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GullySystem
Manufacturing · Software for gear manufacturers

Follow every gear from forged blank to hobbed, hardened and inspected tooth.

Gear making is a chain of cutting, heat treatment and grinding in which the tooth form is only known to be right at the end. The gear manufacturer software ties blank lots, hobbing programmes, heat treatment batches and tooth inspection charts to each part number. Customer drawings, revisions and delivery dates stay with the work. Nothing is retyped.

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At a glance

A gear shop turns forged or bar blanks into teeth through hobbing, shaping or shaving, then sends them for case hardening and finishes them by grinding or lapping. The tooth form is checked at the end, so an error made at the hob can travel through four more operations before anyone sees it. That is costly.

Production control for gear makers keeps the blank lot, the cutter, the heat treatment load and the inspection chart under one part number. Each order carries the drawing revision, module, tooth count and quality grade. Setup begins with your gear drawings and their revisions.

How the work runs today

A gearbox builder or machine maker sends a drawing with module, number of teeth, pressure angle, helix angle, bore and a quality grade. You quote from blank cost, hobbing time, heat treatment and grinding, then release a batch against a route. Blanks arrive from the forge with a heat number and a hardness check. Turning comes first, then teeth, then deburring, carburising, quench and temper, and a final grind of bore and profile. Each step has an owner.

The inspection room measures profile, lead, pitch and runout on a gear tester and keeps the chart with the part. Backlash and contact pattern are checked on a mating master where the customer asks for it. Many shops send heat treatment to an outside process house. They wait for the load to return. Parts then go to grinding, marking and packing with the report in the box. Then the truck leaves.

Where it breaks

What goes wrong for gear manufacturers without a proper system.

A tooth error is found three operations late

A hob wears and the profile drifts. The batch has already been carburised before the gear tester shows it. Nobody can say which cutter, machine or blank lot made it. The scrap is blamed on the operator.

Outside heat treatment loses its trail

Loads go to a heat treater mixed from several customers and return with a hardness note on a slip. Case depth and core hardness need to match the right gears. Slips are filed by date. Not by part.

Hob and cutter life is guessed

Hobs, shaper cutters and shaving tools are reground and reissued without a count of gears cut. The tool store relies on the operator saying a cutter feels dull. That is not a count.

Grade and drawing revision slip through

Customers change module corrections, tip relief or bore tolerance between orders. The shop floor still holds the old route, and a batch is cut to last year’s drawing.

Rework is not costed

Gears that fail on lead or pitch go back for regrinding or lapping. The extra hours never reach the part cost, so the price list stays unchanged for repeat orders.

What the software does

What we would build for gear manufacturers.

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

Drawing, module and grade register

Every gear is a part record with module, tooth count, helix hand, pressure angle, bore, grade and drawing revision, so a repeat order opens already filled in.

Blank lots and heat numbers

Receive forged and bar blanks against the order, record heat number and hardness check, and link the lot to every gear cut from it.

Hobbing and shaping routes

Set the operation sequence for each part with machine, cutter, setup sheet and cycle time, and let the operator record counts per shift.

Heat treatment load tracking

Record which gears went to carburising, quench and temper in which load, with case depth and hardness results held against the batch on return.

Tooth inspection charts

Store profile, lead, pitch and runout readings from the gear tester against the batch, and flag any gear outside the drawing limits.

Cutter and hob life

Count gears per hob and shaving cutter, log regrinds, and warn the tool room before a cutter runs past its allowed count.

Quotations and despatch

Price a gear from blank, cutting, heat treatment and grinding hours, then pack with the inspection report and a delivery note.

Before you talk to a supplier

A requirements checklist for gear 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 gear manufacturers.

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

Gear Manufacturer Management Software

Blank lots, hobbing routes, heat treatment loads, tooth inspection charts, cutter life and despatch for gear manufacturers.

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Solutions inside

The business modules gear 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 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 gear manufacturers ask before they call.

Can a gear be traced to its blank and its heat treatment load?

Yes. The blank heat number, the hob that cut it and the heat treatment load are linked to the batch. One query opens all three.

Does it store tooth inspection results?

Readings from the gear tester are saved against the batch and the serial where you mark one. The chart layout your customers expect is agreed during the first workshop.

Can we keep our outside heat treater in the same record?

Yes. A gear sent out stays on your route as a pending operation. On return, the hardness and case depth report is attached to the same batch.

Is it suited to a shop that cuts only a few gear types?

Not always, because a spreadsheet is enough for a handful of repeat parts. Once cutters, heat treat loads and several customers overlap, a system that holds routes and charts starts to help.

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.

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