One record for billet heats, dies, forging lots and outside treatment.
Follow a forging from bar receipt through press and hammer planning, die life, induction heater logs, weight and profile checks, magnetic particle testing and outside normalising to the dispatch bay. Each lot carries its steel heat, its die set and its test results. The die shop, the press crew, the inspectors and the dispatch desk all read one lot.
- Your part numbers, die sets and steel grades go in as you name them
- Bar in stock, lots still open and jobs out at vendors are brought over from your registers
- GullySystem staff change check sheets and fields whenever you ask
GullySystem sets this up so a precision forging shop can follow steel from bar heat to the dispatch bay. A lot records the billets, the heating, the die set, the weight and profile checks and the crack tests, and returns from outside treatment are matched against what was sent.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Customer order and drawing
An order is entered against a part number, its drawing revision, weight tolerance and finish allowance, and the delivery dates and schedule releases are held with it. One screen shows the whole job.
- 2
Bar receipt and billet cutting
Bars are booked by heat number, grade and diameter. Billets are sawn to the set weight, and the heat number is carried onto every billet lot, so a bin of cut pieces never loses its origin.
- 3
Press planning and heating
Planning places the lot on a press or hammer with a die set that has life left, and heating settings are logged as billets pass through the induction heater or furnace. The operator initials each run.
- 4
Forging, trimming and checks
Blocker, finisher and trim operations run under the lot, and weight, profile and flash are checked at set intervals before shot blasting follows. A bad reading stops the press.
- 5
Testing and outside treatment
Magnetic particle and hardness results are recorded against the lot. Lots going for normalising, tempering or rough machining leave with counts, and they return with a vendor report that is matched to what was sent.
- 6
Packing and dispatch
Forgings are packed in bins or crates with a label carrying part, lot and heat. Paperwork for the buyer is produced from that same lot, so the crate and the invoice cannot disagree.
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.
- Order Management
Orders are held by part and drawing revision, with finish allowance and release dates, so a revised drawing never overwrites the one a lot was made to.
- Batch and Serial Tracking
Bars are booked by heat, billets keep that heat, and every lot carries it forward to the dispatch label.
- Production Planning
Lots are placed on presses and hammers by tonnage, billet size and die availability, and a die past its count blocks release.
- Fixed Asset Register
Each die set is listed with its forgings run, repairs and re-sinking dates, so the die shop and planner see the same wear figure.
- Quality Control
Weight, gauge and flash readings are entered on sheets laid out per part, and a result outside the drawing holds the lot.
- Job Work Management
Lots sent for quench and temper or rough machining leave with a count, and the returned count and report are checked before release.
- Goods Receipt (GRN)
Bars are checked in at the gate against the purchase order and mill certificate, then issued to the saw by heat number.
- Invoice Management
The delivery note and tax invoice are raised from packed lots, with currency and tax rules set per buyer.
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 lots running, dies close to retirement, lots held for magnetic particle results, and the bar steel issued against the forging weight shipped. The gap between them is your scrap and flash.
For planners
Match lots to presses and dies, watch the turnaround at the normalising vendor, and keep delivery dates against customer schedule releases in view. Late returns show first.
For the die shop
Open the register to see which blocker and finisher sets are due for repair or re-sinking, then record the work done with its date. The count resets.
For quality staff
Enter checks, release or hold lots, and review scrap causes by die and shift. Attach outside hardness and laboratory reports as they return, so each lot file is complete when the buyer’s auditor visits.
For stores and dispatch
Bars come in and are sawn into billets for the press. Lots sent to the heat treater are followed out and back, and finished forgings are packed against the order last of all.
The numbers the owner asks for.
- Bar stock and billets by heat number, with weight issued and remaining
- Die sets by forgings run, repairs and re-sinking dates
- Lots by press, hammer, die set and shift
- Forging weight against drawing limit, by part number
- Magnetic particle and hardness results by lot
- Outside treatment counts out and back, by vendor
- Scrap and rework by cause, die set and part
Who this is built for.
- Companies that hot-forge steel parts to near-net shape on hammers, screw presses and crank presses, where die wear decides the day
- Shops that supply crankshafts, flanges, gear blanks and wheel hubs to machining customers who expect a heat number on every box
- Forging units that heat billets by induction and need a heating record per lot
- Plants that run an in-house die shop and need die counts, repairs and re-sinking in one register
- Firms that send forgings out for normalising, tempering and rough machining
When it is not the right choice.
- Plants that form parts from wire at room temperature will find Cold Forging Company Management Software closer, since billet heating and die re-sinking do not arise there.
- A blacksmith or fabricator making single items to order may manage with job sheets and a quotation book.
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
- WhatsApp or other messaging
- Barcode and label printers
- Weighing scales
- Accounting export
Questions owners ask before a demo.
Can a finished forging be traced to its bar heat?
Yes. Billets keep the heat of the bar they were cut from. A lot opened from those billets carries it forward, so a label scan shows the heat, the die and the press.
How does the system know a die is near its limit?
Each die set has a forging count and a limit set by your die shop. Counts are added by lot, and a set that is close to its limit is shown to the planner before the changeover.
Does it connect to a pyrometer or induction heater?
No. Operators key in pyrometer and heater readings by hand. A machine feed can be scoped later with your maintenance team as separate work.
Can we follow an outside heat treatment vendor?
Yes. Each outside job records the lot, the count, the vendor and the due date. When the lot returns, the count and the vendor’s report are checked before release.
Does the software approve our forgings?
No. It records your inspectors’ readings and your vendors’ reports, and the limits you work to are entered from your own drawings and inspection plan.
What about forgings that go for machining outside?
They travel as an outside job with a count and a due date. The machined count and any scrap are entered on return, and the lot history stays whole.
Can two customers share one billet heat?
Yes. A heat can feed lots for different part numbers and buyers. Each lot records the billets it drew, and what remains stays on the bar record.
How do shift supervisors use it?
They open the lot on a shop-floor screen, enter weight and profile readings, and see the die count before a changeover. The screen needs a network link; if the line is down, readings go on a printed sheet and are keyed in afterwards.
What drives the quotation?
The quotation grows with presses, named users and outside routes, and a walkthrough using one of your own forging drawings comes first. The proposal follows in writing.
Can our lot and die records be exported?
Yes. Lots, heats, die history and test results leave in spreadsheet files, and the layout is agreed in the quotation before the first export is run.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Precision Forging Company Management Software with your own data.
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