Steel wire quality is measured in terms of tensile strength, yield strength, elongation and relaxation. Minimum requirements for these specifications are defined by international standards. This research intends to assist in setting the steel wire machine by identifying the relationship and appropriate range among manufacturing process variables and parameters. By knowing these relationships, the setting up machine can be done in short time which leading to cost reduction and achieving quality standard. The results reveal that the treatment setting of temperature was the most significant variable followed by tension. In particular, the three mechanical properties of tensile strength, yield strength and elongation achieved when temperature set at 350°C. Mathematical models were derived for the effect of process variables on tensile strength, yield strength and relaxation. Response optimisation was used to find a composite solution to optimise the response variables simultaneously.Reference to this paper should be made as follows: Kess, P., Tong-In, D., Ayutthaya, P.S-n. and Anusornnitisarn, P. (2014) 'Process innovation in pre-stressed concrete wire using mechanical-based process simulator', Int.