ADVARIS Cable Solution: The common thread running through your cable factory – from quotation to delivery

The cable-specific production environment is characterized by length and reel handling, challenging setup sequences, high metal price volatility, and strict traceability requirements. This complexity quickly exceeds what generic ERP systems or proprietary isolated solutions can handle effectively. This results in media breaks, delays, and blind spots on the shop floor. ADVARIS Cable Solution addresses this gap with an integrated PDM, ERP, and MES platform.

Why “modular thinking” is becoming expensive in cable manufacturing

Many companies have “everything somehow”: ERP for commercial operations, Excel for detailed planning, a separate MES for feedback, plus paper/folders for inspections. The problem is not that there are too few systems, but that data flows are interrupted:

• Offers are based on assumptions rather than actual capacity and real costs.
• Planning ignores setup sequences, buffers, inspection lots, start/stop scrap
• Material availability is unclear: searches are conducted on the shop floor instead of planned deliveries
• Traceability is incomplete or requires a disproportionate amount of effort.
• Decisions are explained retrospectively – rather than being controlled in real time

The result: deviations between planned and actual figures, setup losses, search times, delayed deliveries, and tied-up working capital.

That's why ADVARIS doesn't rely on “yet another module,” but on a process-based end-to-end approach: a digital thread connects as-designed, as-planned, and as-built – on a consistent database.

What exactly is the ADVARIS Cable Solution?

Cable Solution is an integrated industry solution with cable-specific functions, built from modules that work together on a consistent data model, including:

• PDM (Cable Design & Costing): Specification, routings, MBOM, test/inspection plans, variant logic, calculation
• ERP: Purchasing, sales/quotations, order processing, warehousing/logistics, shipping, invoicing, metal accounting, CRM, and controlling
• DPS/APS (Detailed Planning & Scheduling): Detailed planning with limited capacities as the central planning authority
• SFC/MES (Shop Floor Control & Data Capturing): paperless execution, feedback, process/machine data, plant monitor, alerts, historian
• MRO (maintenance): maintenance, malfunctions, orders, link to production

In short: a solution that maps your entire cabling process as a coherent system—not as a collection of individual tools.

The “common thread” in everyday life: How ADVARIS supports you throughout your process

1. Quotation & preliminary calculation: Delivery commitments that are kept

In ADVARIS Cable Solution, quotations are not “estimated” but are prepared on the basis of consistent product and cost data, including metal logic, length/drum requirements, and (if necessary) reliable scheduling through detailed planning.

The benefit for you: less risk in the quotation, fewer renegotiations, and higher commitment quality.

2. Cable Design & Master Data: Variants without effort

Product data (geometry/parameters), MBOM, routing, work/test plans, and variants are maintained in a structured manner and made available for subsequent processes. This reduces maintenance effort and increases data quality, especially for extensive product families and a high variety of variants.

3. Detailed planning (APS): The factory needs a “navigation system,” not Excel

Rough cut planning in ERP is usually not sufficient for multi-stage, highly varied cable processes. An APS (Advanced Planning & Scheduling) system as a central authority enables detailed planning of limited capacities and responds to deviations with “look-ahead” strategies.

You gain realistic plans, less hectic schedules, and more stable delivery dates.

4. Intralogistics & inventory: Precise control of drums and lengths

A plan without knowledge of the materials is pure theory. ADVARIS supports drum/load carrier management, stock length transparency, and warehouse processes, as well as mobile data collection (barcode/RFID), so that materials are available exactly when they are needed—neither too early nor too late.

5. Shop floor execution: Paperless, traceable, controllable in real time

During the setup process, planning quality is reflected in time. Paperless work instructions are available at the terminal. Process parameters are transferred to the system. Sequence-optimized planning reduces changeover frequency and start-up losses. The target is to achieve the first good length in minimum time with stable parameters.

In addition, there is Plant Monitor (real-time visualization), Alerting, and Historian/Archive for analyses and audits.

6. Quality & Traceability: From the batch to the individual length

Quality is created in the process, not in the laboratory. Test and measurement data can be recorded close to the process and linked to material/length/drum information – for repeatable tests, audit security, and rapid root cause analysis in the event of complaints.

7. Shipping, labels, billing, and metal billing: Consistent right through to the invoice

In the end, it's the product that counts. Delivery, documents, and billing are managed using the same database. ADVARIS Metal Billing ensures that metal components are billed correctly in accordance with the agreement.

8. Maintenance (MRO): Availability increases, unplanned downtime decreases

Malfunctions, maintenance, and spare parts/service processes are recorded in a structured manner and linked to the production context, making maintenance more predictable and effective. All information available to the system forms the basis for preventive and predictive strategies. This increases availability and OEE while reducing unplanned downtime.

Who in particular would benefit from the ADVARIS Cable Solution?

If you recognize at least two of the following points in your company, ADVARIS is typically a real boost for your production:

• Detailed planning depends on Excel or the experience of individual planners
• Setup sequences and drum/spool handling make deadlines unstable
• Material is “somewhere,” but not where it is needed
• Lack of order and cost transparency from quotation to invoicing
• Contribution margins and manufacturing costs are only visible in retrospect
• Metal billing/calculation is complex and prone to errors
• Media breaks between sales, purchasing, production, and logistics create duplication of effort
• Traceability takes too much time or is a stress factor during audits
• Shop floor transparency comes too late

Conclusion: The digital thread that brings together appointments, quality, and inventory

ADVARIS Cable Solution is more than just an MES or ERP module. It forms the continuous digital thread for length- and drum-based cable production – from cable design, quotation and calculation, detailed planning with finite capacities and shop floor execution to quality, shipping, metal accounting and maintenance.

The results are measurable: more stable delivery dates, less setup and search time, lower WIP and working capital, audit-proof traceability down to individual lengths, and greater real-time transparency for early detection and active management of deviations.

Schedule your no-obligation initial consultation now.