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GullySystem
Manufacturing · Software for wiring harness manufacturers

Control harness variants, crimp checks and test results from reel to carton.

Wiring harness makers cut wire to length, strip and crimp terminals, assemble leads on formboards and test every circuit before shipping. This software holds harness drawing revisions, variant build lists, reel and terminal lots, crimp height and pull force checks, electrical test results and the labelled carton. A field fault leads back to the lot and the operator.

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At a glance

A harness for one vehicle model can exist in dozens of variants, each with a different count of circuits, connectors and clips. The drawing changes often, and the floor must build to the revision that is live on the day, not the one printed last month. Old copies cause trouble.

Wiring harness software keeps the variant, the wire reel, the terminal lot and the test result linked to the harness that ships. Mix-ups on the formboard show up at the test station, not at the customer’s line.

How the work runs today

Orders arrive as daily or weekly pulls from a vehicle maker, listing the variant codes needed. Quantities shift daily. Planners convert them into cut lists by wire colour, gauge and length, then issue reels and terminals to the cutting and crimping machines. Applicator changes are logged, and crimp height and pull force are checked on the first pieces and at set intervals.

Cut leads move in trolleys to assembly lines, where operators lay them on formboards, fit connectors and seals, apply tape and clips and add labels. Every harness goes to a continuity and insulation tester. Failures are repaired and retested. Nothing skips the tester. Passed harnesses are bagged, labelled and packed to the customer’s count.

Where it breaks

What goes wrong for wiring harness manufacturers without a proper system.

Variant lists are copied between files

Each vehicle option changes the circuits in a harness. The list of what goes on each formboard is retyped from a drawing by hand, and an old copy stays in use on a second line for weeks.

Wire reels and terminal lots are not traced

Reels of different colours and terminal lots from several suppliers feed the same machines. After crimping, nothing on the cut lead says which reel or terminal lot it came from, so a pull test failure has no origin.

Crimp checks are recorded on paper

Crimp height and pull force are checked after an applicator change. The strip of paper stays at the machine. It rarely reaches a quality review, and it is thrown away when the board is full. History is gone.

Tester results do not carry a harness number

Electrical testers pass or fail a harness and show a count. Failures are repaired by name, and the reason is not collected, so the same open circuit keeps returning on the same variant.

Cut length shortages stall assembly lines

Assembly waits for one missing lead colour. Cutting is not planned from the formboard schedule, so trolleys arrive incomplete. Lines sit idle.

What the software does

What we would build for wiring harness manufacturers.

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

Variant and drawing control

Hold each harness drawing, revision and variant build list, so that formboards, kits and cut lists are all produced from the live revision and from no older copy on any shelf.

Wire reel and terminal lots

Book wire reels and terminal lots at receipt, and link each reel and lot to the cutting and crimping orders they feed.

Cutting and crimping orders

Plan cut leads by colour, gauge and length from the assembly schedule, and log the applicator and operator for each batch.

Crimp and pull force checks

Record crimp height and pull force after applicator changes and at intervals, with the limits your quality staff define, and stop a batch on failure.

Assembly lines and formboards

Follow harness lots through formboard assembly stations with operator, connector kit and tape used logged on the lot.

Electrical test results

Store continuity and insulation results per harness number, with repair actions and retest outcomes, and block shipment of any failed unit.

Before you talk to a supplier

A requirements checklist for wiring harness 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 wiring harness manufacturers.

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

Wiring Harness Manufacturer Management Software

Variant lists, drawing revisions, wire reels, terminal lots, crimp height and pull checks, formboard assembly, continuity and insulation tests and carton despatch for harness makers.

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Solutions inside

The business modules wiring harness 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 Engineering and Business Intelligence

Dashboards that answer the owner’s Monday questions without anyone building an Excel sheet first.

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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 wiring harness manufacturers ask before they call.

Can we manage many variants of one harness?

Yes. A harness family holds its variants, each with its circuit list and build rules. Orders pick the variant, and cut lists follow from it.

Does it link a harness to a wire reel?

Yes. Reel and terminal lots are booked at receipt and attached to cutting orders. A finished harness lot shows which reels and terminal lots fed it.

Can the tester results come in automatically?

Results can be keyed at the station. Importing from a harness tester is scoped in the workshop, and which models connect is reviewed during implementation.

How are failed harnesses repaired and retested?

The failure code, the repair note and the retest result are logged under the same harness number. A unit that has not passed cannot be packed.

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