Manufacturing · Auto Parts Manufacturer Management Software

One system for customer releases, part revisions, lot traceability and dispatch labels.

Hold each customer part number with its drawing revision, release schedule, PPAP file and label format, and let every lot carry the press, die and coil heat behind it. Planners, the quality lab, press operators, stores and the dock all read one trace, so nobody argues over which revision ran on which shift. A complaint opens on the lot.

Share your requirements

Part numbers, revisions and customer label formats entered the way each plant receives your boxes, pallets and crates
Open releases, stock and lot history imported
Inspection plans, gauge lists and approval rules agreed with your own quality engineers before the first live release

GullySystem fits this to the way a component supplier ships to vehicle plants. It holds part numbers and drawing revisions, plans production against changing releases, traces each lot to press, die and coil heat, and prints labels and advance shipping notices. Complaints start from the same lot.

Where it breaks today

What goes wrong before the software.

Releases from different plants live in different files

Every vehicle plant sends its schedule with its own columns, whether a weekly electronic call-off file or a spreadsheet, and the planner retypes each into the planning sheet. A late amendment slips through. The truck leaves a few hundred pieces short.

Revisions reach gauges before operators

Revision C reaches the CMM program but not the setup sheet beside the press, so the night shift keeps stamping to revision B. The customer’s incoming gauge rejects the brackets.

Approval packages are gathered at the last minute

Dimensional report, material certificate, control plan and Cpk data sit in four different places, and volume production waits while someone assembles the PPAP file for the customer. The capability study is usually last.

Trace stops at the box label

The box label names a lot, but the die, shift and coil or bar heat number behind it are jotted by hand, if at all. Containment sweeps in too much stock.

Outside process returns are not counted

Brackets sent for zinc plating and gears sent for carburising return short or with rejects, and nobody compares the counts until the line stops at assembly. The shortfall is found late.

Customer-owned packaging goes missing

KLT crates, steel racks and dunnage pile up on a customer’s dock and are counted once a year, so new crates are bought while good ones sit idle at another plant. Nobody chases the idle ones.

How it runs

How the work flows through it, step by step.

1
Part set-up
A customer part number is entered with drawing revision, material grade, die list, control plan and label format, and the PPAP documents attach to that same revision.
2
Release received
Load the schedule from the plant and the system compares it with the previous release, highlighting each part whose quantity or ship date moved. The planner then re-sequences the press line.
3
Plan and material
Machines, dies and material are planned against the release, so a shortfall in coil, bar stock, resin pellet or threaded inserts shows before the run is booked. No press starts short.
4
Production lots
Operators scan the press number, die or mould, shift and heat or resin lot at start-up, and first-off and patrol checks are logged against the lot as it runs.
5
Final check and dispatch
Final inspection against the control plan puts a failed lot on hold, then labels print in the VDA or AIAG layout the customer asks for and ship notice leaves. A held lot cannot ship.
6
Complaints and returns
A complaint opens against the lot. Containment, root cause and corrective action are written into an 8D reply, and returnable boxes are reconciled with the customer plant afterwards.

Modules

What is inside.

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

Customer part master

Hold each part number with revision, material grade, die list, control plan and label format, so a setup never starts from a loose spreadsheet.

Revision control

Release a new drawing revision to the operator terminal and the gauge list together, and the earlier print is blocked at the machine.

Approval package files

Attach ballooned drawings, dimensional reports, material certificates and Cpk studies to the part and revision, so a first-article submission is assembled in one place.

Customer release planning

Load the weekly forecast and daily call-offs from each customer plant, then compare them with the previous schedule before the planner sequences the week.

Material and tooling plan

Check coil, bar, resin, inserts and die availability against planned runs before a press or machining centre is booked.

Lot records

Capture press or machine number, die, shift, heat or resin lot and operator for each production lot, then print the lot number on the box label.

In-process and final inspection

Log gauge and CMM readings by lot against the control plan, with a hold on failed lots and a recorded reason for any release from hold.

Outside process orders

Follow brackets and shafts out to the plater, heat treater or powder coater, then match the counts on return and flag short or rejected pieces.

Labels and shipping notices

Print labels in the layout each account asks for, with barcode content and field order set per customer, and build the advance shipping notice from one dispatch record.

Returnable packaging

Count crates, racks and dunnage issued, returned and held at each customer plant, with the age of every balance so idle stock is chased before new crates are bought.

Customer complaints

Log complaints against lots, record containment and corrective action, and print the 8D reply in the customer’s own layout.

Solutions inside

The business modules it is built from.

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

Product Management
Each customer part number is held with revision, material grade and label format, so planners and press operators read one specification.
Workflow and Approvals
A new drawing revision is approved and released to operators and gauges together, and the earlier revision is blocked at the machine.
Document Management
Ballooned drawings, dimensional reports and Cpk studies attach to the part and revision, so they are found again when a customer asks.
Production Planning
Call-off quantities from each customer plant are compared with the last schedule, and press and die loads are re-planned against the change.
Batch and Serial Tracking
Each lot stores press, die, shift and coil heat, so a box label leads back to the exact run behind it.
Quality Control
Readings are logged by lot at the control plan’s intervals, and a failed lot stays on hold until the lab releases it.
Job Work Management
Parts sent for zinc plating, carburising or powder coating are counted out and back, with short returns and rejects shown against the order.
Barcodes and Labels
Labels print in each customer’s layout carrying lot, quantity and part revision, and the shipping notice is built from the same record.

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 production planners

Compare each new release with the last, then plan presses, dies and coil for only the lines that changed, so Monday starts with a real sequence.

For press and machine operators

See the current revision beside the press, and enter heat, shift and first-off details at the machine without walking back to the quality office. No paper travels.

For the quality lab

Record CMM and gauge results against the control plan, place holds on suspect lots, and prepare the PPAP package for each new part before the customer asks.

For stores and dispatch

Pick lots against a release, print labels and shipping notices, and book crates in and out at the dock.

For account managers

Follow releases, open complaints and deliveries for each customer plant. One screen.

Reports

The numbers the owner asks for.

Release changes by customer plant and part
Lots by inspection result and die
Parts shipped against each release
Plating and heat treatment returns, short and rejected
Crates and racks held by customer plant
Complaints by part and root cause

Good fit

Who this is built for.

Suppliers of machined parts to vehicle makers
Makers of stamped and formed brackets and housings
Plants moulding interior and under-bonnet components
Tier-two suppliers selling to tier-one assemblers
Firms that ship on daily or weekly customer releases

Honest answer

When it is not the right choice.

A small workshop making one-off repairs for local garages, with no scheduled call-offs to plan against, does not need release planning.
Aftermarket retailers need stock and billing.

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.

Part structure

Revisions, die lists, control plans and label formats are set up for the customers you serve, beginning with your two busiest accounts.

Inspection plans

Sampling points, characteristics and limits follow the plans your own quality engineers write, down to gauge number and frequency.

Release formats

Import layouts are built for the electronic call-off files, portal downloads and spreadsheets your customers actually send, one customer at a time until each loads cleanly.

Opening records

Open releases, finished stock and earlier lot history are imported from your existing sheets, then checked by planner and lab before the first live release.

Currency and tax

Plants sit in different countries, so currency, tax lines and Incoterms are set on each customer account.

Works alongside

Email
Customer release files
Label printer
Barcode scanner
Accounting export

Common questions

Questions owners ask before a demo.

How does it stop an old drawing revision being used at the press?

Releasing a new revision locks out the earlier print at the press, so operators see only the current drawing, and the gauge list changes with it.

Can I see what changed in the customer’s latest release before sequencing the week?

Yes. The new schedule is compared line by line with the last, and every part whose quantity or ship date moved is highlighted for the planner, who then re-sequences the press line.

What does lot trace include?

Press, die, shift, operator, and coil heat or resin lot for each production lot, plus its first-off and final inspection results. A box label points back to that lot.

Which label formats can it print?

Layouts are built per account, such as VDA or AIAG formats, and barcode content, field order and lot or revision prefixes follow whatever each customer specifies in its supplier manual.

Can outside process orders be reconciled?

Yes. Parts sent for zinc plating or carburising are counted out and back, and short returns and rejects show against the order before the next assembly step is started.

How are returnable boxes counted?

Issues and returns are booked per customer plant. Each plant’s balance of crates is visible with its age.

How does a complaint get handled?

It is raised against the lot, and the trace appears at once. Containment and corrective action are recorded, and the 8D reply prints in the customer’s own layout.

Does it replace our quality system?

No. It holds the production and inspection records tied to lots, while IATF 16949 certification, your quality manual and customer audits stay with your own quality staff.

Can we load our existing part list?

Yes. Part numbers, revisions and open releases can be imported from spreadsheets, and planners and quality engineers go through the imported rows before the first live release.

What does a first meeting cover?

A short session using two of your parts and a recent release. Once seats and modules are fixed, the offer is sent in writing.

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

Industries

Businesses that use this.

Auto parts manufacturers

Related products.

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See Auto Parts 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.

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Start with your requirements

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