One system for models, SMT runs, test yield, cartons and returns.
Each consumer model is held once, with its colour, plug and carton variants, panelised board bill, SMT runs, moisture-sensitive reel control, ICT and ageing results, and warranty returns. Planners see what the line can build. Operators key counts at the station, and when a unit comes back, the service desk traces its date code to the run that made it.
- Models, variants and carton rules entered the way your line builds them
- Part lists, stock lots and open dealer orders migrated
- Changes to line stations and forms made by GullySystem staff on request
A speaker, router or charger is followed from the reel store to the retail carton. The system holds bills with colour and plug variants, stencil and reflow records, floor-life clocks for moisture-sensitive chips, ICT and ageing results, carton labels, dealer orders and returns. One date code leads back to its run.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Order and plan
A brand, retailer or distributor orders models in set colours and quantities; the planner checks stock of PCBs, housings, adaptors and cartons, then fixes a run date. Shortages of a single connector or cell show early.
- 2
Kit and reel issue
Storekeepers issue reels, trays and PCB panels to the line against the run, and each dry bag cut open is logged with a time. Any chip past its floor life is held for the baking oven.
- 3
SMT and inspection
The run records stencil, solder paste lot, feeder setup and reflow profile, while AOI rejects are counted and sent to rework with a fault code such as tombstone or bridge. Each setting is read off the record.
- 4
Assembly and test
Boards are fitted into housings with batteries, cables and antennas. Jig and ICT results are logged per unit or per batch; rejects go to the repair bench with the fault written beside the serial.
- 5
Ageing and final check
Units sit on ageing racks for the burn-in hours the plan sets, and a final functional check is signed by name before the batch is released to the packing hall. No signature, no release.
- 6
Packing and dispatch
Units are scanned into inner and master cartons while labels print with the date code, and the dispatch note matches the order line. A dead-on-arrival return later is booked against the same codes.
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
Every chip and housing carries its latest purchase rate, so a model’s cost, with colour and plug variants included, is visible before any dealer price is agreed with the buyer.
- Production Planning
Brand orders by model and colour are set against stock of PCBs, housings and cartons, and the planner fixes the sequence of runs by line.
- Work Order Management
A run order opens with its stencil, paste lot and feeder setup, and boards in, out and rejected are counted at pick-and-place, reflow and AOI.
- Batch and Serial Tracking
The date code on a returned carton opens the production lot behind it, with panel lot, housing moulder and ageing rack recorded beside it.
- Quality Control
Jig results, burn-in hours and a signed functional check are held per batch, and fault codes send rejected boards to the repair bench.
- Barcodes and Labels
Inner and master carton labels print with model, colour and date code, and scanning each unit into its carton keeps the count exact all the way up to the pallet.
- Job Work Management
Kits sent for contract SMT or moulding leave on a dispatch note, and returned product is matched to it with defects and charges recorded.
- Sales Returns and Credit Notes
A dead-on-arrival unit is booked in with its fault, and the action taken becomes a credit note or a replacement order.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For owners and plant managers
Watch runs, yield by model, orders due and returns by lot from a phone. No calls to three supervisors.
For production planners
Match brand orders against stock of PCBs, housings and cartons, then set the order of runs line by line so that one changeover serves two similar models.
For line supervisors and operators
Record counts and rejects at the station, scan cartons, and see the model now on the line, using three screens that cover the whole job without a manual.
For the quality and service teams
Trace a returned date code to its run, read the ICT and ageing results, and group faults by supplier lot or by solder paste batch. Patterns appear quickly.
For purchasing and stores
Receive reels, log the cut of every dry bag, issue kits, and see which connectors or lithium cells will fall short for the next run before the buyer is asked.
The numbers the owner asks for.
- Runs by model, line and shift, with boards in, out and rejected
- First-pass test yield by jig and by model
- Opened dry bags and parts held for baking
- Returns by date code, fault and supplier lot
- Packed and dispatched quantities against each dealer order
- Component cost against selling price by model
- Outside assembly receipts and defect counts
Who this is built for.
- Makers of mobile chargers, power banks and cables
- Manufacturers of speakers, headphones and audio products
- Producers of LED drivers, lamps and smart lighting products
- Companies assembling set-top boxes, routers and small smart devices
- Brand owners whose products are built on their own SMT line
- Makers of small domestic electronic appliances
When it is not the right choice.
- A shop that only resells finished electronics will find Electronics Retail Management Software closer.
- Makers of low-volume drives and controllers built to order will find Industrial Electronics 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
- Barcode and label printers
- Optical inspection and test jig logs
- SMS or WhatsApp
- Accounting export
- Courier tracking
Questions owners ask before a demo.
How do colour and plug variants work?
A model has one parent bill, and colour, plug and market variants sit beneath it and change only the parts that differ. Orders pick the variant, and the line is told which housing, adaptor and carton to pull. Nothing is copied by hand.
Is the floor life of opened moisture-sensitive parts tracked?
Yes. Cutting a dry bag is logged with its time, and the hours left count down against the limit for that part. A chip past its limit is held and marked for baking before it can be kitted.
How does a return lead back to a production run?
The date code printed on the carton opens the run record. From it you read the panel lot, ICT results, ageing rack and housing moulder for that batch, which narrows a field failure to one cause.
Can it print carton labels with barcodes?
Yes. Labels carry model, colour, date code and barcode, and print at the packing table. Scanning every unit into its carton keeps the packed count exact, from the inner box up through the master carton to the pallet.
Does it work with an outside SMT assembler?
Yes. Kits go out under a dispatch note and boards come back against it with defects and charges recorded. Your own line and the contract assembler then sit side by side in the first-pass yield report.
What about brand-specific packing instructions?
Each brand or retailer can carry its own carton artwork, manual and label layout, and the packing screen shows the instruction that belongs to the order being packed. A white-label pack is checked against its own box before it leaves.
Is a model costed before an order is accepted?
The bill uses the latest purchase rate of each part, so a model’s cost is visible while the quotation is still being typed. Rates move as new purchase invoices are recorded against reels and housings.
How long does it take to learn on the line?
Operators use three screens: count, reject, scan. Supervisors and planners get fuller views, and floor staff learn at their own workstation during normal shifts, so the SMT line never stops for a class.
What happens to our records if we leave?
Models, bills, run history and returns can be exported as spreadsheets; the handover format, including date code and serial columns, is agreed in the written proposal.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Electronic Product 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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