A dealer sends back a carton of failed downlights, and we can’t tell which driver batch they used.
Lighting manufacturers assemble LED fittings from bought-in drivers, PCBs and housings, with BOMs in Excel and warranty claims on WhatsApp. GullySystem builds BOM, production and warranty tracking for lighting units, linking each fitting to its component batches. It starts with a free technology audit.
You make downlights, panels, strips, street lights and custom fittings for projects. Every model is a BOM of components, many imported, some short at the wrong moment.
The fitting leaves your factory with a warranty, and that promise comes back to you years later.
Dealers order standard models, while architects and lighting designers ask for project quotes with custom wattage, colour temperature and finish. You check component stock, quote, and plan assembly.
Drivers, LED boards and housings are issued to the assembly line, and fittings go through burn-in testing before packing. Imported components come with long lead times, so buying is planned on gut feel and Excel.
After sale, dealers and project clients send failed fittings back for replacement. Someone checks warranty from the invoice date, tests the unit and claims from the driver supplier where possible.
What goes wrong for lighting manufacturers without a proper system.
Warranty claims can’t be traced
Without serial numbers linked to component batches, you can’t prove which supplier’s driver failed.
Components run short mid-order
The BOM in Excel doesn’t reserve stock, so a project order uses drivers promised to a dealer.
Project quotes take too long
Every custom quote means recalculating the BOM by hand for a new wattage or finish.
Dealer returns pile up untested
Returned fittings sit in a corner, and dealers wait for replacements while their customers complain.
What we would build for lighting manufacturers.
Named the way your team already talks about the work. We start with whichever part the audit shows is costing you most.
BOM by model and variant
Components for each model, wattage and finish, used for costing, purchase and assembly issue.
Component stock with batch and supplier
Drivers, boards and housings stocked by batch, reserved against orders.
Serial numbers and test records
Each fitting’s serial linked to its component batches and burn-in result.
Warranty and replacement register
Returns logged by serial and dealer, warranty checked from the invoice, and supplier claims raised.
Project quotations
Custom quotes built from the BOM, with revisions saved for the architect.
The services behind it.
ERP, CRM and Business Software Implementation
One record of stock, orders, customers and accounts, set up so your team opens it every day.
Learn moreCustom Software and Product Engineering
Software built around how your business actually runs, when nothing off the shelf fits without workarounds.
Learn moreIoT and Edge Computing
Machines, meters and sensors feeding the same system your office uses, even when the network drops.
Learn moreData Engineering and Business Intelligence
Dashboards that answer the owner’s Monday questions without anyone building an Excel sheet first.
Learn moreHow the work runs from Bengaluru for your city.
- 01
The audit, by call
A screen-share and a look at the sheets, Tally reports and WhatsApp groups your team uses. No travel needed.
- 02
A written proposal
Scope, what we build first and the cost, agreed in writing before anything starts.
- 03
Build in short rounds
Working screens shared every few weeks. Your team tests them from your own office.
- 04
Go-live, in person when it helps
For data migration and training we can come to your city. Travel is agreed in advance.
- 05
Support online
Fixes, changes and hosting handled remotely by the same team that built it.
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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Read the case studyQuestions lighting manufacturers ask before they call.
Can we keep Tally for accounts and GST?
Yes. Sales, purchases, imports and stock values can post to Tally, while BOM and warranty detail stays in the new system.
Do we need serial numbers on every fitting?
Not always. Batch-level tracking may be enough for low-cost fittings, and serials matter most for drivers and project fittings. The audit helps you choose.
Is a ready manufacturing ERP a better fit?
If your products are standard and warranty is simple, a ready ERP can do the job. Custom work helps when project quotes and warranty tracing are where you lose money.
Can dealers log returns themselves?
Yes. A dealer portal can take return requests with serial and photos, and show the status of each replacement.
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.
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
- We reply the same working day
- Your details stay private