One system for customer products, engineering changes, forecasts, builds and returns.
Manage customer products, bills of materials, engineering change notices, rolling forecasts, reel and tray sourcing and build lots in one system. Board serial numbers, in-circuit and functional test results, box build and RMA returns sit beside them. Each customer’s approved vendor list stays apart while the SMT lines are shared. Engineering, purchasing, stores, production and quality read the same revision.
- Customer list, product masters and bill of materials formats set up with your planners
- Open orders, forecasts and reel stock migrated
- Changes to certificate layouts per customer handled by GullySystem staff on request
Electronics contract manufacturers keep customer products, change notices, forecasts and SMT build lots in one record, with screens set up for your lines. Each customer’s revision, bill of materials and approved vendor list stays apart. Every board carries a serial number linked to its reel lots, firmware and test result, and RMA returns attach to that record.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
New product introduction
Gerber files and the bill of materials are reviewed, manufacturability queries go back to the customer, a pilot build is planned and the first article is inspected and signed off. Each gate has a name.
- 2
Forecast and sourcing
A rolling forecast and firm orders drive purchase planning for the distributor and the broker. Long-lead and single-source parts are flagged, with approved alternates listed beside them.
- 3
Build release
A lot opens against the current revision. Reels, trays and tubes are kitted from owned and consigned stock, with moisture-sensitive parts logged, and shortages are listed by build date.
- 4
Assembly, programming and box build
Boards pass stencil printing, pick-and-place, reflow and AOI, then harnesses and sub-assemblies go into enclosures. Firmware is flashed and the version recorded against the board.
- 5
Test and serialisation
Each board runs on a test fixture and receives a serial number linked to its reel lots, firmware and measured result. Failures go to rework with the fault code attached.
- 6
Shipment and returns
Each unit ships against the customer’s order with its certificate of conformance. Returned units are logged with the failure found, and repeating causes are grouped by lot.
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 customer’s product carries a revisioned list of parts with reference designators, and the source of every line is marked as bought or consigned.
- Workflow and Approvals
A customer’s change notice moves through approval with its affected parts and effective date, then reaches purchasing, stores and the SMT line together.
- RFQ and Quote Comparison
Quotation requests for long-lead and single-source parts go to chosen distributors, and returned prices and lead times are compared side by side.
- Batch and Serial Tracking
Every board gets a serial number tied to its reel lots, firmware version, operators and fixture result, readable long after it has shipped.
- Warehouse Management
Customer-supplied reels are held by shelf location and by owner, apart from purchased stock, with every movement in and out recorded.
- Work Order Management
An enclosure build moves through cable assembly, board mounting, labelling and final inspection, with a status and a named owner at each station.
- Quality Control
A returned unit is logged with its bench failure and repair, and repeated causes are grouped by product, solder lot and component lot.
- Order Management
Firm orders and the rolling forecast of each customer are stored together and compared with reels on order and in stock.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For programme managers
Follow each customer’s products through introduction, volume builds and open change notices without chasing four departments for status.
For engineering
Review Gerbers and bills of materials, record manufacturability queries and release revisions with an effective date, so the line loads the right programme.
For purchasing
Compare forecasts with reels in stores, chase long-lead parts and manage approved alternates against each manufacturer part number.
For production and test
Open the current revision, record AOI and fixture results by serial number and send failures to the rework bench with the fault attached.
For quality and customer support
Trace a unit to its component lots, analyse returns by failure cause and send the customer a lot-level report that matches the shipment.
The numbers the owner asks for.
- Customer products by revision and open change notices
- Forecast against reels on hand and on order at the distributor
- Excess and obsolete components by customer
- First-pass yield by product, AOI station and build lot
- Units traced to a capacitor lot or bootloader version
- RMA returns by failure cause, product and customer
- Consigned reels held per customer
Who this is built for.
- Contract manufacturers that assemble boards and full products for several brands
- Providers of box build with enclosure integration and cable work
- Companies that run new product introduction for start-up hardware customers
- Firms that mix turnkey purchasing with consigned customer reels
- Providers that handle repairs and RMA returns for the products they build
When it is not the right choice.
- A shop that only populates boards from supplied kits will find PCB Assembly Company Management Software closer.
- A company that builds its own branded product will find Electronic Product 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
- Customer portal links
- Test fixture result files
- Label printers
- Accounting export
Questions owners ask before a demo.
Can a customer see their own builds?
A login can show a customer their products, orders, shipments and returns. What appears is set per customer, and nothing belonging to another customer is visible to them.
What happens to parts left over after a forecast drops?
The system lists components bought for a cancelled or reduced forecast by customer and age, so the excess inventory conversation has numbers. The commercial settlement is yours to agree, and terms differ by contract.
How are alternates approved?
An alternate is proposed by purchasing, approved by the customer or engineering, and recorded against the manufacturer part number on the line. Builds then use it only from its effective date.
Can one product use both turnkey and consigned parts?
Yes. Each line of the bill of materials states whether you buy it or the customer supplies it, and stock counts and shortage lists follow that flag.
Does it read firmware programming results?
Yes, the firmware version loaded can be entered or imported from the programmer’s log file. How a given tool exports that log is checked during implementation.
Can we trace a failure to a component lot?
Yes. Search by board serial number or by reel lot and the system lists every unit carrying it, along with shipment details and the customer it went to.
How do we move from spreadsheets?
Your existing customer products, bills of materials, open orders and reel stock are imported from the files you already keep. A planner checks a sample for each customer before go-live.
Is there a standard price?
No fixed list price exists. Users, customers and test stations all affect the quote. We first demonstrate with one of your own customer products, then put the quotation in writing.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See EMS Provider 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.
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