Part revisions, customer schedules, assemblies and rejections tracked per component.
Every part number sits at its drawing revision, beside the customer’s weekly call-off, the mould and cavity that cut it, and the first-article report that cleared it. Degating, ultrasonic welding and insert cells finish it against a routing, with resin lot and regrind ratio recorded per run. A return finds its cavity.
- Part codes, drawing revisions and tool lists keyed in following each customer’s issue
- Open schedules, tool records and current stock migrated
- Changes to part and packing records carried out by us at your request
Plastic component makers hold drawing revisions, customer call-offs, mould ownership, first-article reports and degating, welding and insert cells in a single record per part number. Each part shows its mould, cavity, resin lot and tray specification. A return traces back to the shot run and cavity. A superseded revision cannot be picked.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Drawing and quotation
The buyer’s drawing revision, tool ownership terms, resin grade and volume are recorded, and the quote prices moulding at cycle time before adding each assembly step and returnable packing. No price without a revision.
- 2
Tooling and first article
The mould enters the register under its owner, with cavity count and shot counter, and measured samples with the customer’s approval are stored before volume release. Volume waits for sign-off.
- 3
Schedule intake
Each weekly release is loaded and compared with the last, so the planner sees which quantities rose, fell or moved date for every part number. Changes are listed, not hunted for.
- 4
Moulding and cells
Runs are planned against the schedule and the press that holds the mould, then parts move through degating, trimming and insert fitting with counts logged at each step. Every step reports a number.
- 5
Kitting and dispatch
Parts are packed into trays to the customer’s count and labelled with part number and revision, and a delivery note travels with the load recording the tray count out. Trays are counted out.
- 6
Returns and corrective action
A customer return is linked to its run, mould and cavity, the cause is written down, and the corrective action stays open until the customer confirms it. Closure needs the buyer’s reply.
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
Quotes cover moulding, degating, assembly and returnable trays, and each remembers the drawing revision and resin grade it priced.
- Product Management
Each part number holds its drawing revision, mould and packing specification, and a superseded revision is blocked once its cut-in date passes.
- Order Management
Weekly releases are loaded beside the last, so quantities that rose, fell or moved date are listed for the planner before the press plan changes.
- Asset AMC Tracking
Each mould is listed with its owner, rack, cavity count and shot count, which answers a customer’s tooling audit without a search.
- Quality Control
Measured sample dimensions and the customer’s approval date are kept against the part and revision, ready for any later dimension dispute.
- Batch and Serial Tracking
Resin lots, regrind and inserts are recorded per run and linked to the trays shipped, so a suspect lot can be followed forward to customers.
- Work Order Management
Degating, trimming and assembly steps are logged by cell with passed and scrapped counts that must reconcile with the shots moulded.
- Sales Returns and Credit Notes
A returned part is linked to its delivery, run, mould and cavity, and the corrective action stays open until the customer confirms.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For plant managers
Watch schedule changes, stock by revision, return rates by customer, open corrective actions and mould utilisation together on one screen, without asking four departments for a spreadsheet. Monday starts with facts.
For planners
Compare each weekly release with the last, rebuild the press plan around changed quantities, and group mould changes so set-up hours on the larger presses are not wasted. Fewer changeovers, steadier runs.
For cell supervisors
Log counts at each assembly step, pass or scrap parts against the routing, and raise insert shortages from the cell terminal before the line starves. The whiteboard can go.
For quality engineers
Keep first-article reports, take returns back to their run, mould and cavity, and close corrective actions with the customer’s written reply attached to the record. Evidence stays with the part.
For logistics staff
Pack trays to count, print labels with part number and revision, and chase the returnable trays and dunnage still sitting at customer plants. Balances show who holds what.
The numbers the owner asks for.
- Customer call-off changes by part number and week
- Stock by part and drawing revision
- Returns by customer, part, mould, cavity and cause
- First-article approvals with sign-off dates
- Cell throughput: passed, scrapped and reworked
- Returnable trays and dunnage held per customer plant
- Moulds by owner with shot counts and next maintenance
Who this is built for.
- Moulders supplying housings and trims to appliance and equipment builders
- Makers of connectors, cable clips, junction boxes and fittings
- Suppliers of interior trims, door pockets and under-bonnet covers
- Companies that mould and assemble parts with metal inserts, springs and gaskets
- Suppliers delivering kits in returnable trays against weekly call-offs
When it is not the right choice.
- A shop that sells catalogue items over the counter, with no drawings or schedules, can manage with a stock book.
- Companies that are mainly bottle or pipe makers will find Blow Moulding Company Management Software or Plastic Extrusion Company 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
- Customer schedule files
- Barcode label printer
- Accounting export
Questions owners ask before a demo.
Can two revisions of one part be live together?
Yes, for a defined cut-in period, with stock tracked by revision and the old one blocked from picking once the cut-in date passes. Overlap is deliberate, never accidental.
How are weekly releases compared?
Each new release is loaded beside the last, and the planner gets a list of parts where quantity or date moved. The list drives the plan.
Can we show a customer the first-article record?
Yes. The report with its measurements, sample date and sign-off sits under the part and revision, so it can be printed or exported when a buyer asks.
Does it follow returnable trays?
Yes, trays are counted out with each load and counted back on return, and the balance held at every customer plant appears on one screen with its last movement date. Dunnage follows the same rule.
How does a customer return reach the cause?
The return is linked to its delivery and so to the run, mould and cavity, and a corrective action is raised and followed until the customer accepts it. Repeat cavities become visible.
Can it work with a customer’s own supplier portal?
Where a portal offers a file or data link, a connection can be scoped as extra work, and otherwise schedules load from the customer’s file. Scope is written down first.
Can we export part and tooling records?
Part registers, mould lists and return logs export to files, with the layout agreed in the written proposal before work starts. Nothing is locked in.
What should I expect from a demo?
One of your part numbers goes through quote, schedule load, moulding run, assembly, kit packing and a customer return, and the proposal sets out users, sites and the figure. Bring a real drawing.
Who looks after the system afterwards?
GullySystem staff handle questions and master data edits, and planners and quality engineers are walked through the first weekly release cycle on their own parts. Support stays with us.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Plastic 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