Zinc and consumable cost drift
Consumption is booked against each batch as it runs, not estimated at month end.
Drawing and galvanizing
Wire & Bar ERP software
Streamlines metal wire and bar manufacturing, optimizing drawing and galvanizing with real-time tracking and analytics for better production efficiency.
Quick answer
What is wire and bar ERP?
Wire and bar ERP is manufacturing software that follows wire rod from receipt through surface preparation, multi-pass drawing, annealing and galvanizing to finished coils, spools and cut bars. Formezy tracks heat numbers, consumption and test results at every stage.
Losing heat identity across passes
Every drawn lot and finished coil keeps the heat number of its rod.
Test results in separate registers
Tensile, coating and diameter results link to the lot and gate its release.
Segments
Built for every wire & bar segment
3 segments, each with its own shop-floor process flow.
Galvanized wire
Hot-dip galvanized mild and high-carbon steel wire drawn from wire rod, with die passes, zinc use and tensile results per coil.
See the 6-step flow
Bright bars
Cold-drawn, peeled and ground bright bars in carbon, alloy and stainless steel, with size tolerance, straightness and heat traceability per bundle.
See the 6-step flow
Stainless steel wire
Fine and spring-grade stainless wire, with annealing batches, multi-pass drawing and grade-wise traceability.
See the 7-step flowShop-floor process flow
How Formezy runs a wire & bar plant
Choose a segment, then a step. Each one shows what happens on the shop floor, what Formezy records, and what changes as a result.
On the shop floor
Wire rod coils weighed in
Shop-floor impact
Heat traced from receipt
On the shop floor
Rod descaled in acid and rinsed
Shop-floor impact
Chemical cost per tonne
On the shop floor
Rod drawn through dies to size
Shop-floor impact
Die life visible
On the shop floor
Wire run through the zinc bath
Shop-floor impact
Zinc cost per tonne
On the shop floor
Tensile, coating and diameter tested
Shop-floor impact
Off-spec coils held
Quality gate. If it fails: redraw, re-coat or downgrade.
On the shop floor
Wire coiled, weighed, tagged and loaded
Shop-floor impact
Dispatch from data
Galvanized wire, step 1 of 6
Rod receipt
On the shop floor
Wire rod coils weighed in
Shop-floor impact
Heat traced from receipt
On the shop floor
Hot-rolled bars received with heat details
Shop-floor impact
Heat traced from receipt
On the shop floor
Bars cold drawn or peeled to size
Shop-floor impact
Yield per batch
On the shop floor
Bars straightened, ground and polished
Shop-floor impact
Rework visible
On the shop floor
Bars cut to fixed or random lengths
Shop-floor impact
Remnants reused
On the shop floor
Size tolerance, straightness and surface checked
Shop-floor impact
Only approved bars pack
Quality gate. If it fails: re-grind, re-cut or downgrade.
On the shop floor
Bars bundled, tagged and shipped
Shop-floor impact
Certificates from data
Bright bars, step 1 of 6
Black bar receipt
On the shop floor
Hot-rolled bars received with heat details
Shop-floor impact
Heat traced from receipt
On the shop floor
Stainless wire rod received by grade
Shop-floor impact
No grade mix-ups
On the shop floor
Rod annealed to soften it for drawing
Shop-floor impact
Batch traceability
On the shop floor
Scale removed before drawing
Shop-floor impact
Process cost visible
On the shop floor
Wire drawn through many passes
Shop-floor impact
No lost WIP
On the shop floor
Wire annealed in a protective atmosphere
Shop-floor impact
Consistent properties
On the shop floor
Tensile, diameter and surface tested
Shop-floor impact
Off-spec spools held
Quality gate. If it fails: re-anneal, re-draw or scrap.
On the shop floor
Wire spooled, weighed and labelled
Shop-floor impact
Dispatch from data
Stainless steel wire, step 1 of 7
Rod receipt
On the shop floor
Stainless wire rod received by grade
Shop-floor impact
No grade mix-ups
Dashed ring marks a quality gate, where failed material is held before it moves on.
AskEzy AI
AskEzy AI for wire & bar plants
AskEzy is the AI built into Formezy. Ask a question in plain language and get an answer from your live ERP data — no searching through modules and no waiting for reports.
- Answers from live dataPlain-language questions on production, stock, quality and sales.
- Summaries & remindersReports summarised; reminders for pending approvals.
- Flags what needs attentionOverdue items, anomalies and trends, across modules.
- Role-based accessEveryone sees only what their role allows.
AskEzy5 example questions for wire & bar
How much wire is waiting between drawing passes right now?
Gives work in progress by pass, diameter and grade, with how long each lot has been waiting.
Summarise yesterday’s galvanizing output and zinc used.
Gives tonnes coated, zinc used per tonne and any coils outside the usual range.
Which drawing machines had the most downtime this week, and why?
Ranks machines by downtime and shows the reasons operators recorded.
Show coils with tensile test results still pending.
Lists coils waiting for results by heat and grade, and flags those holding up dispatch.
Remind me when maintenance is due on the annealing furnace.
Sends a reminder before the scheduled maintenance and shows any open breakdown entries.
Answers come from your own Formezy data and follow each user’s access rights.
Software
The modules behind wire & bar plants
The same connected platform, configured around your process route.
Questions
Wire & Bar ERP: common questions
Still have a question?
Talk to a metal ERP specialist about your own plant and process route.
Which wire & bar segments does Formezy support?
Formezy supports galvanized wire, bright bars and stainless steel wire, each with its own process flow. Plants that combine segments run them in one system.
Does Formezy track multi-pass wire drawing?
Yes. Each drawing pass can be a tracked stage, with work in progress and diameter recorded between passes.
How does it help control zinc consumption in galvanizing?
Zinc consumption is booked against production as it runs, so cost per tonne is visible daily rather than reconciled at month end.
Can wire and bar be traced by heat number?
Yes. The heat number recorded at rod receipt is carried through every drawn lot, coil, spool and bar bundle to the certificate.
Can machine data be captured automatically?
The IoT & Automation module connects devices to capture real-time machine data such as running hours and line speed.
Does it handle both coil and cut-length output?
Yes. Finished wire can be coiled or spooled, and bars can be cut to fixed, mill or random lengths, each tracked by weight and pieces.
Can AskEzy answer questions about a wire & bar plant?
Yes. AskEzy, the AI built into Formezy, answers plain-language questions from live ERP data — for example “How much wire is waiting between drawing passes right now?” — and follows each user’s access rights.
Other industries
Ready to run your wire & bar plant on one system?
See Formezy configured around your own process route, from receipt to dispatch.