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The stranded wire helical spring is normally made from 2 to 7 carbon steel wires that are tied up to form a rope.It is extremely important that the tension of individual wires to remain consistent during reeling as the inconsistency of tension will affect the quality of a spring.To date,there is no research work done on the analysis of tension of wires forming a spring during the manufacturing process.Most of the research work has focused on the analysis of springs tension during static or dynamic loading.Such research is necessary but it is not practical if the quality of the original product (i.e.the spring) is distorted.Hence,this research aims to address the root of the problem-spring with poor quality.In order to accomplish this,the dynamic behaviours of wires during reeling are firstly represented using 3D models.Mathematical models are then developed from the 3D models for further analysis.Finally,the dynamic tensions of individual wires are mathematically derived.The computed dynamic tensions of wires are used to develop remedy solutions to ensure the production of spring with good quality.