Nexans has taken a leap towards unmatched efficiency and quality by selecting advanced CELLMASTER® universal control center from Zumbach Electronic. The highly specialized and complex CELLMASTER® software runs on Zumbach USYS processors, and provides measurement and control of wire and cable diameter and capacitance in the extrusion process, including advanced categories like CAT 6 and CAT 7.

Nexans, a global leader in cable manufacturing, faced significant challenges with irregularities in their network cable extrusion process at their state-of-the-art facility in Tuzla, Turkey, leading to increased production downtime and material waste. To address these issues, and after rigorous evaluation of the possible solutions available in the market, Nexans selected advanced CELLMASTER® universal control center from Zumbach Electronic.

This innovative solution, utilizing FFT (Fast Fourier Transform) protocol, which is a powerful tool used to analyse and control various aspects of the production process, including the detection of periodic irregularities. These irregularities can affect the quality of the cables, especially in data transmission. It also helps to improve start-up times and reduce downtime, resulting in greater output, as well as significantly reducing waste materials, saving money. As a result, Nexans achieved enhanced manufacturing efficiency, reduced waste, and improved overall product quality, solidifying their position as an industry leader.

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The highly specialized and complex CELLMASTER® software runs on Zumbach USYS processors, and provides measurement and control of wire and cable diameter and capacitance in the extrusion process, including advanced categories like CAT 6 and CAT 7.

The analysis and control provided by CELLMASTER® ensures tighter specifications, consistent impedance/capacitance, and overall better product quality. An additional benefit is the ability to predict early machine failure, which itself reduces downtime by identifying potential failures before they occur, and enables planned maintenance during non-peak times, keeping production lines running smoothly. Early detection allows for minor repairs of machinery, rather than major overhauls. This kind of regular maintenance based on predictive insights can extend the operational life of machinery, as well as preventing accidents caused by unexpected machine breakdown.

Nexans partnered with Zumbach Electronic to enhance their network cable quality and maintain their global leadership. They faced issues with irregularities in cable extrusion, causing downtime and waste. By using CELLMASTER® for spectrum frequency analysis, they identified and corrected these irregularities. This technology allowed for immediate corrective actions, real-time adjustments, reduced downtime, and extended equipment lifespan, marking a significant improvement in their manufacturing process.

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Nexans have rolled out numerous CELLMASTER® implementations driving significant improvements in their manufacturing processes. In a world where precision and efficiency are key, Nexans’ strategic adoption of Zumbach’s CELLMASTER® stands as a testament to the power of innovation in achieving operational excellence.