One record for distribution transformers, boards and ring main units.
One record carries the tender, the quoted loss limits, drawing approvals, core steel and copper stock, unit routing, routine tests, witness calls and dispatch for each unit. Each unit has a serial number. Design office, stores, winding shop and test bay all see the same unit, and the buyer’s inspector is booked against it before the oil goes in.
- Product families, routings and test sheets set up as you build them
- Open orders, stock and unit history migrated
- Changes to routings and templates handled by GullySystem staff when asked
Makers of distribution transformers, feeder pillars and ring main units get one place for tenders, drawings, core steel (CRGO) and copper stock, build routing, routine tests and witness calls. Each unit has a serial number. That number is tied to its core lot, its coils, its oil lot and its test report, so a question years later has one answer.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Tender
A tender arrives with rating, voltage ratio, vector group such as Dyn11, loss limits and delivery terms, and the offer is priced from core, copper, oil and tank. The quoted losses are stored with it.
- 2
Drawing approval
The design office issues general arrangement and core drawings, and every buyer comment is logged round by round until the utility signs. Only the approved revision goes to the shop floor. A draft never does.
- 3
Materials
Silicon steel, winding wire, oil and fittings are reserved for the order, then issued against units as the core room and winding shop ask for them. A shortfall in kraft paper or bushings shows early.
- 4
Build
Units pass through core stacking, winding, drying, tanking and oil filling, while boards and pillars follow sheet fabrication, busbar fitting and wiring instead. Each step is signed off by its supervisor.
- 5
Test and inspection
Routine tests are recorded against each serial number, and the buyer’s inspector is booked for any witness test the contract demands on that rating. The outcome is saved with the unit, including the loss figures read at the test bay and the inspector’s name.
- 6
Dispatch
Rating plates, test reports and packing lists are matched before the trailer is loaded, and nothing leaves with a mismatch. The invoice then follows the order.
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 tender is priced from core, copper, oil and tank, and the loss figures quoted in the offer stay with each revision for later comparison against the test bay.
- Bill of Materials
Each rating has a bill listing core steel, winding wire, kraft paper, tank and fittings, so stores can reserve materials before the first lamination is cut.
- Work Order Management
A unit’s work order follows core stacking, winding, drying, tanking and oil filling, and each supervisor closes his own step at the bay as it finishes.
- Quality Control
Ratio, resistance, insulation and loss readings are entered per serial number, and a unit outside its limits is held at the test bay before dispatch.
- Batch and Serial Tracking
Each unit’s serial links to its core lot, coil records and test report, and the rating plate data is printed from that same record.
- Project Document Management
Drawings and buyer comments are filed against the order, and only the approved revision reaches the shop floor, so no core is cut to a draft.
- Stock Tracking and Alerts
Silicon steel and winding wire are tracked by lot and weight, with a warning raised when a coil runs low for the orders in hand.
- Job Work Management
Units sent out for outside processes, or returned for rewinding, travel on their own job route and come back against the original record, with their history intact.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For design engineers
Prepare drawings and log buyer comments round by round. Release approved revisions to the core room only after the utility has signed, because a draft never leaves the office.
For tender estimators
Price units from the bill of core, copper and oil, store the loss limits quoted, and follow each tender through to its outcome and the buyer’s purchase order.
For winding and assembly supervisors
See which units wait for coils, drying or tanking. Record each step as it finishes, with the bay, the date and the supervisor who closed it, so the schedule stays honest.
For the test bay
Enter ratio, resistance, insulation and loss readings per unit, then mark it passed or held, with the vector group check on the same sheet as the megger reading. No loose paper.
For dispatch staff
Match plates, reports and packing lists before a consignment leaves the yard, because a mismatch holds the trailer at the weighbridge until someone corrects the plate. Check twice.
The numbers the owner asks for.
- Units by build stage and by order
- Quoted against measured losses per unit
- CRGO and winding wire consumed by order
- Witness calls booked with outcomes
- Drawings awaiting buyer approval
- Rewind jobs open by customer
Who this is built for.
- Makers of distribution transformers built to utility specifications
- Manufacturers of ring main units and feeder pillars
- Plants building distribution boards and metering panels
- Workshops that both build and rewind transformers
- Suppliers who sell by tender to utilities and large contractors
When it is not the right choice.
- An electrician who assembles small boards on site can work from drawings and notes, and has no use for a serial register.
- A shop whose output is mainly lineups of withdrawable panels should look at Switchgear Manufacturer Management Software, which follows that kind of build more closely.
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
- Accounting export
- Label printer
- Drawing file storage
Questions owners ask before a demo.
Can the promised loss be checked against the test result?
Yes. The tender stores the loss limits and the routine test enters the measured values beside them. Any unit above a limit is flagged before it reaches the dispatch bay.
How is core steel tracked?
Coils are received by lot and weight and consumption is booked to each unit, so the lot number shows on the unit’s record beside its winding sheet.
Can it follow oil filling?
Oil is issued by quantity against the unit at the filling step, with the drum or tanker lot and its breakdown voltage noted beside it.
Does it manage the buyer’s witness test?
Yes. A call is booked against the unit, and the inspector’s name and result are saved into the dispatch file for the buyer’s store.
Can pillars and boards use the same system?
Yes. They follow a shorter route of sheet fabrication, busbar fitting and wiring, and they share the same serial register and test records as the transformers.
How are repairs recorded?
A returned unit opens a repair job with its own steps and its own history, and the dates are written on it. The original serial is linked if the unit is known, so an earlier rewind is visible to the next shift.
What decides the price?
Users, product families and test sheets set the figure. We walk through a sample transformer record with you and your estimator, then put the price into a written proposal.
Can we keep drawings in the system?
Yes. Every comment round stays attached to the order beside its drawing, and the approved revision is easy to spot among the superseded ones.
How do we bring in existing data?
Core steel, winding wire and units in progress are imported from your spreadsheets. Your design engineers then compare loaded stock with the bin cards, line by line, before any real order goes in.
Does it certify our products?
No. It stores your records and reports. Compliance with IEC 60076 or a utility approval stays with your quality and regulatory team, who sign the test certificates.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Power Distribution Equipment Maker Software with your own data.
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