Variant, reel lot, crimp check and test result recorded for each harness built.
Customer call-offs (called pulls here), harness drawings, wire reels, terminal lots, cutting, crimping, formboard assembly, continuity test and despatch are kept together. A harness lot carries its drawing revision, the reels and terminal lots behind it, the crimp checks taken and the tester result. Planners, cutting, assembly, the test bench and dispatch work from one record. A wrong connector variant is caught before the carton closes.
- Variants, circuit lists and test steps entered as you build them
- Open pulls, wire stock and terminal lots brought across
- Variant and inspection field changes made by GullySystem staff on request
Harnesses are followed from the customer’s variant pull to the labelled carton in Wiring Harness Manufacturer Management Software from GullySystem. It holds drawing revisions, reel and terminal lots, applicator changes, crimp height and pull force checks and tester results. Each harness serial can then be traced back to its reel, terminal lot and crimp press.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Customer pull
Each pull is the customer’s call-off, and it arrives daily or weekly with variant codes and quantities, and they are entered against the harness family and its live drawing revision. Old pulls stay on file.
- 2
Cut list
The system produces cut leads by wire colour, gauge and length, and the reels and terminal lots are issued to the cut-and-strip and crimping machines. Stock is booked down at once.
- 3
Cut and crimp
Operators log the applicator, the first-piece checks and the batch counts, while crimp height and pull force readings are recorded against the press for that shift.
- 4
Assemble
Trolleys of leads go to formboards with connector, grommet and clip kits. Each assembly station logs the harness number and the operator, so no unit loses its history.
- 5
Test
Every harness is tested for continuity and insulation on the board tester. Failures are repaired, retested and logged against the serial.
- 6
Pack
Passed harnesses are bagged, labelled with variant and serial, counted against the pull and shipped.
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
Each harness variant holds its wire, terminal, connector housing, seal and clip list, so cut lists and kits come from the live build list.
- Document Management
The live drawing and earlier revisions are kept for each harness family, and only the current revision is released to cutting and assembly.
- Batch and Serial Tracking
Reels and terminal lots are booked at receipt and linked to cutting orders, so a harness serial lists the lots that went into it.
- Production Planning
Customer pulls become cut lists by colour, gauge and length, spread across cutting and crimping machines by applicator and due date.
- Quality Control
Crimp height and pull force readings are checked against limits set by your quality staff, and a failed check holds the batch at the press.
- Work Order Management
Harness lots run as work orders through formboard stations, noting operator, board and connector kit used for each unit.
- Stock Tracking and Alerts
Housings, seals, grommets and clips have reorder levels, so an assembly kit is not short when the formboard needs it.
- Customer Support
A returned harness is logged against its serial, and the reels, terminal lots and tester results behind it are opened together.
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
See harnesses on formboards, test failures by line and pulls at risk without walking to each station, and spot the press or tester that is dragging the shift down. One screen.
For planners
Release cut lists from the pull, watch reel stock against the next three days of orders, and plan the crimping machines by applicator so changeovers are grouped. Fewer swaps.
For crimp operators
Log applicator changes, first-piece readings and batch counts at the press itself.
For test and repair staff
Enter failure codes, repairs and retests under the harness number.
For dispatch
Pack against the pull, print carton labels with variant and serial, and confirm counts before the truck leaves, so a short shipment is caught at the dock door.
The numbers the owner asks for.
- Harnesses built by family and variant
- Crimp check results by applicator and terminal lot
- Test failures by circuit and line
- First-pass yield by variant
- Reel and terminal lot usage
- Pulls against despatch by customer
- Field faults by serial
Who this is built for.
- Makers of vehicle harnesses for car, truck and two-wheeler makers
- Suppliers of engine and body harnesses
- Shops building harnesses for tractors and construction equipment
- Makers of battery and charger cable assemblies
- Contract harness assemblers working to customer drawings
When it is not the right choice.
- A small electrician who rewires vehicles one at a time will find a job tracker closer.
- A maker of printed circuit boards would find Manufacturing Production Management Software a better match.
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
- Tester file import
- Accounting export
Questions owners ask before a demo.
How are many variants managed?
Each harness family holds its variants with circuit lists and kits, a pull selects the variant, and the cut list and kit follow from it. Nobody retypes a pinout.
Can a harness be traced to its wire reel?
Yes. Reel and terminal lots are booked at receipt and attached to cutting orders. A harness lot lists the reels and terminal lots that fed it.
Does it enforce crimp checks?
Yes, when you switch it on. A batch can require a crimp check after every applicator change, and the next batch waits until the height and pull force readings are entered and accepted. No reading, no run.
How are test failures logged?
The tester result, failure code, repair note and retest outcome sit under the harness number. A unit that has not passed cannot be packed.
Can it import tester results?
Values can be keyed at the station today. Importing from tester files is scoped in the first workshop, depending on the board tester you run.
What happens when a drawing is revised?
The new revision becomes live and earlier ones stay on file. Cut lists and kits are produced from the live revision, while old lots keep the drawing they were built to, which settles disputes.
How is the cost set?
It follows users, lines and testers to connect. You see a demo built on your own variants, and the written proposal follows.
Who owns the harness records?
You do. Continuity test results, crimp pull checks and despatch records come out as files in a layout we settle before you sign.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Wiring Harness 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