Custom software · Manufacturing companies

Build a production system around your routing, not around somebody else’s factory.

A factory is described by its routing. It may have seven operations where a package expects three. A drawing is revised on Tuesday, and half the value of a job sits in a job worker’s shed two streets away.

The money is lost in the gap between the plan the office made on Monday and what the shift actually did. That gap closes only when the floor can record a day in a few taps, and when material that has left your gate is still on your books.

GullySystem designs manufacturing software around your own operation. It covers bills of material with their drawing revision, work orders, job cards, stores, job work delivery notes, inspection stages and the costing that says what a part really took.

Share your requirements

Who this is for

Manufacturing businesses we can build for.

Forty people in a fabrication shed, or three plants making the same component to different drawings. Your routing decides the shape of it.

Machinery and equipment manufacturers
Special purpose machine builders
Control panel manufacturers
Fabrication and sheet metal units
CNC machining shops
Auto component manufacturers
Foundries
Forging units
Plastic moulding units
Rubber products units
Electrical and electronics manufacturers
Pump and valve manufacturers
Packaging material manufacturers
Food processing units
Chemical and paint manufacturers
Textile and garment units
Furniture manufacturers
Building material manufacturers
Job work units
Contract manufacturers
Export-oriented units
Multi-plant manufacturing groups

What can be built

The modules, and what each one covers.

Nothing here is a fixed package. Each module is built, left out or changed to match how your organisation already works.

Bills of material and drawing revisions

The parts list for a product, with the revision it was cut from written on it.

Multi-level bill of material
Part master
Drawing and revision number
Bought, made and job work parts
Alternate parts
Scrap allowance
Customer-specific variants
Where-used list
Revision history
Engineering change notes

When a drawing is revised on Tuesday, the work orders already open can be flagged instead of quietly running on the old revision.

Production planning

Order and forecast load
Material requirement working
Shortage list
Work centre load
Shift plan
Weekly and daily schedule
Priority and due dates
Capacity against commitment
Plan against actual

Work orders

Order
Work order
Material issue
Operations
Inspection
Finished stock
Dispatch

What the job card carries

One card per work order, readable by the person who works from it.

Work order and part number
Drawing revision
Quantity to make
Routing and operation sequence
Machine and work centre
Operator
Setting and cycle time
Material issued
Quantity produced
Rejected and reworked quantity
Operation status
Supervisor sign-off

Shop floor reporting

Shop floor screens have to suit a supervisor who works from a notebook.

Operation start and end
Shift-wise production
Machine downtime and reason
Operator output
Work in progress by stage
Hold and resume
Idle time
Rework entry
Daily production report

Entry from a tablet on the floor works only when it takes seconds, so the screen is cut back to what the shift actually has to record.

Machines and work centres

Machine list
Work centre grouping
Capacity per shift
Setting and running time
Machine-wise load
Downtime reasons
Operator mapping
Maintenance status
Utilisation

Job work and subcontracting

Material that has left your gate and not returned is the easiest stock to lose.

Job work vendor
Delivery note
Material sent
Process and rate
Expected return date
Quantity received back
Rejection at the vendor’s end
Material still outside
Job work bill verification
Ageing of pending delivery notes

Delivery note formats and the tax returns your accountant files follow the rules of the day. The system prepares the data and does not decide the rule.

Stores and inventory

Raw material
Bought-out items
Consumables
Work in progress
Finished goods
Rack and bin location
Batch and heat number
Minimum and reorder level
Stock ageing
Non-moving items
Transfer between stores
Physical count and adjustment

Material issue to production

Requisition
Approval
Issue
Consumption
Return of balance

Purchase

Purchase request
Approval
Enquiry
Quotation comparison
Purchase order
Goods receipt
Invoice
Payment

Vendor records

Vendor master
Items supplied
Rate contracts
Lead time
Purchase history
Delivery performance
Quality rejections
Outstanding payments
Documents and bank details
Vendor rating

Vendor portal

The Friday call about a delivery date can become an update the vendor makes directly.

View purchase orders
Confirm delivery dates
Upload invoices and test certificates
Dispatch details
Goods receipt status
Rejection notes
Payment status
Rate contract
Queries

A portal only helps when vendors open it. Most factories start with the handful who supply most of their value, and widen it later.

Incoming inspection

Goods receipt note
Sample size
Inspection parameters
Accepted and rejected quantity
Deviation acceptance
Rejection reason
Debit note to vendor
Return to vendor
Material test certificate
Inspection record

In-process quality

Stage inspection points
First-article inspection
Drawing dimensions
Instrument used
Observed readings
Pass and fail
Operator and inspector
Hold at a stage
Corrective action

Final inspection and testing

Final inspection checklist
Functional testing
Load and run trials
Customer inspection visit
Test report
Serial number allocation
Packing list
Release for dispatch

Where the customer sends an inspector, the same checklist can be shared before the machine is built, not after the inspector arrives.

Rejection, rework and scrap

Rejection at each stage
Reason code
Rework instruction
Rework cost
Scrap quantity and value
Where it happened
Repeat defects
Customer complaints
Corrective action

Instruments and calibration

Instrument register
Identification number
Location and department
Calibration frequency
Last and next calibration date
Calibration agency
Calibration record
Overdue alert

Maintenance

A breakdown costs twice: the machine, and the delivery date that depended on it.

Machine-wise history
Preventive maintenance schedule
Checklist per machine
Breakdown complaint
Technician assignment
Downtime
Spare parts used
External service vendor
Annual maintenance contract
Repeat breakdowns
Maintenance cost per machine

Reading data from the machine

Where a controller allows it, run hours, counts and stoppages can be read from the machine instead of typed at the end of a shift.

This depends on the controller, its protocol and what the machine supplier permits. It is checked machine by machine before it is offered.

Enquiry to order

Enquiry
Costing
Quotation
Negotiation
Order
Advance
Production plan

Dispatch and documents

Dispatch plan
Packing and box list
Invoice
Delivery note
Transport document details
Transporter and vehicle
Transport receipt number
Proof of delivery
Dispatch history

Tax invoice series and transport documents follow the rules of the authority concerned. The system assembles the data and the authority decides what it accepts.

What a part actually cost

Material cost from the bill of material
Job work cost
Machine hour rate
Labour cost
Consumables
Scrap recovery
Estimated against actual
Order-wise profitability
Customer-wise profitability

Actual cost is only as honest as what the shift reports, which is why the floor entry screen matters more than the costing screen.

Workers and attendance

Worker records
Contract labour
Shift and muster
Attendance from the biometric machine
Overtime
Piece-rate output
Skill and machine mapping
Leave
Gate pass

Traceability

A customer may ask about a part made eleven months ago. The answer takes minutes.

Batch and heat number
Raw material supplier
Work order
Operator and machine
Inspection records
Dispatch details
Customer and invoice
Serial number

After the machine leaves

For equipment builders, dispatch is the start of the relationship.

Installed base and serial numbers
Installation and commissioning
Warranty period
Service calls
Engineer visit reports
Spare part orders
Annual maintenance contracts
Renewal reminders

Customer portal

Order status
Production stage
Inspection reports
Dispatch documents
Invoices and payments
Spare part enquiry
Service requests
Drawings and manuals

Role-based access

A planner, an operator, a job work vendor and the customer open the same order, and each sees a different screen.

Management
Plant head
Production planner
Supervisor
Operator
Stores
Purchase
Quality
Maintenance
Dispatch
Accounts
Sales
Vendor
Customer

Multiple plants

Plant-wise production
Stock at each plant
Inter-plant transfers
Plant-wise rejection
Machine utilisation
Manpower
Dispatch
Cost

Management dashboards

The numbers the Monday meeting opens, without anyone building them on Sunday.

Orders in hand
Production against plan
Pending work orders
Delayed orders
Machine utilisation
Rejection and rework
Stock value
Shortage list
Material lying at job workers
Dispatch value
Outstanding receivables
Cost per order

What it connects to

Your accounting software, such as QuickBooks or Xero
Tax invoice and transport document data
Biometric attendance
Barcode and QR scanning
Weighbridge
Existing ERP modules
Customer portals
Supplier systems

Most machines on a shop floor write a file or nothing at all, and older accounting packages want a file import. We open the actual file before anything is agreed.

The journey

One connected workflow, end to end.

Every stage below can sit in one system, so nobody re-enters what the last stage already captured.

Enquiry
Costing
Quotation
Order
Planning
Material
Job card
Production
Inspection
Packing
Dispatch
Invoice
Service

Built in phases

You do not have to replace everything at once.

Each phase is usable on its own, so the system earns its place before the next part is built.

1
Orders, material and stores
Part masters, bills of material, purchase, stores and job work. The records everything else on the floor reads from.
2
The shop floor
Work orders, job cards, operation reporting and work in progress, so the plan and the shift describe the same day.
3
Quality and maintenance
Inspection stages, rejections, instruments, preventive maintenance and breakdowns, held against the machine and the part.
4
Costing, portals and dashboards
Order costing, the vendor and customer portals, management reporting and whatever integrations are worth doing.

How we work

How a build actually runs.

01
Walk the floor
We follow one order from enquiry to dispatch, in your factory, including the parts that live in a register.
02
Map
Products, routings, work centres, stores, job workers, inspection stages, approvals and the handovers between shifts.
03
Design
Screens drawn for the person who will open them. A stores clerk and a planner need different pages.
04
Build
Stores and job cards usually come first, so the factory is working soonest.
05
Run a real order
Your own supervisors push a live order through the system before anything is switched over.
06
Deploy
Go-live on the floor, with the operators and clerks trained on their own screens.
07
Extend
Machine data, portals, costing depth and analytics, added as the plant gets used to the system.

What you bring

What you bring, and when.

The build moves at the speed of the answers. These are the things we ask for, in the order we ask.

01
Job cards, BOMs and drawing files
Send job cards, bills of material, routing sheets, drawing revision lists and stores registers. Completed orders show the real flow. Planning starts here.
02
Planner, shop supervisor and stores keeper
Each answers for a part of the plant. They poke at each demonstration and report gaps. The works head settles planning and floor differences.
03
Standard times, scrap norms and purchase limits
Machine times, scrap allowances, reorder levels and purchase approval limits need a ruling mid-build. Vendor and item masters accompany them. A reviewer is present at each demo.
04
Open work orders and machine data
Open work orders, stock by location and vendor balances are loaded for go-live. Machine monitoring links and accounting software are named at once. The plant head accepts the switch.

What we can build

Systems we can put together for you.

Manufacturing ERP
Production planning systems
Shop floor data capture
Job card and work order systems
Bill of material and costing systems
Stores and inventory software
Purchase and procurement systems
Vendor portals
Quality management systems
Maintenance management systems
Machine monitoring dashboards
Dispatch and documentation systems
Customer and dealer portals
Multi-plant management platforms

Common questions

Questions owners ask before starting.

What is custom manufacturing software?

It is software written around one factory: your part numbers, your routings, the operations you send out on a job work delivery note, and the stages where somebody inspects. Where the process is ordinary a package is cheaper. It earns its cost where the process is not.

We are a small unit with thirty workers. Is this for us?

Often the small unit gains most, because the gap between the plan and the floor is wider. Start with stores, job cards and dispatch, and leave the rest for later.

Can the system handle job work sent outside?

Yes. Delivery notes, the process and rate, the expected return date, what has come back and what is still lying at the vendor’s place are all tracked against the work order.

Will operators actually enter data?

Only if the entry is short. We design the floor screens around a few taps per operation, and where a supervisor enters for a gang, the screen is built for that instead.

Can it connect to our machines?

Sometimes. It depends on the controller, the protocol and what the machine supplier allows, and it varies machine to machine. We check each one rather than assume.

Do we have to move away from our accounting software?

No. Most units keep their books exactly where they are. Invoices, purchases and journals can be posted across, and your accountant carries on as before.

Is the real cost of an order available?

Yes, as far as the floor reports it. Material, job work, machine hours and labour can all land on the order, and the estimate sits beside the actual.

Can quality records be kept in the same system?

Yes. Incoming, in-process and final inspection, instruments, calibration dates and corrective actions sit against the part and the work order, not in a separate file.

Is more than one plant supported?

Yes. Each plant runs its own day, transfers between plants are recorded, and the head office sees the group without ringing three managers.

Can we build only part of it?

Yes. Stores and job cards come first, ahead of quality and costing. A plant that records a shift is ready for the next phase.

What will the software not fix?

It will not make a wrong drawing right, and it will not stop a vendor being late. It tells you sooner, and it keeps the record of what happened.

Could it be offered as a product to other units?

Yes, though it is a different build. Software sold to several factories has to survive routings you did not design, so it is planned that way at the start and not adapted from your own system afterwards.

Your trade

How we work with this trade.

Machinery manufacturers

Build the system your factory actually runs on.

A factory should not have to rewrite its routing because a package expects three operations and you have seven. The software can take the shape of the shop floor instead.

Whether that is a job card application for one shed, a stores and purchase system, or a full manufacturing ERP across plants, tell us how your factory runs today. The routing comes first, because a system that cannot hold your seven operations will not hold anything else.

Tell us how you work

Tell us how your manufacturing companies runs today.

We will tell you what can be digitised, what can be connected, what is worth automating, and what you should leave alone.

What happens after you share your requirements

A senior engineer reads your answers. Nobody phones first.
Within one business day you get a written note: what we understood, what we would start with, and the questions we still have.
If it fits, a proposal follows with the order of work, what we need from you and what you receive at each step.
No call is booked and nothing is paid until you have read the note. Your details stay with us.

Start with your requirements

Seven short steps that tell us what you need. A senior engineer reads them before anyone gets in touch.