Cell grading, weld record, firmware and end-of-line result held under each serial.
Every pack serial opens onto its pouch cell trays sorted by open-circuit voltage and internal resistance (DCIR), with the laser busbar weld checks and M6 bolt torque in Nm just behind them. Firmware and hipot follow. Stores, the module line, the test bay and rework all write to that serial, so a vehicle maker query meets one history instead of a drawer of grader spreadsheets.
- Pack variants, module stations, coolant plate options and hipot test steps keyed in as your line runs, so nothing is assumed about your drawings
- Open orders, graded cell stock and past serial history brought across and counted against the stores before the first shift on the new system
- Grader, test and station field changes made by GullySystem staff on request, without a developer on your side
Battery modules, packs, motor stators and inverters are followed from cell or winding lot to the shipped serial. Grading readings, weld checks, bolt torque, BMS firmware and hipot results all sit on one record, never in a grader’s folder on some forgotten PC. A returned pack traces back to its tray.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Order and variant
The order names the pack variant. Cell count, HV connector, label format and UN 38.3 transport paperwork for lithium cells are attached before anything is released to the line.
- 2
Cell receipt and grading
Lots are booked at the gate. The grader then sorts every cell by capacity and internal resistance against the supplier sheet, and matched cells are grouped into numbered trays ahead of the module builds.
- 3
Module and pack build
Operators work station by station. They weld or bolt busbars, log torque, seat sense boards and the coolant plate, and close the case, with every step naming the serial and the person.
- 4
Firmware and tests
Boards are flashed first. End-of-line then runs insulation resistance, pack voltage, cell balance and CAN bus communication against limits that your engineers set, with the flashed version already on the record.
- 5
Rework
A failed pack moves to rework. The defect code, the part replaced and the retest result go on that same serial, so the repeat offender shows up by part.
- 6
Despatch
Despatch comes last. Each passed pack is charged to its storage level, labelled with its serial and packed, and the cell lot list and test records travel with the shipment.
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 variant lists cell count, coolant plate, BMS board, HV connector and label, so every station draws the right parts for the pack being built.
- Batch and Serial Tracking
Each printed label carries a pack serial tied to its modules and graded trays, so a field query opens the pouch cells behind that pack.
- Goods Receipt (GRN)
Cell lots arrive against the purchase order with supplier test data, are booked by lot, and any cell below grade is kept apart in quarantine.
- Work Order Management
Each pack build runs as a work order through weld and bolting stations, noting operator, torque value and time for every joint made.
- Quality Control
Insulation, voltage, balance and CAN results are checked against limits your engineers set, and a failed pack is held at the end-of-line bay.
- Production Planning
Orders by variant are planned across module stations and test bays, and cell availability by grade is shown before a build is released.
- Stock Tracking and Alerts
Finished packs are held with storage charge level and date, while cells, busbars and BMS boards carry reorder levels so no build starts short.
- Customer Support
A vehicle maker query opens the serial and shows cells, welds, firmware and test history together for the engineer who replies.
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 the floor. Packs in build, hipot failures by bay and customer orders at risk of missing their date are laid against the schedule on a single screen.
For stores
Gate to tray. Stores book cell lots at the gate, issue graded cell groups to the module builds and keep every rejected cell inside the quarantine cage, each with its lot.
For line operators
Scan, then work. At the station the operator opens the pack, scans the cell trays used, records bolt torque and weld checks, and passes the pack on.
For test and rework staff
Results go under the serial. Test staff enter hipot readings, defect codes and retests, and rework technicians note each replaced sense harness or cell.
For dispatch
Check before the truck. Dispatch confirms storage charge on each pack, prints the serial labels and matches every serial on the pallet to the customer order before the truck leaves.
The numbers the owner asks for.
- Packs built by variant and serial range
- Cell lots by module, tray and pack
- Hipot and balance failures by bay and shift
- Rework causes by part and defect code
- BMS firmware versions by pack serial
- Storage charge of finished packs on the shelf
- Field queries traced to a cell lot
Who this is built for.
- Makers of pouch, prismatic and cylindrical cell modules and packs for electric cars, electric buses and two-wheelers sold to vehicle makers
- Suppliers of hairpin wound stators and magnet-bearing rotors for traction motors fitted in electric cars and buses
- Assemblers of inverters, motor controllers and onboard chargers
- Builders of CCS2 charging connectors, crimped high-voltage cable assemblies with shielding braid, and moulded charging gun handles
- Contract assemblers of EV subassemblies such as coolant manifolds and junction boxes working to customer drawings
When it is not the right choice.
- A garage that repairs electric vehicles will find Garage Management Software closer.
- 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
- Grading machine file import
- Accounting export
Questions owners ask before a demo.
Can it trace a pack to its cells?
Yes. A pack serial lists its modules, each module lists its graded trays, and each tray lists the supplier lot plus the capacity and DCIR reading for every cell inside it.
Does it stop mixed cell lots in a module?
It can be set to flag them. When trays from different supplier lots reach one module station, the supervisor decides before the build continues, and the decision is stored.
Can firmware versions be tracked?
Yes. Board serial and firmware version are logged at the flashing laptop and shown on the pack record. If one build is recalled, a single search lists every serial that carries it, together with the customer and despatch date.
What about end-of-line tests?
Results for insulation resistance, voltage, balance and CAN communication are stored per serial, so every reading can be read back later. A failed pack is held. It cannot be packed until a retest passes.
Is it limited to battery packs?
No. Stator winding and controller assembly run beside packs, each with its own route, test steps and serials. A varnish batch, a magnet lot or a controller board lot is traced through the same serial screens.
Can grading machine files be imported?
Readings can be keyed today. Importing from grading and cycler equipment can be scoped, and which models connect is reviewed with your test engineers during implementation.
What affects the cost?
Users, lines and the test equipment to connect set the figure, nothing else. You see a demo built on your own pack variants first, and a written quotation follows afterwards.
Can we export serial histories?
Yes. Serial, cell lot and test records leave in a file layout fixed in the quotation, so your customer archive stays yours.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See EV Component 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
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