One record from pattern and melt to the casting that ships.
Customer part numbers, match plates, core boxes, cupola or induction furnace charges, green sand moulds, pour records, shot blasting, fettling, pressure tests and dispatch all sit in one system. Each casting lot carries its spectro analysis, its flask numbers and its drawing revision. A returned bracket is traced to the ladle that poured it. Melt shop, moulding line, fettling bay and quality lab read the same record.
- Part masters, patterns and melt recipes entered as you cast today
- Open orders, pattern list and customer drawings migrated
- Changes to grades, tests and certificate layouts made by GullySystem staff on request
Foundry Component Manufacturer Management Software serves foundries casting pump bodies, valve housings and gearbox covers, from part masters and match plates to melts, flasks, inspection and dispatch. Each lot carries its spectro analysis, flask numbers and drawing revision, so a rejected casting is traced to the charge and the pattern that made it.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Enquiry and estimate
A drawing arrives with quantity and grade. The estimate weighs casting weight, expected yield, fettling hours and machining allowance together, and the quotation is saved with every revision.
- 2
Part and pattern set-up
An accepted order creates a part master with its drawing revision. Match plate, core box and gauge records are linked, with owner and rack location.
- 3
Melting and moulding
The melt shop weighs pig iron, returns and ferroalloy against the recipe and records the spectro result. Moulds are closed and poured, and each flask is tied to its heat.
- 4
Shakeout and fettling
Castings are counted out of shakeout, then shot blasted, ground and weld repaired. A rejection is written with a defect reason at the station that found it.
- 5
Inspection and processing
Dimension, hardness and hydro test results are recorded per lot. Castings needing annealing, machining or painting go to an outside vendor and come back against the same job.
- 6
Dispatch
Approved lots are packed to the order. The test certificate prints from the heat and test records. Billing follows the loaded truck.
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.
- Quote & Proposal Management
A quotation is built from casting weight, yield, fettling and machining content, and each revision stays against the customer’s part number.
- Bill of Materials
Each grade has a charge recipe listing scrap, pig iron and alloy additions, and every heat is checked against it before tapping.
- Work Order Management
Pour orders carry the pattern, mould numbers and quantity, so the moulding line knows which job follows and the lot is tied to its heat.
- Batch and Serial Tracking
Heat and lot numbers link each casting to its chemistry and test results, which is what the certificate printed at dispatch relies on.
- Quality Control
Rejections are recorded at the station that finds them, with a defect reason, so a blow hole is traced to moulding rather than argued over.
- Job Work Management
Castings sent out for heat treatment, machining or painting are checked by quantity on return, and rejects are charged to the vendor and lot.
- Fixed Asset Register
Patterns, core boxes and gauges are held as assets with owner, location and repair history, including pieces out at a pattern shop.
- Invoice Management
The delivery note and tax invoice are raised from the dispatched lot, using the customer’s currency and tax settings.
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 orders by customer, yield by part, scrap and remelt tonnage, and the bill from outside annealers and machinists without waiting for a month-end sheet.
For melters
Weigh the charge against the recipe, key in the spectro result and see which heats are cleared for tapping.
For moulders
Know which match plate and core box belong to the next flask and log mould and pour numbers as the shift runs.
For fettlers
Count good and rejected castings at the grinding stand and the weld bay, and write the defect reason where it was found.
For quality staff
Record hardness and hydro results per lot, hold or release the lot, and print certificates from verified records.
The numbers the owner asks for.
- Casting yield by part and grade, against the estimate
- Heats tapped with spectro result and rejected lots
- Defects by type, match plate and moulding line
- Core box list with shot count and wear repair due
- Annealing and machining lots out and due back, by vendor
- Customer complaints traced to heat and flask
- Orders by customer with dispatch status
Who this is built for.
- Foundries that cast grey iron, ductile iron or steel parts for machinery makers
- Non-ferrous foundries that pour bronze, brass or aluminium components to customer drawings
- Job foundries that hold customer-owned patterns and core boxes
- Foundries that machine and paint castings before dispatch
- Casting suppliers to pump, valve, gearbox and construction equipment makers
When it is not the right choice.
- A pattern shop that only makes tooling will find Tool Room Management Software closer.
- Foundries that cast only sand for a single product line and hold no customer drawings can run on a simpler batch register.
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
- SMS
- Spectrometer result import
- Accounting export
- Barcode labels
Questions owners ask before a demo.
Can it follow a casting back to a single heat?
Yes. Each flask carries its heat number. Each casting lot carries its flask numbers. A returned part is traced from the lot to the charge and the spectro result.
Does it hold customer-owned patterns?
Yes. A pattern, core box or gauge is a record with an owner, a storage place and a repair history. Sending one to a pattern shop is logged like any other movement.
What happens when a customer revises a drawing?
The new revision is added to the part master. Orders against the old revision are blocked until the match plate record is updated. The block shows on the order itself.
Can we price a casting before we have a pattern?
Yes. The estimate starts from casting weight, expected yield, fettling time and machining content. Pattern cost can be quoted separately or spread across the order.
Can it print a test certificate for each lot?
It prints a certificate from the heat analysis and the lot’s test results. Your quality manager signs off the wording and readings shown before the first live lot.
How are rejected castings handled?
A reject is logged where it is found, with a defect reason and weight. Scrap goes back to the melt plan as remelt. Yield then reflects what was poured.
Does it handle heat treatment or painting done outside?
Yes. Castings go to a vendor against the job and come back by quantity. Rejects found on return are charged to that vendor and that lot.
Can the lab upload spectrometer readings?
Yes. Staff can key the readings or import the file the instrument writes. We confirm the file format when installing.
How is pricing decided?
Users and recording stations set the figure. Send us your pattern list and we will show the system working on it; our quotation comes only after you have seen that.
Who looks after the system afterwards?
GullySystem hosts it and handles changes to grades, defect codes and certificate layouts. Your quality manager decides the rules and our staff apply them.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Foundry 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
Start with your requirements
Seven short steps that tell us what you need. An engineer reads them before getting in touch.
Share your requirements