One system for wire coils, heading, rolling, heat treatment, coating and lot certificates.
Customer releases, wire coil receipt, cold heading, thread rolling, hardening, zinc flake or plating at outside vendors, lot inspection and dispatch for flange bolts, studs, nuts and screws share one record. Each lot carries its coil heat number, furnace load and test results from blank to delivery note. A customer query is answered from the lot.
- Part numbers, drawing revisions and each customer’s label rules keyed as your plant uses them
- Open orders, wire stock and coating vendors migrated
- Lot rules and test plans adjusted by GullySystem staff on request
One GullySystem build holds the orders, wire coils, headers, thread rollers, mesh-belt furnaces and coating vendors of an automotive fastener plant. Each lot keeps its coil heat number, die set, hardening load and coating report. Quality staff hold a failed lot, and a certificate of conformance prints with the delivery note.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Order and schedule
The customer’s order or weekly release is entered against the part and drawing revision. Planning then sets quantities and picks the header, the thread roller and the die set that suit the size and grade.
- 2
Wire issue
A coil is chosen for steel grade and wire diameter and issued to the header by weight. The heat number follows the lot and stays on it until the last carton ships.
- 3
Heading and rolling
Operators log pieces, scrap and stoppages by machine, and the first-off check is signed before the run continues. Thread rolling follows on its own work order with the roll die set noted beside it.
- 4
Hardening and tempering
Furnace load, belt speed, temperature and tempering are written against the lot and hardness samples are entered. A lot outside range stays on hold until quality decides its fate.
- 5
Coating and testing
Lots go to the coating vendor and return against the same record. Quality enters thickness, torque and tensile results next, and only a passed lot is released to packing.
- 6
Packing and dispatch
Packing follows the customer’s label and box rules, such as a barcode label per carton. The conformance certificate goes out with the dispatch paper, and the invoice starts from that same dispatch.
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.
- Goods Receipt (GRN)
Each coil is booked in against its mill certificate, so the heat number and weight are fixed before the header draws a single metre of wire.
- Bill of Materials
A part carries its steel grade, property class, coating and packing items with a revision, so a changed drawing does not reach the header unchecked.
- Order Management
Blanket orders and weekly releases are held per part, and shortfalls against the delivery schedule show before the truck is due at the dock.
- Production Planning
Lots are spread across headers and thread rollers by die set, so similar diameters run together and changeovers between them are fewer.
- Work Order Management
Every run records pieces, scrap, first-off approval and stoppage reasons against the machine, the punch and the die set used.
- Batch and Serial Tracking
A furnace batch names the lots inside it and its settings, so a hardness fault or shallow case depth points straight to one load.
- Job Work Management
Lots sent to plating or zinc flake vendors are tracked out and back, with short returns and thickness reports kept on the lot.
- Quality Control
Sampling plans per customer drive the torque, tensile and hardness entries, and a failed reading holds the lot from dispatch.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For plant managers
Read lots in process, lots on hold, machine output and late customer releases from the office, without walking the shop floor at every shift change.
For header and roller operators
See the work order, die set and drawing, then log pieces, scrap and stoppages on a screen at the machine. The paper shift sheet goes away.
For heat treatment staff
Enter each furnace load with its settings and hardness results, and see which lots wait at the furnace for the next batch of the same grade.
For quality engineers
Run sampling plans, hold or release lots, answer complaints from the lot record and issue certificates. Every complaint reply starts from the heat number on the lot.
For stores and the dock
Book each coil in against its mill certificate, follow lots out to the coater and back, and pack to the customer’s label rule at the dock.
The numbers the owner asks for.
- Open lots at each header, roller and furnace step
- Wire coil stock by grade, diameter and heat number
- Hardness and torque results by lot and customer
- Lots out at coating vendors, with days away
- Scrap by part, machine and die set
- Tooling cost per thousand parts
- Customer releases against deliveries made
Who this is built for.
- Cold forging plants that head bolts, studs and screws for vehicle makers
- Nut and washer makers that supply tier one assemblers
- Fastener plants with their own heat treatment line
- Makers that send lots to outside platers and coaters
- Plants that supply warranty and aftermarket packs as well as line orders
When it is not the right choice.
- A trader that buys in bolts and nuts and sells them on, with no heading or rolling of its own, is better served by the auto parts shop product.
- A machine shop turning one-off pins and bushes is better served by a job shop product than a lot-based fastener plant.
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
- Barcode and label printers
- Weighing scales
- Accounting export
- Customer data exchange
Questions owners ask before a demo.
Does it follow a lot from coil to customer?
Yes, from coil to carton. The lot names its coil, heat number, work orders, furnace batch, coating return and delivery note, and the trail opens from a pallet label or from a heat number.
Can furnace settings be saved with the lot?
Yes, the operator enters belt speed, zone temperatures, quench and tempering for each load, while a direct feed from a furnace controller is scoped separately as extra work.
How are coating vendors handled?
A lot leaves on an outward delivery note and returns against it. The vendor’s thickness report is attached, and any short quantity shows as open until the coater explains it.
Can one part have different test plans for two customers?
Yes, and it is set per customer. Sampling, tests and certificate layout attach to the customer and part together, so the same flange bolt can be tested two ways for two vehicle makers.
Does it count tooling life?
Yes. Pieces made are summed by die set, punch and roll die from the work orders, and a set is flagged when it nears the life you have set for it.
Does the software certify our quality system?
No, it does not certify anything. It holds the records and rules you define, while certification to IATF 16949 and its audits remain with your own quality team and the assessing body.
Can customer releases arrive electronically?
Not by direct link yet. A release is typed in or brought in from a file, and a data link with a customer’s portal is scoped as extra work.
How would existing lots and orders move over?
Part masters, open orders, coil stock and coating vendors come in from your existing sheets. Your stores and quality people confirm the figures before the first live lot.
How can we see a price?
A demo built on a fastener part and a sample lot comes first. The quotation then lists users, plants and connections.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Automotive Fastener 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
Start with your requirements
Seven short steps that tell us what you need. An engineer reads them before getting in touch.
Share your requirements