Customer releases, bar heats, date codes and returnable racks on one record.
Hold the customer’s forecast and firm release, the part master with its PPAP approval file and control plan, and bar heats cut into billets. Upset and hammer lots, quench and temper loads, magnetic particle checks and shipping notices sit beside them. A struck date code leads to the die set, mill heat and shift. Planners, press crews, inspectors and dispatch read the same lot.
- Part masters, control plans and marking rules entered as your customers specify
- Open releases, die list and approval records migrated
- Changes to control plans, labels and shipping notices made by GullySystem staff on request
Forging plants supplying vehicle makers hold customer releases, part masters, PPAP files, billet heats, date codes, magnetic particle checks and dispatch in one record. Each lot links its struck date code to mill heat, die set and shift. Every release is planned against finished stock, billet cover and press tonnage hours.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Release received
The customer’s forecast and firm release load by part number and date, and finished stock plus parts in the quench line are netted off. What remains is the press quantity.
- 2
Billet and press plan
Bar is allocated by grade and mill heat, and the saw cuts billets to weight. Press hours, die readiness and induction heater slots follow. Shorts show early.
- 3
Forging and marking
The billet is heated, struck, trimmed and heat treated, then marked. The date code is stored with the die, the shift and the furnace load, so every part has a parent.
- 4
Plan checks
Inspectors log hardness, flash, length and magnetic particle crack checks at the plan’s frequency. A lot that misses a check is held before it reaches the pack bench.
- 5
Packing and notice
Approved parts go into the customer’s racks with bar code labels. Each dispatch carries an advance shipping notice and a delivery note. The gate books the rack count when the truck leaves.
- 6
Return and review
Empty racks are tracked back by customer. A field complaint is traced to the lot, heat and die, and the control plan is reviewed with the customer’s supplier quality engineer.
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 forecasts and firm releases are held by part and date, then netted against stock to show the quantity the press must forge.
- Bill of Materials
A part master lists steel grade, billet weight, die set and downstream steps, so a release converts into bar, press hours and heat treatment.
- Batch and Serial Tracking
The date code struck on each part is stored with the lot, mill heat, die and shift, which makes a field complaint traceable.
- Quality Control
Dimension, hardness and magnetic particle checks follow the frequency set for each part, and a lot with a missed check is held.
- Production Planning
Press hours are planned against die readiness and billet stock, so the line is not caught short when a release lands.
- Document Management
Dimensional layouts, mill certificates and gauge records are filed against the part and found when a customer asks for a pack.
- Shipping Integration for Order Fulfillment
Packed quantities generate the delivery note and the advance shipping notice in the layout the customer expects.
- Fixed Asset Register
Racks and dunnage are held as assets by customer and location, so overdue returns are seen against each delivery.
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 releases against stock, die readiness, rack balance and open complaints in one view. Late racks and held lots are listed first.
For planners
Net each release against stock and press hours, and see which die or bar grade is short before the run is released to the floor.
For press and marking staff
Know the lot, the die and the marking rule, then log strikes and date codes as the press runs. A worn die is flagged before it spoils a shift.
For inspectors
Record each check at its planned frequency and hold lots that miss one. Magnetic particle and hardness results sit with the lot, not on a loose sheet.
For dispatch
Pack to the customer’s racks, print bar code labels and send the notice, with the rack count recorded at the gate.
The numbers the owner asks for.
- Releases against stock and press plan, by part
- Lots traced from date code to heat and die
- Checks done and missed against the plan, by shift
- Die strikes since repair and repairs due
- Rack balance by customer
- Complaints by part and cause
- Approval packs outstanding by part
Who this is built for.
- Forging plants supplying crankshafts, connecting rods and steering knuckles
- Makers of yokes, flanges and gear blanks for vehicle drivelines
- Tier one and tier two suppliers working to customer releases
- Forging companies that machine and heat treat parts in house
- Plants that use returnable racks for vehicle maker customers
When it is not the right choice.
- General hot forging shops that sell to mixed industries will find Hot Forging Company Management Software closer.
- Companies making only machined components from bar will find CNC Turning Shop 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
- Spreadsheet import
- Barcode labels
- Customer portal export
- Accounting export
Questions owners ask before a demo.
How do customer releases reach the plan?
A release is entered or loaded by part number and date. The software nets it against finished stock and parts in heat treatment, then shows what the press and saw must make before the due date.
What does the date code link to?
The code applied at marking is saved on the lot. That lot holds the mill heat, die set, press and shift, so a complaint opens the whole chain in one step.
Can control plan frequencies be enforced?
Yes. A part’s plan holds check types and frequencies, and a lot is flagged for review before packing if a hardness or crack check is not logged in time.
Can approval documents be stored with a part?
Yes. Dimensional layouts, drawing releases, mill certificates and gauge records are attached to the part master, and the pack is assembled from them when a customer asks.
How are returnable racks counted?
Racks leave with a delivery and return against it. The balance by customer shows which racks and dunnage are late, and the gate count backs the figure.
What if a customer revises a drawing?
The revision is added to the part master with its effective date. Open releases are checked against the current drawing, and the older one stays visible for lots already struck.
Does it cover machining as well as forging?
It records machining steps, in house or at a vendor. Quantities and rejects come back against the same lot, so the date code still resolves to its heat.
Can the shipping notice be sent from here?
Yes, it prints or exports in the layout your customer expects. Sending it straight into their portal is quoted as an extra, since each portal needs its own mapping.
How much does it cost?
Pricing follows the seat count plus the number of customer release schedules and rack label layouts your plant has to match. A demo on your parts comes first.
Who owns the records?
You do. Lot, heat and complaint records can be taken out as spreadsheet files, and the layout is fixed before you sign.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Forged Automotive Parts 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.
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