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GullySystem
Manufacturing · Software for brake component manufacturers

Trace every disc, drum and pad lot from raw mix or casting to the carton.

Brake component makers cast and machine discs and drums, or mix, press and cure friction material onto backing plates. The software ties the casting or friction mix lot to the press cycle, the dynamometer sample, the balance result and the carton shipped. A field complaint can then be followed back to the shift and the batch.

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At a glance

Brake discs and drums start as castings that are rough turned, finish turned, drilled and balanced. Pads start as a powder mix that is pressed onto a plate, cured in an oven, ground and marked. Both are safety parts. Both are judged by what the customer can prove.

Brake component software keeps the lot behind every carton. A returned pad or a pulsating disc leads straight to the casting heat, the press, the oven load and the person who signed the sample.

How the work runs today

On the disc side, castings arrive from the foundry with a heat reference and go to turning cells, where thickness, parallelism and run-out are checked at set intervals. Each rotor is balanced, and weight to be removed is drilled at the marked spot. Coating or a rust preventive goes on. Then packing.

On the pad side, a weighed batch of fibres, resins, fillers and metal powders is mixed and charged into the press. Plates are primed and loaded. Pressed pads cure, are ground to thickness, chamfered and slotted, then inspected for shear strength and marked with the edge code. Samples go to the dynamometer. Results come back later. Cartons are counted. Orders close.

Where it breaks

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

Friction mix batches are not tied to pads

A mix is weighed from a formula sheet, but the pressed pads carry only a date code. If one batch misbehaves, the cartons that contain it are found by guesswork.

Press and cure settings are written on a board

Temperature, pressure and dwell are set by the operator. A cure cycle that drifted during the night is visible only as a scorched or soft pad later.

Rotor balance and runout results are scattered

Balancing machines print a slip for each disc, and thickness checks go on a clipboard. None of it names the casting lot. Audits stall.

Test samples are slow to link back

A dynamometer test or a shear test is done on a sampled pad. The result is filed under a date, so a failure does not point to the exact press load.

Customer part variants multiply

The same disc size comes in vented, solid, coated and slotted forms for several brands. Packing and marking rules are mixed up when the order book is long.

What the software does

What we would build for brake component manufacturers.

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

Friction mix batch records

Record each formulation batch with the raw material lots weighed in, the mixer used and the quantity made, so a pad can be followed to the powder it came from.

Press and cure logs

Log the mould, pressure, temperature and dwell for each press load, and the oven run that followed, tied to the batch of pads that came out.

Casting lots and machining cells

Book castings in with the foundry heat, then follow rotors and drums through rough turn, finish turn, drilling and balancing in the cell that ran them.

Dynamometer and shear test results

Shear and dynamometer results are stored against the lot and its press load. Limits come from your test lab, and a failing lot stays blocked until someone reviews it.

Marking, packing and edge codes

Print the edge code, carton label and packing list from the order, so each variant is packed and marked the way its brand customer asks.

Complaint and return records

Log each returned pad or disc against its lot, and look up every carton that shares the same mix batch or casting heat.

Before you talk to a supplier

A requirements checklist for brake component 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 brake 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.

Brake Component Manufacturer Management Software

Friction mix batches, press and cure logs, casting heats, balancing, dynamometer samples, edge codes and carton despatch for brake disc, drum and pad makers.

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Solutions inside

The business modules brake component 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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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 Engineering and Business Intelligence

Dashboards that answer the owner’s Monday questions without anyone building an Excel sheet first.

Learn more
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 brake component manufacturers ask before they call.

Can a pad be traced to the powder batch?

Yes. Each press load records the friction mix batch and the raw material lots weighed into it. A carton shows both, and one batch can list every carton it filled.

Do you handle both discs and pads in one plant?

Yes. Disc routes and pad routes are kept separate, with their own steps and test plans. Both feed one order book and one despatch screen.

Are test limits fixed by the software?

No. Limits for shear, thickness, balance and dynamometer samples are entered with your own quality people. They are reviewed during implementation, not assumed.

Can returned goods be linked to production?

Yes. A returned item is logged with its edge code or heat number. From there you can open the lot, its press load and any other cartons that shared it.

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