Production Planning and Control processes in Tower Manufacturing are a challenge right from Raw Material procurement to Dispatch stage. Lighthouse ERP^TM 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 ERP^TM 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
  

• 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

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