One connected system for variant bills of materials, build orders, station records, end-of-line tests and dealer dispatch.
Run a vehicle assembly operation from one record per unit. Planning releases build orders against variant bills of materials. Stores and suppliers deliver parts by lot. Operators record torque, fitments and part labels at each station. Testers log end-of-line results, rework is tracked to a cause, and finished vehicles are dispatched to dealers with their documents, ready for warranty and recall follow-up.
- Variants, stations, test sheets and supplier lists entered as your line runs
- Part masters, bills of materials and open orders migrated
- Changes to checklists and test sheets handled by GullySystem staff when asked
GullySystem configures this for vehicle assemblers, from low-volume body builders to full assembly plants. Planners, stores, line supervisors, testers, quality staff and dispatch work from one record per vehicle. It holds the build order, variant parts, supplier lots, station readings, end-of-line results, dispatch and any warranty claim raised later.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Order and plan
Dealer and fleet orders are grouped by variant and market. Planning assigns build orders to weekly slots and checks part availability.
- 2
Kit and release
Stores issue kits per station against the variant bill of materials. A build order is released only when its shortages are cleared or accepted.
- 3
Body, paint and assembly
Each stage records its start, finish and checks against the identification number. Part lot labels are scanned as parts are fitted.
- 4
End-of-line test
A tester records brake, lamp, emission and leak readings. A pass moves the unit to certification and a fail routes it to rework.
- 5
Rework and release
Rework logs the cause, the part replaced and the retest. A released unit is certified and parked for allocation.
- 6
Dispatch and aftersales
Units are allocated to dealer orders and dispatched with documents. Warranty claims and recalls return to the same unit record.
What is inside.
Every module can be switched on, left out or changed to match how your team already works.
The business modules it is built from.
Each one is also available on its own, or inside a system built for you.
- Bill of Materials
Each model, trim, engine and market gets its own bill of materials, and a build order reads only the parts that variant needs.
- Production Planning
Dealer orders become build orders in weekly slots, and parts that are short for a slot are shown before the order is released.
- Work Order Management
Each unit carries a work order through body, paint and assembly stations, and an operator closes a station only after its checks are recorded.
- Batch and Serial Tracking
Part lots and identification numbers are linked at fitment, so a faulty batch returns the units that carry it without reading line sheets.
- Quality Control
Brake, lamp, emission and leak readings are compared to limits, and a failed reading sends the unit to rework instead of the yard.
- Goods Receipt (GRN)
Deliveries are matched to the order, critical lots are held for inspection and only released lots become available to stores.
- Vendor Management
Each supplier record holds its parts, first-article approvals, delivery history and rejection count, so schedules go to those who have earned them.
- Workflow and Approvals
A change moves through design, quality and purchase approval, and stays blocked from the line until each sign-off is recorded.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For production planners
Turn orders into build orders and slots, and see shortages before the order reaches the line.
For stores and purchase staff
Receive deliveries by lot, issue kits to stations and chase suppliers against the schedule.
For line supervisors and operators
Read each unit’s instructions on the station screen and record torque, fitments and part labels.
For quality and test staff
Run end-of-line sheets, hold suspect lots, manage rework and answer a recall query by lot.
For dispatch and sales administration
Allocate units to dealers, print documents and track what has left the yard.
The numbers the owner asks for.
- Build orders by variant against slot plan
- Parts short for release by variant
- Supplier delivery and lot rejection history
- Station defects and torque exceptions
- End-of-line first-pass results by unit
- Rework causes by station and supplier
- Units allocated and in transit by dealer
Who this is built for.
- Assemblers of cars, vans and light trucks
- Bus, coach and specialist vehicle builders
- Makers of electric vehicles in modest volumes
- Body builders fitting bodies to bought-in chassis
- Plants with several variants on one line
When it is not the right choice.
- A maker of one vehicle a month, built by one team from a drawing, can run on a drawing register and a stock sheet.
- A plant that needs machine-level control of robots and conveyors will want line control equipment, which this does not replace.
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.
Works alongside
- Torque tools and test benches
- Barcode and label printers
- Design and drawing systems
- Supplier portals
- Accounting software export
- Dealer ordering systems
Questions owners ask before a demo.
Can it follow a recall to the exact vehicles?
Yes. Part lot labels are recorded at the station against the identification number, so a faulty lot returns the list of units that received it.
How are variants kept apart on one line?
Each build order carries its own variant bill of materials. Kits, station instructions and checks follow the order, not the model name.
Does it read torque tools and test benches?
Where a tool or bench can send or export readings, it is linked in implementation. Otherwise the operator or tester enters them on a station screen.
Can a unit be held if a reading is out of range?
Yes. A torque value or test result outside its limit holds the unit and raises a rework entry with the station and the reading.
How does engineering change control work?
A change names the part, the revision and the unit number from which it applies. Stores and stations switch at that number, not on a date.
Can we manage supplier approval of new parts?
Yes. A new part carries its first-article status, and goods inward blocks release of lots until the approval is recorded.
Can dealers see where their orders stand?
A dealer login can show allocation, dispatch and delivery documents for its own units. It does not show anything about other dealers.
Can it handle bodies fitted to bought-in chassis?
Yes. The chassis arrives as a unit with its own number, and the body build order is recorded against it.
How would our part and bill of materials data get in?
Send the part masters and bills of materials you keep. Columns are mapped to the part and variant records, and your engineers review the load with us.
What would it cost a vehicle plant?
Variants, stations, users and the equipment to connect all move the figure. You first watch a demonstration on your own models, then receive a quotation.
Wondering what it costs? Six questions give you a written scope and the buckets any quote should separate.
Businesses that use this.
See Auto Manufacturer Management Software with your own data.
Tell us how you run things today. We’ll show you the parts that matter to you and say plainly what would need changing.
- No obligation
- A reply within one business day
- Your details stay private
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