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GullySystem
Manufacturing · Software for auto parts manufacturers

Carry each customer’s part number, drawing revision and release schedule on one record, from coil to dock.

This software holds each customer’s part numbers, drawing revisions and first-sample approval files, so a plant supplying vehicle makers keeps every print and approval on one record. It plans presses and machining cells against changing releases, records inspection for each lot, and prints labels and shipping notices in each customer’s format. Releases change. Plans follow.

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At a glance

An auto parts plant makes components to a customer’s drawing, such as a stamped bracket, a rubber bush, a cast housing or a moulded clip. The buyer is a vehicle maker. Each part number carries a drawing revision, a control plan, a failure-mode analysis (FMEA) and often a first-sample approval file (PPAP) before volume begins. Releases change without notice.

Parts are made in lots, gauged at set intervals, packed in returnable boxes and labelled in the customer’s own barcode format before they leave. Dispatch follows a release. When a defect turns up at the vehicle plant, the customer raises a complaint and expects an eight-step corrective-action report, known as an 8D, that names its cause. Every cause must be provable.

How the work runs today

The planner opens the customer’s latest release and sees that the weekly quantity has moved up for two part numbers and down for a third. Press time is booked against the old figures. The coil on order suits neither. The shift supervisor wants to know what to run tonight, which die to change over first, and whether the coil for the third part will arrive in time.

The quality lead is hunting for the inspection record of a lot shipped nine weeks ago. A complaint has arrived, and the customer wants the containment steps, the capability history for the failed feature, and a list of what is still in the supply chain.

Where it breaks

What goes wrong for auto parts manufacturers without a proper system.

Customer releases change the plan daily

Weekly and daily schedules arrive from several vehicle plants, each in its own file layout, and the planner retypes them into a sheet. A late amendment is missed until a truck is short. The line stops at the customer.

Drawing revisions reach the shop late

A customer revises a drawing and the quality department updates the gauge, but the press operator still works from the earlier sheet at the machine. The lot is made to the old print. It is rejected on arrival at the dock.

First-sample approval files are scattered

Dimensional layouts, material certificates, the control plan and capability data for a new part sit in different folders, and volume production waits while somebody gathers the pieces. Sign-off drifts week by week.

Lot traceability stops at the pallet

A returnable box carries a label, yet the shift, press, die and coil lot behind it sit in a notebook. A defect found at the customer cannot be contained to a few boxes, so the pallet is sorted by hand.

Returnable boxes and labels go astray

Customer-owned boxes, dunnage and barcode label formats are tracked by memory, so boxes pile up at the customer and a label format is wrong. A truck is refused at the dock. Cost lands on the supplier.

What the software does

What we would build for auto parts manufacturers.

Named the way your team already talks about the work. We start with whichever part the audit shows is costing you most.

Customer part numbers and revisions

Hold each customer part with its drawing revision, material, control plan and PPAP file on one record, so that operators see the current print at the press. Nobody works from a superseded sheet.

Release schedules

Load customer releases and plan presses, tooling and coil against changing quantities. Every change is marked against the last release, so planners see what moved before booking.

Lot production and inspection

Record the machine, die, shift and material lot for each production lot, along with in-process and final gauge results, so that a feature outside its limit holds the lot.

Labels and shipping notices

Print customer-format barcode labels and advance shipping notices from the dispatch record, with nothing retyped. A wrong format is fixed once for every later shipment.

Returnable packaging

Track boxes and dunnage issued to each customer plant and returned from it, with balances by plant. Shortfalls show before the customer raises a charge.

Complaints and containment

Log customer complaints with the lot trace, containment steps, 8D corrective action and the date each step closed. Repeat causes show up by die and by supplier lot.

Subcontracted processes

Ship components to the plater, heat treater or e-coat line, then book back what returns good and what is rejected, with the outgoing and incoming weights side by side.

Before you talk to a supplier

A requirements checklist for auto parts manufacturers.

What to cover, which reports to ask for and what to put to every vendor, ready to print or save as a PDF.

Open the checklist
Ready product

A product already built for auto parts manufacturers.

It is adapted to how your business works before it goes live, and anything your trade needs that it lacks is added then.

Auto Parts Manufacturer Management Software

PPAP files, release-driven planning, lot trace, control plan inspection, plating and heat treatment returns, returnable crates, VDA labels and 8D replies for auto parts makers.

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Solutions inside

The business modules auto parts manufacturers use most.

Each one is also available on its own, or inside a system built for you.

Services

The services behind it.

Business Process Automation

Approvals, reminders, follow-ups and reports that run on their own instead of on someone remembering.

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API and System Integration

Accounting software, WhatsApp, payment gateways, tax portals and your own apps sharing one set of numbers.

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ERP, CRM and Business Software Implementation

One record of stock, orders, customers and accounts, set up so your team opens it every day.

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Data Migration and Moving Off Spreadsheets

Data migration and spreadsheet replacement covers auditing existing files, cleaning and deduplicating records, loading them into a new system and reconciling the loaded result against known totals. Both systems then run side by side before cutover. Originals stay untouched.

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How it works

How the work runs from Bengaluru for your city.

  1. 1

    The audit, by call

    A screen-share and a look at the sheets, accounting reports and WhatsApp groups your team uses. No travel needed.

  2. 2

    A written proposal

    Scope, what we build first and the cost, agreed in writing before anything starts.

  3. 3

    Build in short rounds

    Working screens shared every few weeks. Your team tests them from your own office.

  4. 4

    Go-live, in person when it helps

    For data migration and training we can come to your city. Travel is agreed in advance.

  5. 5

    Support online

    Fixes, changes and hosting handled remotely by the same team that built it.

Our work

Software we have built and run.

We only name clients whose work is published. These are systems our team designed, built and supports.

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Common questions

Questions auto parts manufacturers ask before they call.

Can it take customer releases?

Releases can be keyed in or loaded from the file the customer sends. Whether an automatic link to a customer portal is practical is checked during implementation, as it depends on the file format and the supplier access each vehicle maker allows.

What limits a defect to a few boxes?

Each box label points to a lot, and each lot points to a press, a die, a shift and a material lot. Containment is limited to the boxes made on that die on that date. Other stock ships freely.

Are approval documents stored?

Dimensional reports, material certificates and control plan files are attached to the part and revision. Your quality engineers decide which documents each customer must receive, and the record shows what was sent and when.

Can we try it on our parts?

A working session can run on two or three of your part numbers and a recent release. Once you have chosen modules and seats, a written offer sets out the setup and the monthly cost as separate lines.

What happens after I share my requirements?

An engineer reads what you send and replies within one business day. We then look at the software, spreadsheets and WhatsApp groups your business runs on today and write down what works, what slows your team down and what is missing. A demo login, a screen-share or a few screenshots are enough. You get a short written summary ordered by priority, with no obligation to hire us afterwards.

How much will the software cost?

We don’t publish a price, because it depends on what the system has to do. That first review settles the scope, and the cost goes into a written proposal before any work starts.

Related

Related industries.

Category

Part of a wider group.

Talk to us

Tell us how your business runs today.

A few lines on your spreadsheets, software and WhatsApp groups is enough. We reply the same working day.

  • No obligation
  • A reply within one business day
  • Your details stay private

Start with your requirements

Seven short steps that tell us what you need. An engineer reads them before getting in touch.

Share your requirements