maintenance needs are continuously monitored. By collecting equipment performance data, MES systems improve maintenance planning and reduce unexpected downtime.
Operator Performance and Workforce Management: Operators' performance, working time and work efficiency are monitored. This data is used to determine the training needs of operators and optimize workforce distribution.
Productivity and Production Speed: Productivity rates and production speeds of production lines are regularly analyzed. MES systems provide reports and analysis on productivity, allowing the necessary steps to be taken to improve production processes.
Gains Achieved in Cable Special MES Systems
- Cost Tracking and Management: Raw material costs, labor costs and overhead costs are tracked. MES systems provide cost control and profitability management by analyzing cost and profitability on a product basis.
- roi is reduced to 1 month by preventing advertising errors with incorrect text submission.
- With inkjet printer control, each equipment saves 60 minutes / day.
- With the automatic collection of spark signals, spark / error / meter information is transferred to subsequent operations with 100% accuracy.
- Improves raw material consumption by 8% with dosing integration.
- It saves an average of 20 minutes per day in a process with the job merging operation.
- Realized / planned Product Tracking with Electronic Scale Communication ensures the ideal amount of precious metal shipment.
- 30% improvement is achieved in ramp factor losses caused by personnel performance.
- With GANTT, 100% sequential job accuracy is ensured.
- The revisions in the work orders list of the planning office are downloaded to the field, providing 35% improvement.
- Instant warnings in process data ensure product error-free.
- Improves raw material finding times by 45% with lot tracking and instant display of the remaining quantities in the lot.
- It provides 25% improvement in reel order tracking times with reel ID-LOT matching.