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GullySystem
Manufacturing · Software for machinery manufacturers

Follow each machine from parts list to installed base, spares and service contract.

Machinery manufacturers build machines to order from spreadsheet parts lists and parts machined outside, so assembly waits on one missing bracket and service contract revenue slips away unnoticed. The production system covers the parts list against the drawing revision, outside machining, assembly and factory acceptance testing. The installed base, service contract renewals and later wear parts are built around it.

At a glance

You build packaging machines, belt conveyors, special purpose machines, gear pumps, control panels and test rigs, and almost every one carries a change made for one customer. It might be a longer infeed belt or one make of drive swapped for another, and the only record is one engineer’s memory. Memory is not a record.

The sale is only the start. Installation, warranty claims, spare gaskets and bearings, and service contract visits carry on long after dispatch, and that long tail of service is where the steady money sits.

How the work runs today

An enquiry arrives with specifications. The date is a hope. Design prepares a proposal, the customer approves the general arrangement drawing after two rounds of changes, and the purchase order lands with an advance payment. The delivery date was fixed before anyone checked the load on the machining centre and the lathe, and the parts list is typed into a spreadsheet.

Purchased items are ordered: motors, gearboxes, pneumatic cylinders, proximity sensors. Shafts, base plates and brackets go to outside machining vendors on delivery notes, and assembly waits for the last part to return. The factory acceptance test (FAT) happens at your works, and the customer often stands beside the machine with a checklist of his own.

After dispatch your engineer installs and commissions the machine at the customer’s site, then signs off the site acceptance test with the maintenance head. Breakdown calls, spare orders and service contract visits arrive by phone afterwards. Whoever picks up handles them.

Where it breaks

What goes wrong for machinery manufacturers without a proper system.

One missing part holds up assembly

A parts list in a spreadsheet does not show which parts are ordered, received, or still lying at the outside vendor’s shop, so the fitter finds a missing coupling at assembly. The delivery date has already been promised.

Design changes do not reach the shop floor

A revised drawing goes out by email on Tuesday, but the old revision is already on the machining job card. The plate is cut wrong.

What was installed where is unknown

Serial numbers, motor makes and controller program versions for each customer’s machine sit in old files, on a computer someone has since replaced. The service engineer arrives without them.

Spares and service contract revenue is left on the table

Nobody tells the customer that his service contract ends next month or that the wear parts, such as seals, belts and bearings, are due. He buys both locally.

What the software does

What we would build for machinery manufacturers.

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

Project parts list with revisions

List parts for each machine against the drawing revision, marked purchased, made in-house or sent outside, then received into stores. Each line shows its vendor.

Work orders and job cards by stage

Raise a work order per machine with job cards for welding, turning, panel wiring and assembly, and book each rejection at the stage where it happened. Each card closes separately.

Delivery notes for machining

Record the bar stock and castings sent to machining vendors, the parts returned, and what is still outside. Each delivery note keeps its own balance.

Assembly and FAT checklist

Define the stages for each machine, record the test results, and note the customer’s FAT sign-off before it leaves the works. Failed points are listed for rework.

Installed base register

Record every machine sold with its serial number, motor and controller makes, site and warranty dates, so an engineer knows the machine before he reaches the gate. This register is custom work added to the production system.

Service calls and service contracts

Hold breakdown calls, engineer visits, service reports and service contract renewal dates against the machine itself. This is custom work added in the same way.

Spares and wear parts catalogue

List the spares and wear parts for each installed machine, such as bearings, seals, belts and filters. A quote is raised straight from the service call.

Before you talk to a supplier

A requirements checklist for machinery 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
Solutions inside

The business modules machinery manufacturers 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 machinery manufacturers ask before they call.

Can it work alongside our accounting system?

Not directly. A file of purchase, sales, outside machining and service invoices can be prepared for your accounting software, and that carries its own quote. Parts lists, serial numbers and service history stay in the new system.

Should we buy the ready production system instead?

Start there if production is your biggest problem. The ready system handles the parts list, work orders, job cards, outside machining, rejections and dispatch well, and most plants begin with it. The installed base register, service contract renewals and the spares catalogue for later wear parts are built on top of it as custom work.

Can service engineers use it at a customer site?

Yes, as part of the custom service work. The engineer opens the machine’s history on his phone, fills the service report with photographs of the worn coupling or burnt contactor, and the customer signs on the screen.

Can machines report their own status?

Some can. Where a machine carries a controller that shares data over Modbus or Ethernet, the monitoring dashboard reads it. Sensors and gateways for machines without a controller are bought in your name and fitted on site, and that is scoped as its own project.

Which things set the price for a machine builder’s system?

Machines built to order, the parts lists with revisions, the outside machining vendors, and the users from design to service all matter. Installed base and service contract tracking are separate parts. The quotation follows scope review.

What should a machine builder gather before we begin?

Collect a project parts list, a drawing revision record, a job card, a machining delivery note, an acceptance test checklist and a service contract. A design lead and a shop floor supervisor should be named for the screen checks.

Who owns the installed base records once the builder moves away?

The builder holds installed base records, and the code with them. Parts lists, test results, service calls and contracts can be handed over in plain files at your request. Its builders also support it. GullySystem hosts by default.

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 these wider groups.

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