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Transmission Line Tower Vertical

Production Planning and Control processes in Tower Manufacturing are a challenge right from Raw Material procurement to Dispatch stage. Lighthouse ERPTM achieved a breakthrough in the modules enabling the optimization of R.M. (angles) usage for meeting production planning requirement of a group of work orders spanning multiple types of tower structures.
   
Lighthouse ERPTM for TLT has the potential of recurring savings of Rs.30+ Lacs per annum based on a reduction of 0.50% wastage resulting in savings of 120+ MT of angles scrap based on 24000+ MT yearly production.

Key Processes in Transmission Line Tower

  • Sales Contract and Delivery Orders
  • Excel import/creation  of Bill of Material (BOM)
  • Work Order generation against Proto, Mass, Extra, Shortage.
  • R.M. Procurement & Production Planning for a batch of multiple work orders
  • Batch wise Angle procurement length Optimization
  • Auto bundling plan
  • Process wise Fabrication and contractor bill passing
  • Galvanizing in house or sub contract.
  • Ready for Inspection: Provision for Third Party Quality Inspection
  • Packing Slip based on dispatch instruction
  • Excise & Commercial invoice

1.   Finance & Accounts

  • 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

2.   Taxation

  • Service Tax / VAT/ CST
  • Excise
  • TDS/ FBT
  • Entry Tax
  • Forms Tracking like C-forms, Waybills etc 

3.   Security Gate Management

  • Inward Register for all vehicles
  • Outward Register
  • Generation of Loading & Unloading Slips
  • Report of all Vehicles in Plant

4.   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.

5.   Store Inventory Management

  • 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
  • Gate pass – Loan Issue, Repair, Non Returnable, Convertsion 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.

6.   Raw Material Inventory Management

  • 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 & Weighted Avg.)
  • Grade wise Details of Stock
  • Raw Material Consumption Reports
  • Inward Freight Management 
  • Rejected stock management
  • Purchase Order, Delivery Order, P.O. Amendment/
    Cancellation,
  • GRN linked with Weighment Slip, and Q.C. linked bill passing
7.   Raw Material 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.

7.   Excise and 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.

8.   Excise and Dispatch - Sales & Marketing

  • Data Entry of Lab Reports for incoming raw material,
  • Periodic Running Consumption Raw Material Tests,
  • Periodic Running Production Quality Tests ,
  • Q.C. test reports for outgoing finished goods before dispatch .

9.   HR & Payroll Module

  • Employee Data with qualification, previous jobs, family, hobbies etc.
  • Appraisals
  • Tour & Training details
  • Muster Roll with OT, C-off
  • Shift Management/ Leave Management/ Loan Management
  • Payroll Generation with Auto Arrears
  • Statutory Forms of PF/ ESCI/ Professional Tax/ Wage Register etc.
  • Gratuity Calculation
  • Income Tax Computation with Form-16 generation.

10.   Database Administration (DBA)

  • Configuration Management
  • Security Management- User rights and controls
  • Data Freezing
  • Tests for data entry errors and rebuilding
  • Backup Management
  • Rectification of procedural errors like allowing editing after approvals.
  • Accounting year carry forwarding routines

Click Here For Detailed System Study Of TLT Manufacturing Process