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GullySystem
Manufacturing · Software for automotive component manufacturers

Match each buyer’s schedule, part-wise rejections and dispatch to the lots you actually made.

Automotive component manufacturers supply pressed, machined, cast, moulded and assembled parts to vehicle makers and Tier-1 buyers against monthly schedules. Schedules arrive on a portal, rejections return as debit notes, and the quality file lives in folders. The software ties each schedule line to work orders, stage job cards, inspection, bin labels and dispatch, so a returned part leads back to the lot that made it.

At a glance

You make brackets, pressings, machined shafts, castings, rubber and plastic parts or sub-assemblies for vehicle makers and their Tier-1 suppliers. Every part number has an approved process, a packing standard and a buyer who counts defects per million.

Volumes follow the buyer’s production plan, which moves every month. Prices are fixed tightly. Rejection, premium freight and unchecked debits therefore come straight out of what the plant earns.

How the work runs today

The month starts with a schedule from each buyer, read off a supplier portal or a mail and often revised mid-month. Planning splits it into weekly or daily quantities, checks raw material and tooling, and releases work orders to the press shop, machine shop or moulding line.

Parts pass through their stages with in-process checks, then final inspection and packing in the buyer’s bins or trays. Each bin needs a label. Dispatch raises the invoice with its e-way bill, and an advance shipping note goes on the buyer’s portal where asked.

The buyer’s receipt note, line rejections and debit notes follow later. Accounts matches them against invoices by hand, and quality answers each complaint with a corrective action report.

Where it breaks

What goes wrong for automotive component manufacturers without a proper system.

Schedules change faster than the plan

A revised schedule lands mid-month, while the whiteboard plan still shows the old quantities. One part runs short, another piles up.

Debit notes are accepted without checking

Line rejections, shortages and rate differences come back as debits against invoices, and nobody sets them against what was shipped. The amount is simply written off.

A complaint cannot be traced to its lot

The buyer reports a defect on a part number, and the plant cannot say which shift, machine or material lot made it. Containment becomes guesswork.

Internal rejection is not counted by part

Scrap and rework are noted on paper at the stage, then totalled at month end without the reason. The same defect repeats.

Bins leave with the wrong label

A handwritten label carries the wrong part number or quantity, and the buyer’s stores hold the whole consignment. Sorting happens at your cost.

What the software does

What we would build for automotive component manufacturers.

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

Buyer schedules and work orders

Enter each buyer’s schedule by part number, with revisions kept, and release work orders against it. Planners see the load already queued on each line and machine before agreeing to a pull-in.

Stage job cards with shift and operator

Record quantity passed, rejected and sent for rework at blanking, pressing, machining, welding or moulding, with the operator, machine and shift on each card.

Rejection by part, stage and reason

Count rejection, rework and scrap per part number, by stage and by a reason list your quality team agrees. A doubtful lot is held until it is cleared.

Coils, sheets, bars and granules

Count raw material by grade and size, and issue every lot against a work order number. Shortages against open schedules go to purchase as a requirement.

Plating, heat treatment and painting vendors

Track parts sent outside on a challan, and see which vendor still holds how many pieces of which part number.

Bin labels, challans and invoices

Pack accepted parts, print bin labels on a barcode or label printer, and raise the challan and GST invoice with the fields an e-invoice or e-way bill filing needs.

Debit note and complaint register

Built on top of the production record during implementation: each debit note or complaint is logged against the invoice and lot it names, with the corrective action report kept beside it.

Ready product

A product already built for automotive component manufacturers.

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

Manufacturing Production Management Software

Work orders, multi-level bill of materials, job cards by stage, raw material issue, rejections, subcontracted job work, dispatch and GST billing for manufacturers.

See the product
Solutions inside

The business modules automotive component manufacturers use most.

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

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, Tally 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.

Common questions

Questions automotive component manufacturers ask before they call.

Can it read schedules straight from a vehicle maker’s supplier portal?

Not on its own. In the standard set-up, schedules are typed in or loaded from the export file the portal gives you. A direct link depends on what each portal allows, and it is scoped buyer by buyer.

Does it hold our PPAP files and control plans?

Not in the ready production product. A register for each part’s quality documents, complaints and corrective actions is added during implementation. The software keeps your records and does not certify any process.

Can a complaint be traced to the shift and machine?

Yes, through the work order. Job cards hold operator, machine and shift for every stage, and each lot traces to its work order and the material issued against it.

Will it show defects per million for each buyer?

Internal rejection by part and stage is counted as standard. A buyer-wise view built from supplied and returned quantities is a report set up during implementation.

What happens in the free technology audit?

We 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 to start. You get a report ordered by priority, and there is 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. The audit settles the scope, and the cost goes into a written proposal before any work starts.

Category

Part of these wider groups.

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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.

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