From forged blank to ground and inspected gear, each part keeps its own record.
Gear enquiries, drawings, blank lots, hobbing and shaping routes, outside heat treatment, grinding, tooth inspection and despatch are all recorded against the order. Each gear carries its module, tooth count, grade and drawing revision, with the blank heat number and the inspection chart attached. Cutter life is counted, and rework hours reach the part cost instead of staying with the operator.
- Part list with module, tooth count and grade entered as you hold it
- Open orders, cutters and routes migrated
- Rule changes made with your quality staff at implementation
Gear shops that cut spur, helical and bevel gears keep drawings, blank lots, routes, heat treatment loads and tooth inspection together in one GullySystem system fitted to the shop. Each part carries its blank heat number, cutter, hardness result and inspection chart from receipt to despatch.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Enquiry and drawing
The customer sends a drawing with module, teeth, grade and quantity. It is logged, checked for missing tolerances and priced from blank, cutting, heat treatment and grinding.
- 2
Order and route
An accepted quotation becomes an order with a route: turning, teeth, deburr, heat treatment, grind, mark and inspect. Machines and cutters are assigned.
- 3
Blank receipt
Forged blanks are received against the order. Heat number and hardness are recorded, and the lot is linked to the batch.
- 4
Cutting and treatment
Operators log pieces per shift on each operation. Gears going for case hardening are placed in a load. The outside house is recorded as the process owner.
- 5
Grinding and inspection
Returned gears are ground and measured. Tooth charts are saved to the batch, and any gear outside limits is held for rework or scrap.
- 6
Packing and despatch
Accepted gears are marked, packed with the inspection report and a delivery note, and the batch is closed with its actual cost.
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.
- Estimate/Quotation Management
A gear is priced from blank, cutting minutes, heat treatment and grinding time, and each revised price is kept beside the earlier one.
- Batch and Serial Tracking
The forge heat number travels with the blank into every gear cut from that lot, so a hardness query reaches the right batch.
- Work Order Management
Each batch opens with its turning, tooth cutting, heat treatment and grinding steps, and machines are loaded against the due date.
- Job Work Management
Gears sent for carburising stay on the route as pending outside work, and the returned hardness report closes the step.
- Quality Control
Profile, lead, pitch and runout readings are saved to the batch, and any gear outside the drawing limit is held.
- Bill of Materials
A gear set lists its blank, bore sleeve and marking requirements, so a repeat order draws the same material and operations.
- Goods Receipt (GRN)
A forging delivery is counted against the purchase order and its heat number checked before the blanks are accepted to stock.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For the owner
Watch open batches, outside heat treatment loads, rework cost and quotations awaiting a reply without walking the shop.
For production planners
Release batches to hobbing and grinding machines, and see which cutter or blank lot holds a job up.
For machine operators
Open the batch route and setup sheet at the machine, and key in the pieces cut when the shift closes.
For the tool room
Track hob and shaving cutter counts, regrinds and spares, so a cutter is changed before it drifts.
For inspectors
Record tooth charts and dimensional checks against each batch, and hold a gear that falls outside the drawing.
The numbers the owner asks for.
- Batches by operation, machine and due date
- Gears cut per hob and shaving cutter
- Outside heat treatment loads open and returned
- Tooth inspection results by part and batch
- Rework and scrap hours against quoted cost
- Blank lots with remaining stock
- Orders delivered against promised date
Who this is built for.
- Shops that hob, shape and shave spur and helical gears for gearbox makers
- Makers of bevel and worm gear sets for machinery
- Firms that cut gear blanks and send teeth to outside grinding
- Sprocket and timing pulley makers that share the same hobbing machines
- Gearbox builders with an in-house gear cutting section
When it is not the right choice.
- A shop that only buys finished gears and resells them does not need a route and cutter record.
- Fastener and spring makers will find Automotive Fastener Manufacturer Management Software or Spring 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
- Gear tester data import
- Accounting export
- Barcode labels
Questions owners ask before a demo.
Can we keep the drawing revision with each order?
Yes. The revision is saved on the part and copied to every order. When a customer revises a tip relief or bore size, the older orders still show what they were cut to.
How is hob life tracked?
Operators enter gears cut per shift against the cutter fitted. The tool room sees the running count and the number of regrinds. A warning appears near the limit you set.
Can a returned heat treatment load be matched to gears?
Yes. A load lists the batches and pieces sent out. When the process house returns, the case depth and hardness values are attached to those batches.
Does it work for helical and bevel gears too?
Yes. Fields such as helix hand, spiral angle and ratio are added for the gear types you make. Inspection limits are set for each type with your quality staff.
Can the inspection chart go to the customer?
Yes. Inspection readings sit against each batch and print on a certificate format you agree with us. Send it to the customer by email, or slip it into the carton.
What happens to scrap and rework?
Failed gears are recorded with the operation that caused it. Then regrind or lap hours are added to the batch cost. The next quotation can use the true figure.
Can our outside heat treater see the system?
Not by default. Your staff book the load and enter results returned on the supplier report. A supplier login is a possible extension scoped with you.
How much does it cost?
No price is published here. It depends on how many machines, users and routes are set up, so you watch a demo built on your own gear types and the figure then arrives in writing.
Can we move our spreadsheets in?
Part lists, open orders, cutter lists and customer contacts are taken out of your spreadsheets, and a sample load is checked with you before the rest.
Who helps when a route needs a change?
GullySystem staff make the change. A new operation or a different inspection limit is changed in the set-up, with a note kept of what changed.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Gear 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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