Lighthouse ERP
Steel Wires Products Manufacturing
Simple to Use
Easy to Implement
Flexible to Customized Solution
Critical applications in a variety of industries, including engineering, construction, oil and gas, and automotive, rely heavily on steel wires. Made from wire rods of stainless steel, black carbon steel, or specialty steel alloys, steel wire ropes require manufactured precisely and subject to rigorous testing in order to satisfy end users' needs. Manufacturers are under increasing strain to produce high-performance wire goods effectively and economically as the demand for these products rises globally, particularly as the production of refractories is expected to reach $186 billion by 2030.
Lighthouse ERP for Steel Industry is built to meet these exacting needs. Backed by decades of domain experience since 1987, Lighthouse offers an industry-specific, highly configurable Steel Wire ERP Software tailored to the unique challenges of wire and steel product manufacturing. From raw material costing, Inventory & Material Management with material management module and production planning, Production Planning & Control module to traceability, plant integration, and batch-wise quality tracking (Quality Management module), Lighthouse ERP empowers manufacturers with complete operational visibility.
Whether it’s managing plant-level processes, logistics, inventory, or financial controls Lighthouse Manufacturing ERP ensures steel wire manufacturers can operate with greater accuracy, control, and profitability.
Steel wire production involves multiple drawing parameters like drawing speed, lubrication cycle, and deformed ratio must be maintained at each pass. Managing these manually leads to inconsistent product quality and tool wear.
Customers in oil and gas, marine, and construction demand traceability from final wire products to the specific heat number of raw wire rods and their chemical/mechanical test certificates.
Wire drawing dies have limited life cycles. Overuse without tracking leads to poor surface finish, diameter tolerance issues, and increased scrap.
After drawing, wires undergo coiling or spooling, sometimes into intermediate forms before final packaging. Tracking semi-finished inventory in multiple winding stages is complex.
Steel wire annealing consumes gas or electricity in continuous furnaces. Cost per ton varies based on energy efficiency, which is hard to monitor manually.
Drawing wire from thicker to thinner gauges results in material loss. Tracking yield loss stage-wise and mapping theoretical vs actual outputs is critical for profitability so adopting ERP Software becomes necessity.
Fine wire products are shipped in spools or coils of varying sizes and weights. Planning dispatches based on available vehicle capacity, and maintaining grade/size-level accuracy, is a logistical challenge.
With numerous grades, finishes, and sizes, stainless steel inventory management becomes complex. Mismanagement can lead to overstocking of slow-moving items or shortages in critical grades.
Steel wire manufacturing ERP software ensures complete traceability by automatically documenting every batch from finished coils back to raw material heat numbers and quality test certificates (QTCs).
ERP for wire and cable industry tracks deformation ratio, drawing speed, annealing cycles, and pass count ensuring each batch meets required tensile and elongated values.
Die usage, tool change cycles, and their impact on performance are monitored automatically.
Integrates with PLC/DCS systems to track actual electricity or fuel usage by batch, machine or process.
Standard vs actual yield is compared in real-time, and scrap is tracked by type, source, and stage.
Whether it's gauge-wise, grade-wise, or contract-based pricing, the ERP intelligently picks the correct rate at order creation.
Real-time dashboards give visibility into throughput, cost per ton, downtime reason codes, and shift-level performance.
System generates delivery orders tied to weighbridge slips, product specs, and advance payments all in one flow.
ERP maps costs across departments, machines, and batches including raw material, fuel, tool, and labour.
Every inward, outward, WIP, or inter-yard transfer is captured with location, batch, and quality details.
Allocate processes across multiple work centers with time-based production schedules for better resource utilization and efficiency.
Support for process-specific BOMs and MRP that considers drawing parameters like deformation ratio, annealing cycles, and drawing speed.
Automatically reallocates unused or partially used raw material or WIP stock from one process to another to reduce inventory waste and improve flow.
Analyze breakdown by date, shift, equipment, and reason to reduce unplanned downtime and improve machine efficiency.
Generate live MIS reports for production costing, machine efficiency, and energy usage to drive faster, informed decision-making.
Covers complex plant scenarios like rake, inter-yard transfers, purchase returns, sales returns, and scrap disposal with proper documentation.
From group to issue slip, financial data can be drilled down to the most granular level ideal for cost control, audits, and profitability analysis.
Supports automated workflows for approval and posting of bills related to purchases, services, and freight.
Supports three-stage sales cycle Enquiry, Sales Contract, and Order with flexible pricing options (cash/volume discounts, credit control, period-based rates).