Billets, dies, strikes and trimmed forgings on one record.
Forging enquiries, bar stock by mill heat, die sets, induction heater and press logs, flash trimming, normalising, magnetic particle inspection and dispatch all sit on one job record. The heat number stays with the lot from the saw to the dispatch bay. A crack found at the customer is traced back to the bar and the die, and the press shop, die shop, furnace area and inspection bay open the same lot.
- Your bar grades, die sets and forging part numbers are entered the way you run them now
- Running orders, the die list and mill certificates come across with them
- Changes to a part, a test set or a report layout are made by GullySystem staff when you ask
Hot Forging Company Management Software runs bar stock, billet cutting, die sets, hammer and press logs, flash trimming, normalising, magnetic particle inspection and dispatch for forging shops. Each forging lot records its bar heat number, die set and scrap, so a lap, crack or short fill is traced to the steel and the die.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Enquiry and die quotation
A forging drawing arrives. The estimate adds flash and scale loss to finished weight, prices the die and the piece rate, and the quotation keeps every revision for the buyer’s later questions.
- 2
Die and tryout
The order creates a part master. The die set is linked, cut or repaired, and a tryout lot is checked on the gauges before regular production is released to the press.
- 3
Billet cutting
Bar is drawn from stock by heat number, cut on the band saw to billet weight and issued to the forging lot with that heat attached to every piece.
- 4
Heating, forging and trim
The lot runs through the induction heater and press with billet temperature, strike count and operator logged against it. Flash goes to the trim press, and pieces are counted.
- 5
Normalising and inspection
Forgings are normalised or quenched and tempered, shot blasted, then checked for cracks by magnetic particle, for hardness on a Brinell tester and for dimensions on gauges. Failing lots are held.
- 6
Dispatch
Approved lots leave packed with heat number and inspection report. The invoice is drawn straight from the dispatch entry, so billing never waits for a retyped sheet from the packing bench.
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 adds flash and scale allowance to finished weight, then prices the die and the piece rate, with every revision kept for later enquiries.
- Bill of Materials
Each part master lists grade, billet weight and downstream steps, so an order knows what bar to cut on the saw and what follows the press.
- Batch and Serial Tracking
The mill heat number is carried through sawing and forging, so a finished lot shows the exact steel it was made from and its certificate.
- Work Order Management
An order releases the lot to a hammer or press, and heater temperature, strikes and operator are recorded against it as the work runs.
- Production Planning
Lots are planned across hammers and presses against die availability and billet stock, so the next die is ready on the rack before the line stops.
- Quality Control
Crack, Brinell and gauge results are recorded per lot, and a failing lot is held at the inspection bay before it can be packed or invoiced.
- Job Work Management
Forgings sent to machining or coating vendors return by quantity against the job, with rejects charged back to the vendor on the same record.
- Fixed Asset Register
Die sets are held as assets with strike count, regrind history and rack location, including those out at a repair shop awaiting return.
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, material loss by part, die life and outside process cost without walking the shop floor to ask the foreman for a verbal report.
For the die shop
Know which die is due for regrind, keep its repair history, and release it for the next lot once the tryout pieces pass.
For heater and press operators
See the next lot, its billet heat and its proven settings, then log strikes and temperature as the work goes on at the hammer.
For furnace staff
Build batches by lot, record the furnace cycle and attach each hardness reading to the right part number.
For quality inspectors
Record crack, hardness and gauge results, hold failing lots, and print the inspection report that travels with the shipment to the buyer.
The numbers the owner asks for.
- Material loss per part, billet against forging and flash
- Die life used and regrind due, by die set
- Scrap by lap, short fill and crack, split by die and press
- Lots in normalising or quench with hardness status
- Outside machining and coating lots out and due back
- Customer complaints traced to bar heat and die
- Orders by customer with dispatch dates
Who this is built for.
- Open die and closed die forging shops supplying machinery makers
- Hammer and screw press plants forging carbon, alloy and stainless steel
- Forging shops that saw billets, normalise and shot blast in house
- Companies that keep customer-owned die sets on their racks
- Forging suppliers to bearing, gear, flange and pipe fitting makers
When it is not the right choice.
- Cold forging companies will find Cold Forging Company Management Software closer.
- A shop that only buys forged blanks for machining 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
- SMS
- Accounting export
- Barcode labels
Questions owners ask before a demo.
Can it track strikes per die?
Yes. Every lot adds its strike count to the die set. The register shows the total since the last regrind and flags a die that reaches the limit you set for that die family.
Does it keep the mill certificate with each forging?
Yes. The bar heat number travels with every billet, so a finished lot shows its heat and the mill certificate behind it. An auditor sees the chain in one screen.
How is material loss calculated?
Billet weight goes in, and forging weight and trimmed flash come out, so the gap is scale and scrap. It is shown per part and per lot.
Do hammers and presses run in one plan?
Yes. Each hammer and press is a work centre with its own rate and capacity, and lots are planned across all of them against die availability and billet stock.
Does it handle normalising batches?
Yes. Lots are loaded into a furnace batch, the cycle is recorded, and hardness results attach to each lot in that load. A reading cannot land on the wrong part.
What about dies that belong to customers?
Each die set has an owner, a rack location and a strike history. A die at a repair shop shows as out until it returns to the rack.
What if a customer changes the drawing?
A new revision is added to the part master. Orders are checked against the current revision before a lot is released to the press, so old drawings do not slip through.
Do invoices export to our accountant?
Yes. Invoices and receipts export in a layout agreed during the first workshop, and forging records go to spreadsheets as well.
What decides the cost?
Users and recording stations drive the cost. A trial on a sample of your own forgings comes first, followed by the written quotation.
Who maintains it after go-live?
GullySystem hosts it and applies changes to defect codes, furnace cycles and report layouts. Your quality lead decides the rules, and we make the change.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Hot Forging Company 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