The Scope in our Lighthouse ERP software for TLT vertical comprises of following modules:

1. Finance & Accounting module

• Cash Book, Bank Book, Journal & Ledger
• Credit Note and Debit Note
• Sales/Purchase Register
• Bank Reconciliation
• Balance Sheet & Trial Balance
• Management Information Reports
• TDS Module

Activities covered are:-

• Preparation of Indent (For some required categories the Indent generation will be auto)
• Enquiry Generation
• Preparation of Purchase Order
• Preparation of GRN
• Quality Inspection of received Material
• Classification of all items on Item Schedule, Item Category And Item Class
• Item Stock Ledger 
• Stock Valuation on First In First Out Basis (FIFO)
• Two units of Measurement 
• Grade wise Details of Stock
•  Stores Consumption Reports
•  Minimum, Maximum and Re-order Level of Stock 
• List Of suppliers with last purchase price
•  Order on Rate Contract Systems
• Job Work-order systems
• Various Gate passes – Loan Issue, Repair, Non Returnable, Convertion, Job work etc.
• Rejected stock management
• The stores module will have ISO 9002 compliances such as Vendor Rating based on consistency, timeliness, quality adherence services.

Activities covered are :-

•  Preparation of Indent 
• Preparation of Purchase Order
• Preparation of GRN on Section Weight and tonnage
• Report on Difference of Weigh Bridge & Sectional Weights
• Quality Inspection of received Raw Material
• Classification of all items on Item Schedule, Item Category And Item Class (MS & HT)
• Item Stock Ledger
• Stock Valuation on First In First Out Basis (FIFO)
• Grade wise Details of Stock
• Raw Material Consumption Reports
• Inward Freight Management
• Rejected stock management

Base Unit of Purchase Order, Delivery Order, P.O. Amendment/
Cancellation, GRN linked with Weighment Slip, and
Q.C. linked bill passing

4. Raw Material Angle lengths optimization module :

The deciding of length of angles for a project such that wastage is minimized based on various criterions:

• The length should be between 6 m and 12.5 m.
• It should preferably be in the multiple of 250 mm
• There should not be more than 3 sizes to be cut from the same length.
• Minimum of 15 mm balance must remain

Above allocation of all the size & section is based on the no. of members per tower, no. of towers planned for.

5. Production: This is a highly customized module to incorporate the stage wise

production process a part goes through in the making culminating with galvanizing, inspection and bundling. A small write up on Outline of Production and Planning for TLT industries is attached in Annexure – 6.

6. Excise & Dispatch - Sales & Marketing

Base Unit of Sales Order, Delivery Order, sales Order Amendment/Cancellation, Excise Gate Pass linked with Weighment Slip, Freight Order, and Q.C. Reports and test certificates. Manufacturing Excise reports along with PLA ,RG1, RG23 A Part I & Part II,RG23 C Part II , Raw Material Register (Earlier called Form IV. along with Annexure and monthly Abstract,ER1 (Earlier called RT12) returns , Job Work 57E and 57F registers and other statutory reports.

 7. Weighbridge Automation

Base Unit of linking of electronic weigh bridge with the COM/USB port of the node of weigh bridge room, truck deployment in the yard management of incoming and outgoing material

8. Quality Control

Data Entry of Lab Reports for incoming raw material, periodic running consumption raw material tests, periodic running production quality tests , and outgoing finished goods before dispatch Q.C. test reports.

9. Payroll & HRD module

• Payroll module – capturing of attendance, provision to link to attendance recording system, pay slip preparation, arrears calculation and auto JV creation of full salary & wages with respective posting heads for accounts.

• Personnel Department – Shift, Leave, Loan, Advance , Tour , Salary Grade and Increments management

• Human Resource Development – Training, Appraisal, Career Path
  after joining and before joining

1) One particular project conforms to one compatible set of design of towers named A, B, C, D.(Some name it as P, Q, R, S) A being the lightest  and D   being the heaviest. Each type of tower has extension in 3m/6m/9m length. Each type of tower has a foundation kit (to be placed within RCC concrete) comprising of Stubs, Cleats, Earthing strips. Each type of tower may need 1 or more Template structure for proper location of foundation bots etc.

 2) Some other attributes of the project are

•  Flow of current - AC/DC
• Voltage in KV e.g. 132/220 KV
• Single Circuit/Double Circuit

 3) A project could be Supply only, or Supply cum Erection basis.

 4) A Contract is signed for total no. of towers. Release Order is given for part of the total contract. One Release order is further divided into various destinations (Store/site office) at the time of inspection operations

5) One Tower is divided into various parts through Bill of Material (BOM). A tower may have 100 to 400 fabricated parts and other fasteners (Bought out items). The fabricated parts are mostly of mild steel (some times of high tensile steel).
Mostly angles of various sizes and thickness are the main raw material and MS plates are the next major section. Other sections such as Flats, Channels are also used though much less in quantity. Angles may vary in size from 40x40x4 to 200x200x12.

The Bill 0f Material table has following structure

Mark No. Section Length Unit Wt per Qty per Total
Wt piece tower Weight

 6) The Mark no is extremely vital. Each fabricated part is stamped with the specified Mark No. for accurate identification at manufacturing, galvanizing, inspection, dispatch, storage, erection, shortage rejection, rework processes. The Mark no. is divided into 3 parts

•  Project & Type of tower e.g. M28CK
• Part No. 1 to 400
• A 1 character long suffix (L-Left, R-Right, X-Extra, etc)

Thus a typical Mark No is M28CK-42X, having attributes as
Section: L75x75x6
Length - 6016 MM
Section Weight 6.8 kg/m
Weight per piece: 40.91 kg
2 Nos. per tower and 81.82 Kg weight per tower.

 7) Each fabricated part is made of a steel section. Steel procurement is done project – Release Order- wise. Based on the steel section details, BOM is summarized into the section wise weight requirement per tower and

 8) multiplied by number of towers planned to be produced to arrive at steel procurement requirement.

The steel procurement is done in Random/ Fixed length. Fixed length also has tolerance in ±50MM.

 9) Another vital aspect of TLT manufacturing is to minimize wastage. A prime material of Rs.19, 000/- to 20,000/- MT is converted into Rs. 6,000/-      MT. scrap

In order to optimize the steel usage, we may stack the angle length wise in a range of 100 mm, that is 11.000 m, 11.100 m and so on and work out a plan of cutting schedule of parts of various lengths of a same section such that wastage (left over lengths) is minimized.

10) The production process may involve following operations.

• Straightening (STT) All parts go through 
• Cutting (CUT) All parts go through
•  Stamping (STM) All parts go through
• Punching (PUC) All parts go through
• Drilling (DRL) Some parts go through this process
• Bending (BEN) Some parts go through this process
•  Punch After Bending (PAB) Some parts go through this process
•  Drill after Bending (DAB) Some parts go through this process
•  Notching (NOC) Some parts go through this process
• Heel Grinding(HGR) Some parts go through this process
•  Welding (WLD) Some parts go through this process
•  Grinding (GRD) Some parts go through this process
• Galvanizing (GAL) All parts go through this process
• Offered for Inspection (INO) All parts go through this process
• Approved After Inspection (INA) All parts go through this process

A Route Card is prepared for each item. There are 2 Bays – Fabrication & Galvanizing. The finished black part is sent to Galvanizing in a batch. Galvanized items are bundled together for ease of transport.

 11) The inspection by client or client’s authorised agency is a vital link in the whole chain. All material is offered for inspection and material is dispatched only after the material is approved by the inspection agency.

 12) The steel section (RM) is inspected at Rolling mill itself by Power Grid Corporation themselves for their projects; whereas for other projects inspection is done by Company’s staff. . Hence a different colour coding is done for following combinations.

• Power Grid – MS
• Power Grid – HT
• Non Power Grid – MS
• Non Power Grid - HT.