Board revisions, firmware builds, assembly orders, test results and repairs for each serial number.
Follow product families, board and firmware revisions, reel stock, assembly and test orders, repairs and OEM schedule lines down to the serial number of each unit. Every unit shipped carries its own record: the bill of materials used, the burn-in rack it sat in and the buyer who took it. Support and engineering open the same card when a drive comes back, and nothing about its build has to be guessed from an old email or a handwritten note.
- Product families, revisions and test plans entered as your engineers define them
- Part masters, serial history and open OEM orders migrated
- Changes to build steps and test forms made by GullySystem staff on request
This system keeps product families, bills of materials, assembly and test orders, serial numbers and repair returns together for makers of drives, controllers and power supplies. Each unit links to its board revision, firmware build, burn-in result and customer. End-of-life parts show every product and order that depends on them.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Enquiry and quotation
An OEM or distributor asks for a quantity of a drive, controller or power supply, sometimes with a custom label or a parameter file loaded at the factory. Quote it from the price list, stating the board revision offered.
- 2
Order and kit
A confirmed order becomes a build order against the current bill of materials. Storekeepers pick reels, trays and housings into a kit and record the lots that left the store, so a shortage of a connector or a crystal shows early.
- 3
Assembly
Boards are populated on your own pick-and-place line or sent to a contract assembler and received back. Solder paste printing, reflow, optical inspection and any hand soldering are recorded against the board lot.
- 4
Flash and functional test
Firmware is flashed, a serial number is assigned and the unit goes onto a test jig. Measured output voltage, ripple and the pass or fail result are attached to the serial number.
- 5
Burn-in and release
Units run in the burn-in rack for the period the test plan sets, and an engineer reviews the log and releases the batch. Failed units move to the repair bench with the fault noted. Passed units wait for packing.
- 6
Shipment and support
Units are packed with a test report and a delivery note. A repair or firmware update years on is booked to the serial number the unit left with, and the history stays whole.
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
Reference designators, quantities and approved alternate makers sit on one bill, so a second-source capacitor is chosen once and reaches stores and purchasing.
- Batch and Serial Tracking
Each drive or controller gets a serial number at the test station, stored with its board lot and firmware build for later fault calls.
- Work Order Management
A build order lists the kit, the board lot and the test plan for a batch, and records each stage as operators finish it.
- Quality Control
Jig measurements, burn-in duration and an engineer’s sign-off are attached to the unit, and a failed unit is held from shipment.
- Job Work Management
Kits sent to an outside assembler leave under a dispatch note, and boards returned are matched to it with their defect counts.
- Stock Tracking and Alerts
Reels and trays are tracked by lot with shelf-life dates, and a short or expiring component raises an alert before a kit is picked.
- Ticket Management
A returned drive becomes a numbered repair ticket carrying the customer’s fault report, parts replaced, promised date and warranty status.
- Quote & Proposal Management
Quotations draw on the product price list with quantity breaks and lead times, and an accepted quote turns into an order with schedule lines.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For owners and the managing director
See orders due, units in test, parts at risk of end of life, repairs open and payments pending, by customer, without asking the planner.
For design and test engineers
Release a revision, mark the serial number it begins at, and review burn-in logs against the limits in the test plan. Open any returned unit to see its exact build.
For production and the stores
Pick kits, log reflow and flashing, and see which reels are short. Quarantined lots stay visible, so a doubtful reel is not issued to a kit by mistake.
For purchasing
Watch lead times and end-of-life flags, compare distributor quotes and place orders only with approved sources. Alerts come before the last-time buy closes.
For the support and repair desk
Look up a serial number, read its build and test history, and book the repair with the parts used. Parts used are saved on the same card.
The numbers the owner asks for.
- Build orders by status, product family and promised date
- Units by board revision and firmware build, with customer
- Components flagged end of life, with stock and open orders affected
- Burn-in and functional test failures by product and by cause
- Repairs received, completed and pending, with parts and cost
- Contract assembler receipts and defect counts
- OEM and distributor orders open, with dues by customer
Who this is built for.
- Makers of motor drives, soft starters and frequency inverters
- Builders of PLC modules, I/O units and industrial communication gateways
- Manufacturers of industrial power supplies and converters
- Companies that assemble HMI panels and operator terminals
- Firms producing instrumentation electronics in small, repeat batches
- Makers that do their own assembly and also use a contract assembler
When it is not the right choice.
- A hobby bench that builds a few boards a year can use a simple parts list and a notebook.
- High-volume consumer product makers with automated lines will find Electronic Product 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
- Test bench result files
- Barcode and label printers
- SMS or WhatsApp
- Accounting export
- Distributor price and stock files
Questions owners ask before a demo.
Does it record the firmware version on each unit?
Yes. At final test, the flashed firmware build is stored against each unit serial and its PCB batch. A search by firmware build lists every unit that carries it.
Can we see which products use a part that is being discontinued?
Yes. Flag the part as end of life and the system lists each bill of materials, stock lot and open purchase order that touches it. Engineering and purchasing look at one list.
Will it read results from our existing test jigs?
Yes, when the jig saves a result file. Files can be attached to the unit by import, or entered by the operator at the station, and the jig software stays as it is.
How are boards built by an outside assembler handled?
Kits go out under a dispatch note and boards come back against it. The defect count and the charge are held on the same order, so quantity out and quantity back stay matched.
Can a repair be linked to the original build?
Yes. The returned unit is booked by serial number, so its board revision, firmware and test report show beside the new fault. Parts fitted during the repair go onto that same card.
How are engineering changes controlled?
A revision is released with a reason, an effective date and the serial number it starts from. Kits and build orders pick up the new bill of materials from that point.
Can distributors and OEMs see their own orders?
Yes. A customer view shows order status, shipments and invoices for that customer only, and which screens a buyer sees is settled with you before they log in.
What happens to our current spreadsheets?
Part lists, serial registers and customer files are cleaned and loaded before go-live. A copy of every original sheet stays with you.
Can we take our records with us if we ever leave?
Yes. Serial history, bills of materials and order records export as spreadsheets, and we agree the file format and handover steps in writing before any work begins.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Industrial Electronics 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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