Lighthouse ERP
Steel Melting Shop
Simple to Use
Easy to Implement
Flexible to Customized Solution
The steel melting Shop segment of the steel industry is known for its high capital investment and heavy reliance on bulk raw materials like scrap, sponge iron, and alloys. While the demand for steel continues to rise, the industry is facing mounting challenges such as volatile raw material prices, a shortage of skilled labour, and rising operational and maintenance costs.
To navigate these challenges, leading steel manufacturers are embracing Steel ERP Software that enhances production planning, ensures accurate costing, and supports real-time control.
Lighthouse ERP for steel melting shop is purpose built to address the unique complexities of steel melting operations. Backed by over 38 years of industry experience, this steel melting shop ERP continues to evolve to meet modern shop floor demands.
From casting management to inventory control, and from real-time traceability to accurate costing, Lighthouse ERP ensures every stage of the steel melting process is connected, visible, and efficient. It delivers cost-effective, high-performance ERP software for steel melting shops, helping businesses increase productivity, support informed decision-making, and boost profitability.
The cost of scrap, sponge iron, ferro alloys, and fluxes changes frequently based on dollar value, making it hard to maintain stable production costs.
Steel melting is energy intensive. Without proper monitoring, fuel and electricity costs escalate rapidly and unpredictably.
Difficulty in mapping finished billets back to specific heats or raw material batches during quality issues or customer complaints highlights the need for steel manufacturing production tracking software.
Shift-wise and equipment-wise production is often logged manually, leading to data inaccuracies and poor yield analysis.
Without centralized equipment maintenance logs, plants suffer from unexpected failures, reduced machine life, and production halts.
Without automated tracking, actual vs. Standard yield discrepancies often go unnoticed, leading to loss of material and revenue.
Absence of real-time per-heat costing delays financial analysis and affects pricing, profitability, and future planning.
The ERP for steel captures all cost components raw material, fuel, consumables, power for real-time per-heat and per-ton profitability tracking using steel manufacturing cost analysis software.
Enables complete backward traceability from finished goods to raw material heats and quality test certificates steel manufacturing inventory management.
ERP logs production shift-wise, equipment-wise, and records breakdowns with root causes improving uptime and reliability.
Compare standard vs. actual yields heat-wise to minimize losses and improve process efficiency.
Automatically pulls temperature, pressure, and other melting parameters from plant automation systems into ERP for precise tracking.
Tracks material flow across all stage's inward, storage, melting, WIP, dispatch preventing stock leakages and mismatches with the help of steel manufacturing inventory management software.
Provides multi-level reports (Group → Division → Plant → Equipment) for real-time insights into cost, performance, and stock- a core module of steel industry ERP solutions.
Plan and manage BOMs, material requirements, and monthly schedules based on process parameters. Track equipment breakdowns by date, shift, and machine with downtime reasons to reduce production losses.
Monitor billet output heat-wise with detailed size, lot, and storage control, while efficiently managing the lifecycle and usage of rolls throughout production. Integrated into Billet and Slab Production ERP and Casting Management Software modules.
Automatically calculate raw material costs based on recovery rates and pricing, while capturing every inward and outward movement across key checkpoints for complete material flow visibility.
Maintain clear visibility and control of stock across multiple locations like Raw Material Yard and Bagging Areas, while efficiently managing all types of plant-wide material movements including transfers, returns, and scrap handling. Manages via Inventory Management and Warehouse Management ERP Modules.
Track mould life and replacement schedules alongside managing consolidated and division-wise financial books, ledgers, and profitability reports for accurate accounting. Features align with Financial Accounting ERP module.
Ensure real-time visibility of inter-division transactions and implement approval workflows for purchases, job work, freight, and contractor bills to enhance financial control.
Handle the complete sales cycle from enquiry to delivery, including advance-based delivery orders with detailed grade-wise and size-wise tracking. Fully covered under the Sales and Distribution ERP Module.