Coil heats, punch strokes and header lots on one record.
Follow a wire coil from the weighbridge to the dispatch bay. Coil receipt against the EN 10204 3.1 certificate, former scheduling, die insert life, first-off gauging, outside carbonitriding or zinc flake coating, and final sorting sit on one record. Each lot names its heat and die set. Vendor weights are kept too.
- Part numbers, die sets and wire grades such as SAE 1022 or 10B21 entered as your shop names them, with nothing renamed for the software
- Open lots, coil stock and vendor jobs brought across from your coil register and job cards before the first shift
- Field and rule changes made by GullySystem staff on request
A lot record built on the coil, the header and the die set carries the mill certificate, punch strokes, first-off head height, carbonitriding return weight and sorting rejects together. A bolt returned by a buyer leads to its wire heat. One search finds it.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Order and part setup
A buyer’s order is entered against a part number, its drawing revision and the wire grade, while schedule releases and call-off quantities sit beside the part for the planner. No second file is opened.
- 2
Coil receipt
Each coil is booked with heat number, rod diameter and weight, and coils waiting for spheroidise annealing or phosphate soap coating show the process they still need. The mill certificate is attached.
- 3
Scheduling the headers
The planner assigns the part to a header or former by station count and wire size, and the due die set appears with its stroke count before release. Changeovers follow wire diameter.
- 4
Forming and inspection
The setter records the changeover. First-off head height and shank diameter are entered and approved, then samples for laps and cracks are logged through the run with the operator named on each line.
- 5
Outside processes
Lots go to hardening, tempering, carbonitriding or zinc flake vendors with weights and counts out. Returns are checked against the outgoing record, and the vendor’s case depth or salt spray report is filed with the lot.
- 6
Sorting, packing and dispatch
Sorted lots are packed in cartons, each with a label carrying the lot number, and the delivery note, packing list and invoice come off the same record. Nothing is retyped.
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.
- Order Management
Customer orders are held by part and drawing revision, with release dates and call-off quantities that the planner reads when placing lots on a header.
- Batch and Serial Tracking
A lot is linked to its wire heat, header, die set and shift, so a carton label leads back to the coil and on to sibling lots.
- Production Planning
Part numbers are placed on machines by station count and wire size, and same-wire jobs are grouped so heavy tooling moves less often.
- Quality Control
Head height, diameter and crack samples are entered on a part sheet, and an out-of-range reading holds the lot until a supervisor signs off.
- Job Work Management
Lots sent for carbonitriding or zinc flake coating carry weight out, weight back and the vendor’s report, and the difference shows before the lot is released.
- Goods Receipt (GRN)
Coils are booked at the weighbridge with heat number, rod diameter and weight, and the mill certificate is attached before the coil is issued.
- Fixed Asset Register
Dies, heading punches and shear blades are listed as assets with their parts, strokes since regrind and scrap date, so replacement is planned and not guessed.
- Invoice Management
The delivery note and invoice are raised from the packed cartons and lot labels, using the currency and tax rules set for each buyer.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For owners
See lots running, tool life in danger, parts out with vendors and rejections by customer, and compare wire cost per part with the price quoted.
For planners
Place part numbers on headers and formers, group changeovers by wire size, and watch coil stock against the call-offs ahead. A header short of wire shows before it stops.
For setters and operators
Open the setup sheet for a part. Log strokes at each punch change, and enter first-off head height and shank diameter at the header without walking to the office.
For quality inspectors
Log the sample readings, then pass the lot or hold it. Review rejection reasons by header and die set so a cracked head is traced to its tool before the next lot repeats it.
For stores and dispatch
Book wire coils in at the weighbridge against the mill certificate, send lots to carbonitriding and plating vendors, and book them back by weight and count. Pack finished cartons to match the dispatch note.
The numbers the owner asks for.
- Wire coils in stock, issued and remaining, by heat number
- Heading punch and die insert strokes since regrind, with sets due for scrapping before the next order
- Lots by header and shift, with first-off outcome
- Plating and carbonitriding weight out against weight back
- Laps, seams and head cracks by die set
- Call-offs due, with the lots covering them
- Wire weight, slug loss and sorting scrap per part set against the quoted price for that part
Who this is built for.
- Shops that cold form bolts, screws, pins and rivets on multi-station headers and need each lot tied to a wire heat for the buyer’s audit
- Companies that make shafts, sleeves and cold-extruded parts
- Cold forming units that supply fasteners and small components to distributors and OEM buyers, and answer a complaint with a lot number
- Plants that send lots out for hardening, tempering or plating and take them back
- Firms that run dozens of die sets and need to know how worn each insert is before the order is released to a header
When it is not the right choice.
- A shop that only trades in finished fasteners will find Fastener Manufacturer Management Software or a distribution product closer, because it forms nothing from wire and needs no die set.
- Hot forging plants that heat billets before forming will find Precision Forging Company 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
- WhatsApp or other messaging
- Barcode and label printers
- Weighing scales
- Accounting export
Questions owners ask before a demo.
How is a complaint traced back to a coil?
Enter the carton label or lot number. The lot shows the coil heat, header, die set, shift and inspection samples, and from the heat number every other lot that wire fed is listed beside it.
Can tool life be tracked without a stroke counter?
Yes. Setters enter the count at each tool change, and the register adds up strokes since regrind. A machine counter feed can be added later as separate integration work. It is quoted on its own.
Does it plan changeovers?
In part. The planner sees wire size, station count and the die set for each part, and places same-wire jobs together so die changes fall. It does not run an automatic optimiser.
How are parts at a plating vendor followed?
A lot is sent out as an outside job with count, weight and vendor. When it returns, the received weight is compared and the coating or hardness report is filed, and only then is the lot released for packing.
Can several part numbers share one coil?
Yes. A coil can be split across lots, and each lot records how much wire it drew, while the remainder stays on the coil record until it is used.
Can inspectors use it at the machine?
Yes. First-off and sample sheets open on a tablet or a shop-floor screen with the operator named on each entry, though a network connection is required at the machine. Weak signal means a printed sheet, keyed in later.
Does the software certify our parts?
No. It records the checks your inspectors perform and the reports your vendors send, while the limits come from your own control plan. Your inspectors keep those limits current.
Can our existing die set history be loaded?
Yes. Die sets, their parts and counted strokes can be loaded from a spreadsheet, and the quality team checks the first batch before go-live.
What is the cost?
The quotation depends on how many headers, users and outside vendors you run. Before any figure is quoted, we run a walkthrough on your own part numbers and die records. Header count and vendor load then set the quotation.
Can we take our lot records out?
Yes. Lots, coils, tool history and rejection logs can be exported in files your team can open, with the format and timing written into the quotation.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Cold Forging Company 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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