Refractories Manufacturing

World Refractories production in 2018 was 39 Mn MT.Iron and steel industry is the major end-user of refractories, mainly used in internal linings of furnaces. Different types of refractories are used depending on temperatures and service conditions of applications such as boilers, furnaces, kilns, ovens etc.

Lighthouse ERP for Refractories Manufacturing Industry is designed to handle complete needs in most efficient, effective & accurate way. Lighthouse ERP has continuously evolved since 1987 and Lighthouse is committed to provide a industry- specific, comprehensive and robust solution for the Aluminium Industry. Lighthouse' technical expertise and mapping of key requirements is the key behind its success. Lighthouse Refractories ERP is designed to provide complete visibility across all supply chain, Logistics, Inventory and financials

Key Features in Refractories Manufacturing

Sales / Delivery Order tracking along with production upto dispatches for pending and executed qty.

Production Planning / Scheduling (Production Order) based on Sales Orders.

Product wise routine can be defined for Basic Item, Basic Unshaped Item, Fire Clay, Insulating Item, Monolithic Item and PCPF.

Process wise production capturing is possible for Pressing, Loading, Unloading, and Sorting processes. For monolithic item – Mixing & Finish Goods.

Rejection & Rectification management for damaged material.

Sales Order to Sales Order stock transfer utility is available, if access material produced or immediate requirement of produced material for another customer.

Effective Production Planning & Control

Raw Material (Alumina & Bauxite) consumption in each heat with size, Lot & Godown Control

Production Planning

Item BOM, Material Requirement Plan, Monthly Production Schedule, process parameters like temperature, pressure etc. Standard to actual Recovery calculations to manage variance analysis Breakdown Analysis (Date wise, shift wise, Shift wise, Equipment wise- Reason)

Quality Control

Accurate MIS on Production Costing / Plant Performance Sophisticated and Accurate MIS on Production Costing / Plant Performance Traceability of FG batch to the input RM heat quality test certificate PLC & DCS - Smart factory Integration with ERP

Efficient Supply Chain

Accurate raw material costing based on rates of different types of Aluminium Scraps & their recovery

All inward and outward movement is tracked at Security Gate, Weighbridge, Quality lab and store/ yard locations

Control of Material Stock at Raw material Stock Yard.

Plant movement: various scenarios including Inward, Outward, Stores Related, Purchase or Sales Return, Rake Inward, Inter-Yard Transfers, Waste or Scrap movement etc.

Carry out batch wise semi finished and WIP pricing while manufacturing

Traceability throughout the manufacturing process from receipt of raw material to finished good

Complete Financial Control:

Per Tonne costing based on Raw Material, Consumables, Cost of fuel, Electricity

Mould Life accounting

Manage Division wise & consolidated finance books Costing/ efficiency , Ledgers & Profitability. Inter division Sales & Purchase on a real-time basis

Accounts approval and bill passing for Purchase, Services (jobwork/ contractors) or Freight scenarios

Various Stock MIS with 10 level drill down

Group->Entity->Division->Plant->Dept->Cost Center->Equipment->Item Group->Item->Issue Slip

Uninterrupted Sales & Dispatch

Enquiry & Quotation followed by three level order cycle Sales Contract, Sales Order and Delivery Orders. Delivery orders can be made on the basis of the advance received and with the details of the actual product to be dispatched (with Grade wise, Size wise product details) Sales Invoicing generated instantly, by linking to Weighslips and Delivery Orders Flexible pricing methods cash discounts, quantity discounts, fixed period sales contracts, credit control etc.

Results you can expect with Lighthouse ERP

Accelerate customer enquiries responses with accurate product costing and delivery timelines.

Gain real time control over operations, deeper insights into your production costs.

Manage customer care, warranty, and service orders as part of your core processes and improve traceability

Ensure that products meet or exceed the high standards of your customers, and adapt to compliance requirements.

Fully integrated with following ERP Modules