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Client Onboarding Portal

When a large infrastructure contractor needed to integrate our wire drawing machines into their quality assurance workflow, the handoff between their engineering team and our production line was handled through spreadsheets and email threads. Every new cable specification meant a round of manual data entry, approval delays, and occasional mismatches between the requested tensile rating and the machine setup.

The portal we built replaced that chain with a single structured intake form. The contractor's engineers enter the required wire diameter, tensile strength range, spool dimensions, and delivery schedule directly into a web interface. The system checks the values against our machine capabilities — for example, a 12 mm diameter at 40 m/s with a 2-meter reel triggers a flag if the requested tension exceeds the pneumatic controller's ±0.5% tolerance window. The portal then generates a machine configuration file that our shop floor operators load directly into the PLC.

During the first three months of use, the contractor submitted 47 cable specifications through the portal. The average turnaround from submission to approved machine setup dropped from 2.5 days to 4 hours. The rejection rate due to incompatible parameters fell from 18% to 3%. The portal also logs every configuration change, which helped both sides trace a tension drift issue back to a misentered spool weight in week two.

  • Reduced manual data entry errors by eliminating email-based specification handoffs
  • Integrated real-time validation against machine limits for wire diameter, speed, and tension
  • Automated generation of PLC configuration files, cutting setup preparation time by 80%
  • Provided a full audit trail for every specification change, improving traceability

The portal now handles all new client onboarding for high-tensile structural cable orders. The contractor's quality team uses it as the single source of truth for every production run, and our shop floor no longer needs to interpret handwritten notes or forwarded emails.

Back to projects

From inquiry to installed line

A structured walkthrough of how we move from your first call to a running wire drawing or spooling system.

01

Load & line audit

We review your target wire diameter, tensile grade, and existing line layout. A short form or call gives us the baseline to propose a realistic setup.

02

Machine sizing & die plan

Based on the audit, we select the drawing block configuration, lubrication type, and cooling capacity. You get a die sequence and speed estimate for your material.

03

Control logic & tension map

We define the PLC program for your pneumatic tension controllers and spooling traverse. The tension setpoints are mapped per strand to avoid breaks or slack.

04

Build & factory test

Your machine is assembled and run with sample wire in our shop. We measure pull force, speed consistency, and spool layering before shipment.

05

On-site commissioning

Our engineers install the system, connect it to your existing line, and train your operators. We stay until the first production reel meets your specs.

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