Manufacturing · Aluminium Die Casting Company Management Software

Alloy melt, die shots and porosity checks on every casting number.

One record follows a pressure die casting from the customer call-off through the melt, the shot sleeve and the trim press to leak test, machining and the dispatch bay. Each lot keeps its melt number and its die number. A cold shut or a gas pocket can then be traced to one cell, one ladle and one shift. Planners, furnace crew, toolroom and quality read the same page.

Share your requirements

Part list, dies and machine tonnage entered from your own drawings and cell sheets
Open call-offs, alloy stock and balances migrated
Route card and test report layouts matched to your customers’ formats

A die caster plans machines and dies against customer call-offs, then logs ingot lots, melts, shot counts, density index readings and helium leak tests in one GullySystem build. Each casting lot keeps its melt and its die. Route cards follow crates through trimming and machining, and delivery notes print from the same record.

Where it breaks today

What goes wrong before the software.

Call-offs change by the week

Customers release quantities by part number and date through a portal or a mailed sheet. A revised call-off lands in an inbox, while the cell plan on the wall still shows last Monday’s figure.

Melt identity is lost at the machine

Metal travels from the reverberatory furnace to the holding furnace to the shot sleeve in ladles and transfer launders. The only mark on a finished casting is a shot time, so a porosity complaint cannot be tied back to the ingot heat in the furnace.

Die maintenance follows memory

A die that has fired many thousand shots needs spray nozzle checks, ejector pin replacement and a look for heat checking. The toolroom hears about it once flash shows on the parting line.

Remelt yield is guessed

Biscuits, runners and overflow wells are weighed rarely. Dross skimmed from the furnace is never booked, so cost per casting rests on an estimate.

Porosity data is held in the quality room

X-ray grades, sectioning photos and reduced pressure test samples sit in lab folders. The planner and the toolroom never see them when choosing which die goes on next.

Machining steps lose the lot

Crates move on to the CNC line, the deburring drum or the impregnation autoclave. The casting lot number sits on the first crate and on nothing after it.

How it runs

How the work flows through it, step by step.

1
Call-off and plan
Call-offs are loaded by part and week. The planner assigns a machine, a die and an ingot lot, then checks the die’s shot total against its cleaning limit before the setter is told.
2
Melt
Ingot and returned gates are charged, degassed with a rotary impeller and sampled for the spectrometer. A passing chemistry result releases the melt to the holding furnace.
3
Casting run
The operator records the die, the plunger speed settings, the intensification pressure and the shots. Good and rejected counts are entered when the run closes.
4
Trim and remelt
Castings go to the trim press while biscuits, runners and overflow wells are weighed back for remelt. Yield per part updates on the spot.
5
Test and machine
Samples go for X-ray, density index or helium leak checks. Passed lots follow the route card to machining, deburring or impregnation.
6
Dispatch
Crates are counted, labelled and loaded. Once the truck leaves, the invoice and the dispatch record close the call-off.

Modules

What is inside.

Every module can be switched on, left out or changed to match how your team already works.

Part list and call-offs

Hold each casting with its drawing revision, alloy grade such as A380 or ADC12, die and route. Load call-offs and revisions by week.

Alloy and ingot stock

Receive ingot by heat lot, issue it to melts, and keep returned gates and dross on separate accounts.

Melt and chemistry record

Record each melt, its charge, degassing time and spectrometer sample, then release it to the holding furnace once the chemistry passes.

Machine and die planning

Plan machines by clamping tonnage and dies by availability and shot count, and show which die change comes next to the setters.

Die register and shot counts

Count shots per die and per cavity set, log sprays, cleans and ejector pin changes, and warn the toolroom before a limit chosen by your own engineers.

Casting run log

Capture die, plunger settings, shots, good castings and rejects for each run, and link the run to the melt that fed it.

Trim, runner and remelt yield

Weigh castings, biscuits, runners and overflow wells, and compute yield per part, per melt and per week.

Porosity, X-ray and leak testing

Key in X-ray grades, density index and helium leak readings, tie them to the casting lot, and hold a failing lot until someone writes down the decision.

Machining and outside processes

Send crates along routes through CNC machining, deburring or impregnation, in house or outside, and book quantities back against the job.

Packing, delivery and billing

Print crate labels and delivery notes, raise the invoice and follow dues customer by customer.

Solutions inside

The business modules it is built from.

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

Order Management
Customer call-offs and revisions are held by part and week, so the planner sees the figure that changed after the cell was loaded.
Batch and Serial Tracking
Each melt gets a number with its charge and chemistry sample, and castings poured from it carry that number into the lot.
Production Planning
Runs are placed on machines by tonnage and on dies by availability, with the next die change visible to the setters.
Fixed Asset Register
Each die is an asset with shot totals, cleans and repairs, so toolroom work follows usage and not a guess.
Quality Control
Sample findings are compared with the limits for the part, and a failing lot is held until a decision is written down.
Job Work Management
Crates sent for machining, deburring or impregnation are listed with quantities out, and returns are booked against the same job.
Stock Tracking and Alerts
Ingot lots and returned scrap are held as separate stock, with a warning when a grade runs low for the booked runs.

Services

How we would put it in.

Setup, data migration, integrations and anything built on top.

Who uses it

One system, each person sees their part.

For owners

See machine hours, rejects by part, die wear, metal yield and the balance each buyer owes.

For planners

Turn call-offs into runs by machine and die, and watch the lots waiting for an X-ray slot.

For the furnace crew

Charge melts, record spectrometer results and weigh returned gates.

For die setters and the toolroom

Log die changes, count shots and book repairs for the toolroom bench.

For quality and dispatch

Enter porosity and leak readings, release lots, and pack crates against the delivery note.

Reports

The numbers the owner asks for.

Call-offs against shipments by part and week
Melts with chemistry results and castings made
Shots and rejects by die
Metal yield by part and by melt
Porosity and leak test findings by lot
Machining route quantities in and out
Dies due for cleaning or repair

Good fit

Who this is built for.

High pressure die casters supplying housings, covers and brackets
Cold chamber die casting shops with their own melting furnace
Casters who pass parts to an in-house machining line
Casting companies that send parts out for impregnation or surface finish
Plants serving automotive, appliance and electrical buyers

Honest answer

When it is not the right choice.

A foundry that pours sand or gravity castings by hand will find Iron Foundry Management Software closer for sand-mould work.
A small tooling shop that makes only prototype dies can use a job-shop tool instead.

Made to fit

Adapted to your business before it goes live.

You are not handed a login and left to it. The product is set up around your records, your people and the tools you already use.

Your alloys and dies

Your cell sheets and toolroom cards supply the alloy grades, die numbers and cavity layouts that we enter before the first shift.

Test and release rules

Your quality engineers give us the chemistry limits, X-ray grades and leak thresholds. We load them so the inspector sees pass or fail beside each reading.

Route cards

Machining and finishing steps follow your actual routes, whether the work stays on your CNC line or goes to an outside impregnator.

Existing records

Live call-offs, ingot stock and customer dues are brought in before the plant starts using it.

Works alongside

Barcode and label printers
Email
Spreadsheet import for customer call-offs
Accounting export

Common questions

Questions owners ask before a demo.

Can a casting be linked to its melt?

Yes. Each run records the melt used, and the casting lot shows that melt beside its spectrometer sample.

How are die shots counted?

The operator enters shots when a run closes, or per shift on a long one. The total is kept per die and per cavity set, and the toolroom reads it on the die card.

Does it handle scrap and remelt?

Yes. Biscuits, runners, overflow wells and rejects are weighed back, and yield is worked out for the part and for the melt.

Can porosity results be stored?

Yes, against the lot and the sample number. X-ray grades, sectioning notes and leak readings are all kept, and a lot that fails is held until the decision is typed in.

Does it cover machining?

It covers routing and counts. Each machining step is a line on the route card with a count in and a count out, while spindle programs and tool offsets stay inside the machining department’s own controllers.

Can customer call-offs be imported?

Yes. A sheet of part numbers, weeks and quantities is mapped once, then loaded again whenever the buyer sends a fresh call-off.

How does it treat parts sent outside?

A vendor job lists the crates sent to the impregnator or the plater and what comes back. Missing quantities stay open until someone explains them.

Is a machine connection needed?

No. Shots and plunger settings are typed in by the operator. Reading a shot counter straight off the machine controller can be taken up later.

How is cost decided?

Price follows the cells, the users and the checks you want kept. Share your requirements and a written quote follows.

Can data be exported?

Yes. Melt records, machine runs, test findings and shipments can be written to a file, and the column layout is yours to choose.

Wondering what it would cost? Share your requirements and an engineer will come back with a scope.

Industries

Businesses that use this.

Aluminium die casting companies

Related products.

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