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GullySystem
Manufacturing · Software for lighting manufacturers

Tie every luminaire to its driver lot, LED bin and burn-in result.

Lighting manufacturers assemble LED luminaires from bought-in constant-current drivers, MCPCB light engines, extruded heat sinks and die-cast housings, with bills of materials (BOMs) in Excel and warranty claims arriving on WhatsApp. BOM, production and warranty tracking are built together here, so each fitting carries the lots that went into it. A returned carton names its driver supplier.

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At a glance

You make downlights, flat panels, linear profiles, flood lights and one custom pendant for a hotel lobby, and every model is a BOM of components, many of them imported. One part is always short. It is always the week it is needed.

The fitting leaves your factory with a warranty printed on the carton. That promise comes back two or three years later as a dead luminaire, carried in by whichever dealer shouts loudest, with an invoice that may or may not match.

How the work runs today

Dealers order standard models by wattage and beam angle. Architects and lighting designers ask for project quotes at their own CCT, CRI, IP rating and finish, and expect them by evening. You check component stock, quote, and plan the assembly line around whichever drivers and housings are physically on the shelf.

Drivers, MCPCB boards, heat sinks, lenses and housings are issued to assembly, and fittings then sit on a burn-in rack before packing. Imported LEDs carry long lead times, so buying rests on a sheet two weeks old, and tenders still want the LM-79 test report and LM-80 data with the quote.

After the sale, dealers and project clients send failed fittings back. Someone checks the warranty against the invoice date, powers the unit on a bench, reads the driver output, and claims on the supplier wherever the paperwork allows it.

Where it breaks

What goes wrong for lighting manufacturers without a proper system.

Warranty claims cannot be traced

With no serial number tied to driver and LED lots, you cannot prove whose driver failed. You replace the fitting and absorb the cost, and the supplier never hears about the batch at all.

Components run short mid-order

A BOM in Excel reserves nothing, so a project order quietly consumes the drivers promised to a dealer. He finds out on dispatch day. The carton count is short.

Project quotes take too long

Every custom quote means rebuilding the BOM for a new wattage, beam angle or powder coat colour, while the architect has asked three suppliers. Whoever answers first wins the specification.

Dealer returns pile up untested

Returned luminaires sit in a corner for weeks while the dealer waits. Nobody bins the failures by driver lot or measures flicker on the bench, so the same weak batch keeps shipping and nothing is learned.

What the software does

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

List components for each model, wattage, CCT and finish, so one BOM drives costing, the purchase order and the issue slip for the assembly line without being retyped.

Component stock with batch and supplier

Hold drivers, MCPCB boards, heat sinks, lenses, diffusers and housings by lot and supplier, with shortages shown against open orders, so a project order taking a dealer’s drivers is visible before dispatch.

Work orders and job cards by stage

Raise a work order per model and batch, with job cards for reflow soldering, wiring, hi-pot test, burn-in and packing. Rejections are booked at the stage where they occur.

Serial numbers and test records

Link each fitting’s serial to its driver lot, LED bin and burn-in result, so a luminaire returned in year two is traced to the driver batch inside it.

Warranty and replacement register

Log returns by serial and dealer, check the warranty against the invoice date, and raise the claim on the driver supplier with the lot attached.

Project quotations

Build custom quotes from the BOM at the designer’s wattage, CCT and finish, and keep every revision. When a lobby pendant is respecified a second time, the first drawing and price are still there to compare.

Before you talk to a supplier

A requirements checklist for lighting 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

The product we start from for lighting manufacturers.

It is the closest ready product to this trade. The parts your work needs that it lacks are added before it goes live, and we say up front which those are.

Manufacturing Production Management Software

Work orders, multi-level bill of materials, job cards by stage, bar and sheet issue, rejection reasons, subcontracted job work, dispatch and tax billing for manufacturers.

See the product
More products

Other products in the same sector as lighting manufacturers.

Solutions inside

The business modules lighting manufacturers use most.

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

All solutions by area

AI by department

Where AI can help lighting manufacturers.

Each one reads records you already keep, and a person approves every decision.

Services

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.

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Custom Software and Product Engineering

Software built around how your business actually runs, when nothing off the shelf fits without workarounds.

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IoT and Edge Computing

Machines, meters and sensors feeding the same system your office uses, even when the network drops.

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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

All our other services

Guides

Written for lighting manufacturers.

Practical notes on running the business, not product marketing.

Excel BOMs or Production Software for an LED Lighting Factory

When an Excel BOM is enough for an LED lighting maker, and when drivers, custom quotes and warranty returns call for production software instead.

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.

Published case studies

The work we have published.

We only name clients whose work is published. None of them is in this trade; they show how the team works, not that it has built for this trade.

All case studies
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PG management software where allocation, rates and invoices are derived from bed-level occupancy and not maintained in parallel spreadsheets.

Read the case study School transport services

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Registration, fee collection, routing and finance write to the same records, closing the gap between journeys run and fees collected.

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Vikasa RDO: making SHG loan recovery auditable

Loan proposals, recoveries and commissions sit on one record, with a person attached to every state change, so a business handling a bank’s money can show where each rupee went.

Read the case study
Common questions

Questions lighting manufacturers ask before they call.

Can we keep our accounts system for accounts and tax?

Yes. No accounting connector comes with it, so an export of sales, purchases and stock values is added during set-up as separately priced work. BOM and warranty detail stay here.

Do we need serial numbers on every fitting?

Not always. Lot-level tracking is enough for low-cost bulbs and battens. A serial earns its label on drivers and project work.

What does the ready production system cover, and what does not?

It covers the BOM, work orders, job cards, outside job work, rejections and dispatch. Serial-level warranty tracing and claims back on your driver supplier are built on top of that base.

Can dealers log returns themselves?

Not out of the box. A dealer portal taking the serial number and a photograph of the failed unit is custom work, added once the warranty register inside the factory is running.

How is a luminaire maker’s system costed?

Variants in the bill of materials, the assembly stages and any dealers logging returns drive the figure. Burn-in test rigs are an extra link. Project quotations are a separate item, priced once the BOM screens have been tried on your range.

What must a lighting maker put together first?

Bring the component list with suppliers, a job card from the line, a serial and test record, a warranty claim file and a project quote. A production planner and a service person should be named for questions and for checking screens. Real paperwork helps lighting manufacturers most.

Do serial and warranty records stay with the maker?

Models, component stock, serial tests and warranty claims belong to the maker, and a flat-file export exists. The maker holds the code. Original builders look after it, with GullySystem acting as host unless you want otherwise.

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.

Across India

Cities where lighting manufacturers are common.

Related

Related industries.

Category

Part of a wider group.

Selling online

Also sell online?

The e-commerce pages cover the online side of this trade: storefronts, dealer ordering and the link to your stock.

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.

What happens after you share your requirements

  1. A senior engineer reads your answers. Nobody phones first.
  2. Within one business day you get a written note: what we understood, what we would start with, and the questions we still have.
  3. If it fits, a proposal follows with the order of work, what we need from you and what you receive at each step.
  4. No call is booked and nothing is paid until you have read the note. Your details stay with us.

Start with your requirements

Seven short steps that tell us what you need. A senior engineer reads them before anyone gets in touch.

Share your requirements