Build a renewable equipment system around your serial numbers, your test data and your projects.
Solar and renewable equipment is sold against a warranty that runs for decades. Years later, a customer may ask which cell lot, which glass and which test result sat behind one module or one battery pack.
Inside the plant, those answers live in separate places. Stores hold receipts for cells and busbar ribbon. The line keeps flash test files. Quality holds inspection sheets, and sales holds the project order and the dispatch list.
These records can be designed as one system around your own products. A serial number would link the material lots, the line, the test curve and the shipment. A claim from site would open that chain in one view.
Renewable equipment makers we can build for.
A module line, a mounting structure shop and a battery pack assembler all track different things. The build follows what your plant actually makes. Fabrication shops that only cut and galvanise steel may fit the metal fabrication page better. Installers who buy finished kit and fit it on roofs are a different business again.
- Solar panel manufacturers
- Solar mounting structure manufacturers
- Solar inverter manufacturers
- Solar component manufacturers
- Battery pack manufacturers
- Wind turbine component manufacturers
- Energy storage system manufacturers
- Junction box and connector makers
- Solar cable and harness makers
- Solar water heater manufacturers
- Charge controller and power electronics makers
- Tower and blade component suppliers
- Solar street light manufacturers
- Module frame and glass processors
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.
Product models and the bill of materials
Each model carries a revision of its bill of materials, and the plant builds against the revision in force on the day.
- Module, inverter and pack model master
- Cell count and layout per model
- Bill of materials with revision history
- Approved alternate suppliers per part
- Engineering change notices
- Effective date of each revision
- Datasheet and drawing links
- Rated power and electrical class
- Customer-specific variants
Incoming material and supplier lots
Stores receive cells, wafers, glass, encapsulant, backsheet, ribbon, battery cells and power semiconductors. Each receipt gets a lot record.
- Supplier and purchase order reference
- Supplier batch and test certificate
- Cell efficiency bin and colour grade
- Glass thickness and coating sheet
- Encapsulant shelf life and storage
- Incoming sample inspection result
- Hold, release and reject status
- Storage location and humidity log
- Shelf life alerts for adhesives and films
A rejected lot stays visible, so nobody pulls it into a work order by mistake.
Production planning and work orders
Planners turn confirmed orders into line schedules. Each work order names the model, the quantity, the bill revision and the line.
- Order book by model and delivery date
- Line and shift schedule
- Material availability check against stock
- Work order with the bill revision attached
- Kitting list for the line
- Partial completion and carry-over
- Rework and reprocess orders
- Scrap and yield by line
Line stages and serial numbers
- Cell sorting
- Stringing
- Layup
- Lamination
- Framing
- Junction box
- Flash test
- Packing
- Serial number assigned at layup
- Operator and station at each stage
- Lot of cells, glass and film consumed
- Stage timestamp and line
- Stage rework with reason
Inverter and pack lines would use their own stages. The stage list is drawn from your floor, not from ours.
Flash testing and electrical results
The tester produces a curve for every unit. Stored against the serial number, that curve would feed its power, voltage and fill factor straight into the unit’s file.
- Power, voltage and current at test
- Fill factor and series resistance
- Binning by measured power
- Electroluminescence image link
- Insulation and ground continuity test
- Retest history for the same serial
- Tester calibration record
- Reference module check at shift start
Battery pack assembly and cell matching
Pack builders match cells by capacity and internal resistance before welding. Which cells went into which pack must be readable afterwards from the pack serial.
- Cell grading data by lot
- Matched cell groups per pack
- Weld and torque records
- Battery management board and firmware version
- Charge and discharge cycle test
- Insulation and leak test
- Pack serial and cell serial link
- Storage and transport class of the pack
Dangerous goods papers for packs follow the rules of the route you ship on, and these are reviewed with your logistics team.
Structures, fabrication and coating
Mounting structure makers cut, punch, weld and coat steel or aluminium to a project drawing. Every cut list, coating batch and packing list follows that drawing.
- Project drawing and revision
- Cutting list and nesting
- Purlin, rafter and bracket schedules
- Welding and punching operations
- Galvanising or anodising batch
- Coating thickness readings
- Fastener and hardware kits per project
- Packing list by structure type
Quality plans and inspection
Quality teams define what is checked at receiving, at the line and at final inspection. Plan and readings would sit side by side, so an auditor sees what was required and what was found.
- Inspection plan per model
- Visual defect catalogue and grading
- Sampling rules for incoming lots
- Peel and pull strength readings
- Gauge and instrument register
- Non-conformance report
- Corrective action with owner and date
- Customer audit extracts
Reliability and sample testing
Some tests run for days in a chamber and sit outside the production line. They still belong to a lot and a model.
- Thermal cycling and damp heat runs
- Sample units drawn from production
- Chamber load and result
- Test report storage
- Third-party lab references
- Link from test to model and lot
Finished stock and warehouse
Finished goods are stored by model, power bin and serial range. Dispatch picks from that stock.
- Pallet and container load records
- Stock by model and power bin
- Serial range per pallet
- Location in the warehouse
- Reserved stock against orders
- Damaged-in-store write-off
- Ageing report on unsold stock
Projects, quotes and orders
Sales teams quote for a project, not a single unit. The quote carries quantities by model and the delivery plan.
- Enquiry and tender register
- Quote with model, quantity and currency
- Price validity and revision
- Customer purchase order
- Staged delivery schedule
- Advance and milestone payment terms
- Site address and contact
- Order status for customers
Dispatch, export and documents
Each shipment carries papers that name the serial numbers inside. Pallet records would feed the packing list, so serial numbers are never retyped for the forwarder.
- Packing list with serial numbers
- Tax invoice in the customer’s currency
- Commercial invoice and export papers
- Test report copy per shipment
- Freight forwarder and container details
- Delivery proof and receipt
- Customs references kept with the order
Warranty, claims and field returns
A site complaint starts with a serial number. The claims team should see what the plant knew about that unit.
- Claim intake with photos
- Serial lookup to lot, line and test curve
- Warranty term and start date
- Inspection and failure analysis
- Replacement or credit decision
- Returned unit tracking
- Failure reasons by lot and supplier
- Supplier chargeback
Spares, service and monitoring data
Inverter and storage makers carry spares and service visits after the sale. This sits beside the plant records.
- Spare parts catalogue per model
- Service visit and engineer report
- Firmware release and installed version
- Fault codes mapped to causes
- Annual service contracts
- Optional import of monitoring portal data
Purchasing, costing and accounts
Purchasing buys against the bill of materials. Accounts costs each model from the lots that went into it.
- Purchase requisition from shortages
- Supplier rate and lead time
- Currency and landed cost per lot
- Cost sheet per model and revision
- Job costing for structure projects
- Customer ledger and receipts
- Your tax rules on invoices and credit notes
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
- Quote
- Order
- Material receipt
- Work order
- Line stages
- Test
- Final inspection
- Dispatch
- Warranty
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
Models, lots and work orders
Product models, bill revisions, supplier lots and production orders. The plant starts building against a recorded revision.
- 2
Serials and test data
Serial numbers at the line, flash test curves, inspection readings and the link from each unit to the lots inside it.
- 3
Projects and dispatch
Quotes, orders, pallet records, shipment papers and invoices in the customer’s currency.
- 4
Claims and analysis
Warranty claims, returned units, supplier chargebacks and reports on yield, failures and lot quality.
How a build actually runs.
- 01
Walk the line
We follow one module, pack or structure from goods receipt to the truck and note every record created on the way.
- 02
Read your documents
Bills of materials, inspection sheets, test reports and customer audit forms show what has to be stored.
- 03
Design the serial chain
We agree where a serial number is born, what attaches to it, and which stages are allowed to change it.
- 04
Build in stages
Models and lots come first, because every later record points back to them. Test data and claims follow.
- 05
Connect the equipment
A tester or scanner that exports a file can be read directly. We check this against your machines early, before design is fixed.
- 06
Run beside the old records
One line goes first. Operators compare the new screens with their sheets until they trust them.
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
Bills of material, test reports and batch cards
Send over a module bill of material, a flash test report and the line traveller. Add a supplier certificate. They show how a serial number gains its history.
- 02
Production, quality, stores and projects
Each area keeps records the others need. Quality owns test limits. Stores own supplier lots. The plant head settles clashes.
- 03
Pass limits and grading bins
Pass limits, grading bins and supplier acceptance rules are set while modules take form. Line leaders try screens at the station. Their feedback comes before the next module.
- 04
Stock in hand and serial history
Stock and the serial history you wish to keep come across. The quality head approves the test data connection.
Systems we can put together for you.
- Solar module production tracking
- Serial number and traceability systems
- Flash test data capture
- Battery pack assembly records
- Inverter manufacturing management
- Mounting structure project software
- Bill of materials and change control
- Incoming lot inspection systems
- Warranty claim and returns tracking
- Export dispatch and document software
- Supplier quality dashboards
- Customer portals for order status
Questions owners ask before starting.
Can every module or pack carry a serial number linked to its materials?
Yes. The serial is created at a stage you choose, and each lot consumed after that is attached to it.
Can flash test results be loaded without typing them?
Where the tester exports a file or a database, yes. We check the format against your equipment before design starts.
How would a warranty claim be traced?
A claims clerk keys in the serial number. Up come the lots, the line, the test curve and the shipment.
Does this suit a structure fabricator and not only a module line?
Yes. The same pattern of lots, work orders and inspection fits steel and aluminium work, with project drawings in place of cell lots.
How are customers abroad invoiced?
Each customer can be given a currency, and quotes, invoices and receipts follow it. Your own tax rules sit on top.
What about the accounts software we already use?
Often a link is possible. How far it goes turns on the interfaces your accounts package offers, which we review while implementing.
What about dangerous goods papers for battery shipments?
Class and papers can be held per shipment. The rules themselves depend on your route and are checked with your logistics team.
Do we need to replace what already works?
No. A ready GullySystem product may cover part of it, and the custom build covers the records that are particular to your plant.
How we work with this trade.
Ready products for this work.
If one of these fits, it is cheaper and faster than building from scratch. We will say so.
Build a record that follows each unit for its whole life.
A warranty that runs for decades means little if nobody can say what went into a module. Once a serial number opens its lots, its test and its shipment, a claim becomes a short conversation.
Bring a bill of materials, a test report and a recent claim. We will show how they would join, and say which parts a ready GullySystem product already covers.
Tell us how your solar and renewable energy equipment manufacturers 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.
Share your requirements