Notes for owners · Industry-Specific Software Guides
What a Machinery Manufacturer Should Track Every Month
A machinery manufacturer should track six things monthly. Three sit on the shop side: orders against shop load, parts pending per machine, and parts with job workers. Three come after: FAT and dispatch, service calls on the installed base, and AMC and wear-part dates falling due. Together they show what is late and what is coming.
Ganesh HS, Strategy and Technology, GullySystem · · 3 min read
Orders, promised dates and shop load
Delivery dates are often fixed before anyone checks the shop. Each month, list open machines with their promised week and the stage each has reached. Put the queued load per stage beside it.
A machine that is late is usually visible weeks early. The list makes it visible to the owner too, not only to the supervisor.
Parts still pending against each machine
Assembly waits on the last part. A BOM in Excel rarely says which parts are ordered, received or still outside. Track every line on the BOM against the drawing revision it was built from.
Count the pending lines per machine at month end. The number matters less than the trend. A machine whose pending list is not shrinking needs attention now.
- Bought-out items ordered but not received
- Parts made in-house still on the floor
- Parts sent to machining job workers and not returned
- Lines built from an older drawing revision
Assembly, FAT and dispatch
Record each FAT with its result and the customer’s sign-off. Note the punch points raised and when each was closed. Dispatch follows the sign-off, not the other way round.
Monthly, count the machines that passed FAT, those waiting, and those that failed a first test. Repeated failures at one stage point to a fixture, a supplier or a drawing.
The installed base and its service calls
Keep a register of every machine sold, with serial number, motor and PLC makes, site and warranty dates. An engineer should know the machine before reaching the gate.
Count the breakdown calls each month by machine model and by cause. Recurring causes go back to design. They also tell you which wear parts customers will need next.
AMC renewals and wear parts due next
Warranties end and AMCs expire on known dates. List the ones falling due in the next two months and call before the customer buys elsewhere. The same goes for wear parts with a known life.
Where a machine’s PLC or controller shares data, run hours can feed that list. Sensors and gateways are a separate decision. Not every machine needs one.
- Warranties ending in the next two months
- AMC contracts up for renewal
- Wear parts due by run hours or by age
Monthly machine builder review sheet
Six rows on a single page: shop load, pending parts, job work outside, FAT and dispatch, service calls and renewals due. Write this month’s count and last month’s beside each row. The rows that move the wrong way set the agenda for the review.
Open a blank worksheet to printQuestions owners ask
Does the ready production product cover the installed base and AMC?
Not on its own. It covers the BOM, work orders, job cards, outside job work, rejections and dispatch. The installed base register, AMC renewals and spares catalogue are built on top of it.
Can it schedule the shop automatically?
No. The load queued on each machine and stage is visible, and a planner sequences work and moves target dates by hand.
Can our machines report their own run hours?
Where a machine carries a PLC or controller that shares data, GullySystem’s IoT Monitoring Dashboard reads it. Sensors and gateways are bought in your name and fitted on site, scoped as a project of their own.
Will these figures reach Tally?
Not in the standard set-up. Sales, purchase and stock figures can be read inside the system. An export to Tally is quoted separately, once your accountant fixes the ledger heads.