Resin lot, mould, press settings and paint batch held against each moulded part.
One record covers vehicle maker releases, polypropylene and ABS resin lots, masterbatch, desiccant dryers, moulds, press settings, paint, assembly, checking fixtures and sequenced despatch. A moulded lot carries its resin lot, the mould and cavity it ran in, the approved melt temperature and holding pressure, and the paint batch it went through. A fitment complaint ends in a lot number.
- Moulds, presses and part routes entered as your shop runs them
- Open releases, stock and tool lists brought across
- Route and inspection field changes made by GullySystem staff on request
Bumpers, door trims, fascia and housings are followed from resin lot to sequenced rack. Dryer hours, mould and cavity use, melt temperature, shot weight, paint defects and fixture results are recorded against each lot. A complaint on a moulded part traces to its tool and its resin. Setters start from saved settings.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Release
Weekly releases and sequence calls from the vehicle maker are entered by part and colour, with delivery dates, rack rules and label formats. Changes to a call overwrite the old line.
- 2
Material and mould
Resin and masterbatch lots are booked in. Planners match each mould to a press by clamp tonnage, and drying is logged against the hopper before it is charged with pellets.
- 3
Moulding
Operators log cycle time, shot weight and rejects such as flash, sink marks and weld lines, and approved settings are saved per mould and press for the next run.
- 4
Booth and fitting
Parts move to the paint booth, ultrasonic welding and clip fitting. Each stage notes defect types and quantities against the moulded batch, so a run of dust nibs traces upstream to its press.
- 5
Inspection
Parts are measured on checking fixtures and gauges, with gap and flush readings kept per lot, and a lot outside its limits is held for review by quality.
- 6
Sequenced despatch
Racks are packed in the customer’s build order, labelled by position and sent with a packing list. A swapped colour shows before the rack leaves.
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.
- Batch and Serial Tracking
Resin and masterbatch lots are booked at the gate and issued to a press order, and each moulded lot carries them on to the paint booth.
- Production Planning
Weekly releases are scheduled against presses by clamp tonnage and mould, with colour changes planned light to dark so purge material and press time are saved.
- Work Order Management
Each press run is a work order on which operators log cycle time, shot weight and rejects such as flash and sink marks, shift by shift.
- Quality Control
Fixture and gauge readings are stored per lot against limits from your quality staff, and any lot outside those limits is held until it is reviewed.
- Fixed Asset Register
Moulds are listed as assets with shot counters, vent cleaning dates and repair history, so the tool room can see which tool is due next.
- Stock Tracking and Alerts
Resin, masterbatch and insert stock are tracked by lot with reorder levels, and hopper draw-down is logged so no press stops for want of pellets.
- Barcodes and Labels
Rack labels and packing lists print in the order of the customer’s sequence, with lot numbers carried on each label for goods inward at the plant.
- Job Work Management
Parts sent to an outside paint house or welding vendor leave on a delivery note and return with defects and counts recorded against the moulded lot.
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
See presses running, moulds due for service, lots on hold and releases at risk of missing the vehicle line, all on one screen at the start of the day.
For production planners
Match moulds to presses by clamp tonnage, plan colour changes from light to dark, and watch resin stock and masterbatch balance before each run starts.
For press operators and setters
The setter opens the job on the press screen and pulls up the stored barrel temperatures, hold pressure and cycle time. Shot weight and short-shot rejects get keyed in during the run, not recalled at shift end.
For the tool room
See moulds approaching their service point. Cleaning, polishing and repair work is logged against each tool as the fitter finishes it.
For despatch
Pack racks in sequence, print position labels and check the list against the vehicle maker’s release before the truck is loaded at the dock.
The numbers the owner asks for.
- Presses by mould, cycle time and reject rate
- Rejects by cause and mould
- Moulds ranked by shot count since last service
- Paint defects by moulded batch
- Resin and masterbatch used against parts shipped
- Purge material by colour change
- Sequence deliveries against releases
Who this is built for.
- Moulders of bumpers, door trims and dashboard parts for vehicle makers
- Shops making under-bonnet housings, covers and clips
- Suppliers with in-house painting and welding lines
- Makers of lighting housings and fascia
- Tier two moulders supplying trim assemblers
When it is not the right choice.
- A shop that moulds household goods will be better served by Manufacturing Production Management Software.
- Vehicle assembly plants will find Auto Manufacturer Management Software closer.
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
- Press data file import
- Accounting export
Questions owners ask before a demo.
Does it stop a press order that has not been dried?
Yes. Drying can be made a required step, and the press order stays on hold until dryer start and end are logged for that resin lot.
Can settings be recalled for the next run?
Yes. Melt temperature, holding pressure and cycle time of an approved run are saved per mould and press, so the setter starts from that run and not from last values.
How is mould life tracked?
Each mould carries a shot counter fed by production entries, and the tool room list shows moulds nearing a vent cleaning or service point, ranked by shots since the last visit.
Can paint defects be matched to moulding?
Yes. A painted lot points to its moulded batch, press and resin lot. A substrate fault such as splay is traced to moulding, so the booth is not blamed for it.
Does it handle sequence calls?
Yes. The customer’s build order is loaded, racks are packed in that order, and labels follow the same list. A swapped colour shows before the rack leaves the dock.
Can we import press data?
Not directly today. Values are keyed at the press, and importing from press controllers can be scoped, with the models that connect reviewed during implementation.
What affects the cost?
Users, plants, number of presses and customer label formats set the figure. A demo is run on your own moulds before the quotation is written.
Can records be exported?
Yes. Lot, mould and shipment records leave in a file format fixed in the quotation, so your history stays with you.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Automotive Plastics 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