One system for work orders, bill of materials, job cards and dispatch.
Run a small or mid-size manufacturing unit from one record set. A sales order becomes a work order. What the store must issue comes from a multi-level bill of materials, and job cards follow the batch through cutting, machining, assembly, finishing and packing. Rejections, rework and subcontracted job work are counted at the stage where they happen. Dispatch raises the GST invoice and the delivery challan from the same work order.
- Parts, grades, stages and your bill of materials entered as the drawing reads
- Customer, supplier, item and opening stock records migrated from your files
- Stage lists and routing changes handled by our staff when a product changes
A sales order becomes a work order in Manufacturing Production Management Software, which GullySystem sets up for machine shops, fabrication units and small assembly plants. Job cards follow each batch through cutting, machining, assembly and packing. Material issues, rejections and subcontracted job work are counted at the stage where they happen. A batch stays traceable to the work order that made it. Part numbers and stage names follow your floor.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Enquiry and costing
A buyer sends a drawing, a sample or a specification. The unit works out material, machine time and job work charges. A quotation then goes back against that enquiry.
- 2
Sales order
The buyer confirms by purchase order, mail or WhatsApp. Quantity, rate, part number, drawing revision and the promised delivery week are recorded on the order.
- 3
Work order and material planning
A work order opens for a batch. The bill of materials lists what the store must issue, and shortages go to purchase as a requirement.
- 4
Production stages
Job cards move the batch through cutting, machining, welding, assembly or filling. Each stage records quantity passed, rejected and sent for rework.
- 5
Quality and packing
Final inspection records readings or checks against the part. Accepted pieces are packed, labelled and taken into finished goods stock.
- 6
Dispatch, billing and follow-up
A delivery challan and a GST invoice are raised from the work order. Payment follow-up and the next order from the same buyer are tracked after.
What is inside.
Every module can be switched on, left out or changed to match how your team already works.
Enquiries and production quotations
Log buyer enquiries with the drawing, sample or specification attached, cost material and machine time, and send a quotation with revisions kept.
Learn moreSales orders and delivery commitments
Hold confirmed orders with part number, drawing revision, quantity, rate, schedule and the delivery week promised to the buyer.
Learn moreMulti-level bill of materials and routing
Keep the material list and the stage sequence for each part, with drawing revisions, scrap allowance and the machine each stage runs on. A sub-assembly carries its own list.
Learn moreWork orders and batch planning
Release a work order for a batch, set its target date, and see the load already queued on each machine and stage.
Learn moreJob cards by production stage
Record quantity passed, rejected and held at cutting, machining, welding, assembly, finishing and packing, with operator, machine and shift on each card.
Learn moreRaw material and consumable stock
Count bars, sheets, castings, resin, fasteners, packing film and consumables by grade and size. Every issue carries a work order number.
Learn morePurchase orders and supplier records
Raise orders on material suppliers from the shortage list, receive against them with inspection, and keep the supplier ledger and rate history.
Learn moreQuality checks and rejections
Save inspection readings and check results, count rejection, rework and scrap by stage and reason, and hold a batch until it is cleared. Each batch traces back to its work order.
Learn moreJob work sent outside, or subcontracting
Track material sent to a job worker for plating, heat treatment, powder coating or printing on a challan, and reconcile what returned against what went.
Learn moreLabour, shift and piece-rate records
Record shift attendance for operators and contract labour, and count piece-rate output from the job cards each person marked done.
Learn moreFinished goods, dispatch and billing
Take accepted pieces into finished goods, pack and label them, and raise the delivery challan and the GST invoice with the fields an e-invoice or e-way bill filing needs.
Learn moreThe business modules it is built from.
Each one is also available on its own, or inside a system built for you.
- Bill of Materials
Each part carries a multi-level material list and routing with drawing revisions, scrap allowance and machine per stage, and sub-assemblies hold their own lists.
- Work Order Management
Planners release a work order for a batch with a target date and see the load already queued on each machine and stage.
- Production Planning
Batch work orders are scheduled against machine and stage loads, so the planner can see where capacity is already taken before setting the next date.
- Quality Control
Inspectors save readings and results, count rejection, rework and scrap by stage and reason, and hold a batch until cleared, traceable to its work order.
- Job Work Management
Material sent out for plating, heat treatment, powder coating or printing goes on a challan, and returns are reconciled against what left the plant.
- Purchase Order Management
Buyers raise orders on material suppliers straight from the shortage list, receive against them with inspection, and keep each supplier’s ledger and rate history.
- Order Management
Confirmed sales orders hold part number, drawing revision, quantity, rate and schedule, along with the delivery week promised to the buyer.
- Stock Tracking and Alerts
Stores count bars, sheets, castings, resin and fasteners by grade and size, and every issue to the floor carries a work order number.
How we would put it in.
Setup, data migration, integrations and anything built on top.
Topics beyond the modules.
Each page covers one part of how the system is used, connected or controlled.
Manufacturing Software Views for Owners, Planners and Supervisors
Each person in the unit reads the part of the production record that their own work needs.
Learn moreReports for Manufacturing Owners and Production Managers
These reports are built from the work orders, job cards, issues and dispatches already entered.
Learn moreManufacturing Software Connections to WhatsApp, Tally and Scales
The production system links to the messaging, payment, accounting and weighing tools a unit already has.
Learn moreOne system, each person sees their part.
For owners
See open orders, work orders by stage, machine load, rejection by reason, material shortages, dispatches made and money due from buyers.
For production planners
Release work orders, read the bill of materials, check material availability, sequence batches on machines and move target dates.
For shop floor supervisors and operators
See the job cards queued for your stage or machine. Mark quantity passed and rejected. Raise a hold when a piece is doubtful.
For stores and purchase staff
Issue material against a work order, receive supplier deliveries with inspection, and watch grades that fall below reorder level.
For accounts and dispatch
Raise challans and GST invoices from closed work orders, record payments, and read buyer outstanding by order.
The numbers the owner asks for.
- Work orders open, in progress and closed
- Production by stage, machine and operator
- Material consumed against the bill of materials
- Rejection, rework and scrap by stage and reason
- Job work sent outside, by job worker, with quantity returned
- Raw material stock and shortages against open orders
- Dispatches, pending orders and buyer outstanding
Who this is built for.
- Machine shops turning and milling components to a buyer drawing
- Sheet metal and fabrication units with cutting, welding and finishing stages
- Small plants assembling pumps, panels or machines against order
- Food and packaged goods units producing in batches to a recipe
- Plastic moulding and extrusion units running jobs machine by machine
- Manufacturers who send plating, heat treatment or printing to outside vendors
When it is not the right choice.
- A trading firm that buys and resells without making anything will find Wholesale B2B Ordering Software closer to its work.
- A single craftsman working to order with no stages, store or job work may find a notebook and a GST billing app enough.
- A plant running continuous process control from instruments needs plant automation, not a production record system.
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
- UPI and payment gateway
- Tally export (quoted separately)
- Barcode or label printers
- Weighing scales
- Biometric attendance devices
Questions owners ask before a demo.
Can a bill of materials have more than one level?
Yes. A sub-assembly can carry its own material list and stages, and a parent part draws it in. How deep your structures go is settled during set-up.
How is material issue tied to a work order?
The store issues against the work order number, so consumption sits beside what the bill of materials expected for that batch quantity.
Can we plan the week against machine capacity, or only see the queue?
Both, within limits. The load already queued on each machine and stage is visible, and a planner sequences batches and moves target dates by hand. There is no automatic scheduler.
Does it tell us the production cost of a batch?
Costing sits at the quotation stage, where material, machine time and job work charges are worked out before a price goes back. Actual cost per unit for a finished batch is not calculated here. Material consumed, rejection and job work for that batch are all on record for your accountant.
Can rejections and scrap be counted stage by stage?
Yes. Each job card records quantity passed, rejected and sent for rework, with a reason picked from a list your supervisors agree on.
Does it track job work sent out to a job worker?
Yes. Outward and inward quantity against each vendor challan is kept, and the shortfall shows until it is written off or returned.
Can operators mark job cards without a computer, and what if the line drops?
A phone or a tablet on the floor is enough for marking a stage done. The system is hosted, so the shed needs a working connection. Where signal is weak, units keep one terminal in the store and mark cards there.
What about drawing revisions?
The revision is held on the part, the order and the work order, so a batch made to an older revision stays identifiable.
Will these figures go into Tally?
Not in the standard set-up. Sales, purchase and stock figures can be read inside GullySystem. An export to Tally is quoted separately, after your accountant fixes the ledger heads.
Do we need this for a unit with two machines?
Perhaps not yet. With one product and no outside job work, a register may still do. A free technology audit can say so plainly.
Wondering what it costs? Six questions give you a written scope and the buckets any quote should separate.
Businesses that use this.
Related products.
Selling these goods online as well?
These e-commerce pages describe the online side: the storefront, dealer ordering and the connections to a system like this one.
See Manufacturing Production Management Software with your own data.
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