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GullySystem
Manufacturing · Software for cold forging companies

Follow each wire coil, die case and heading lot from the pay-off reel to the packed carton.

A cold forging shop shears coiled wire into slugs and upsets them in multi-station headers at room temperature, often for a full shift unattended. The software ties each coil to its die case, punch stroke count and lot. Hardening and zinc flake coating are followed as one job.

At a glance

Cold forging is quick, and a fault repeats at the same pace. A chipped carbide punch or a coil with a seam can fill several bins before anyone looks at the first part. Stop early or pay later.

Production and quality tracking for a header shop puts the coil and the die case at the centre of the record, so a returned bolt leads to a heat number in minutes. Send us your requirements.

How the work runs today

Wire rod arrives on coils tagged with the mill’s heat number and a test certificate for the chemistry. Many shops spheroidise anneal it, draw it down and coat it with phosphate and soap before it reaches the pay-off reel. A planner picks a part number, a die case and a header, and the setter fits the cut-off quill, the transfer fingers and the punches. First-off goes to the inspection table for head height, shank diameter and a look for laps.

Then the header runs. Counters tick, flash and cracks are sampled with an eddy current probe or a magnifier, and a die is pulled when the stroke count says so. Finished lots go outside for hardening, tempering or zinc flake coating, then return to be sorted and packed. Months later a customer asks which coil fed a bolt shipped last spring, and most shops answer from a notebook.

Where it breaks

What goes wrong for cold forging companies without a proper system.

The coil behind a lot is not recorded

A customer finds a seam crack on a delivered flange bolt and wants the wire heat that fed the header that shift. The coil tag went out with the empty reel.

Die life is guessed

Punches, extrusion dies and cut-off knives are swapped by feel or by the setter’s habit, with stroke counts pencilled on a clipboard beside the header. A worn carbide insert runs one shift too long.

Outside heat treatment disappears

A lot leaves for hardening and plating, and the delivery note is the only trace. Kilograms out and kilograms back differ. Nobody can say whether the gap is scale, scrap or a short return from the vendor’s furnace.

Setup knowledge stays in the setter’s head

A changeover on a four-station former takes a setter and a trolley of tooling. When nobody noted the knockout pin length or the transfer finger timing that worked, the repeat order restarts the same trial. Scrap piles up first.

Yield from wire is unknown

Wire is bought by the tonne and sold by the thousand pieces, yet slug cut-off loss, trim flash and rejected parts are never weighed against the coil they came from. Part cost stays a guess.

What the software does

What we would build for cold forging companies.

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

Wire coil receipt and heat records

Log each coil with supplier, grade such as 10B21 or SCM435, diameter, heat number and weight. Hold the mill certificate on the coil record. Block a coil that fails the incoming tensile or surface check.

Die set and tool life register

Keep every die case, punch and cut-off knife against the part numbers it makes, with strokes run since the last regrind. The setter sees which set is due before release.

Header and former scheduling

Plan part numbers across headers by station count, wire diameter and rated parts per minute. Group changeovers by wire size, so heavy tooling trolleys move less often during the week.

Lot and first-off records

Open a lot per coil and part. Record first-off head height and shank diameter, hourly crack and lap samples, and the operator who signed each check.

Outside process tracking

Send lots to hardening, zinc flake or phosphate vendors with weights out and weights back, and compare the two. Record the vendor’s hardness report, then release the lot only when the report and weights agree with the order.

Sorting, packing and dispatch

Record sorting results, carton counts and gross weights per lot. Print the label with the lot number and raise the delivery note that travels with the pallet.

Part cost against wire weight

Set the wire weight per part, the slug cut-off scrap and the outside process charge, then compare the resulting cost with the price quoted to the buyer.

Before you talk to a supplier

A requirements checklist for cold forging companies.

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 cold forging companies.

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

Cold Forging Company Management Software

Coil heat numbers, punch strokes, first-off head height, carbonitriding returns and sorting rejects for cold forging companies, kept on one lot record.

See the product
Solutions inside

The business modules cold forging companies 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, 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.

Common questions

Questions cold forging companies ask before they call.

Can one wire heat be traced to the finished cartons?

Yes. A lot opens against the coil that fed it, and a carton label leads back to the heat number and the mill certificate on file. A coil split across two lots is recorded for each.

Does it count strokes from the header itself?

Not by default. Operators or setters enter counts at tool changes. A counter signal from the machine can be added later as paid integration work, scoped with your maintenance team and your header supplier.

Can parts that go out for hardening and plating be followed?

Yes. Each outside job carries the part, the lot, the weight sent, the vendor and the return date, and the returned weight and the vendor’s hardness report are entered on arrival.

Is this meant for a small header shop with three machines?

It suits a shop whose lots, die cases and outside processes have outgrown a register book. A shop with one header and one customer may not need it, and we will say so at the first call.

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