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GullySystem
Manufacturing · Solutions

Put every job on the floor as a numbered work order, from stage to stage.

A work order puts one job on the floor: what to make, how many, by when, and which stage it has reached. Material is issued against it, and output and rejections are booked to it. The person on the phone can see where a customer’s job stands. The whiteboard stops being the only version of the truth.

What it is

An order arrives on WhatsApp. The supervisor writes it in a diary, the whiteboard carries whatever fits, and by Wednesday the two disagree. A customer rings at four o’clock, and somebody walks to the machine to find out.

Each job gets a work order with a number of its own. Your stages sit on it in the order they actually happen: cutting, welding, coating, packing. Each is marked off as it finishes. What the store issued and what the floor produced are on the same screen.

What it replaces

What your team uses today.

The module takes over these, one at a time, so nothing has to stop while it is set up.

  • The shop-floor whiteboard
  • Verbal material issue at the store
  • A notebook of rejected pieces
Where it goes wrong today

The problems this is meant to ease.

Orders on a whiteboard

The board shows what the supervisor wrote. Nobody else can trust it.

Stage unknown at the counter

A customer rings for a job. The answer waits for someone to walk the floor.

Material issued loosely

Stock leaves the store with a verbal word. Cost per job cannot be worked out.

Rejects and rework hidden

Pieces fail and are redone. The count and cause are lost.

Holds unexplained

A job sits idle for days. Nobody records why.

Inside the module

What work order management does.

Raised from the confirmed order

Item, quantity and promised date carry over from the sales order or the customer’s purchase order. The specification is not retyped.

Your stages, in your words

Stage names are set once and used everywhere. A job shows where it is standing and who has it now.

Material issued to a number

The store issues against the work order and not to a person’s name. Issued quantity sits beside what the material list expected.

Output, rejection and rework

Pieces finished, pieces rejected and pieces sent back are booked to the job as they happen and not totalled on Saturday.

Labour against the job

Which fitter worked which stage, and for how long, where you pay by the piece or by the hour.

A board the counter can read

Jobs by stage, jobs held for material, and jobs past the date you promised. Whoever answers the phone sees the same board.

Where it gets used

What this looks like in a working week.

Illustrative scenarios, written to show the shape of the work. They are not accounts of client systems.

An order is confirmed

A work order is raised from the sales order. Quantity, date and stages are carried over.

Material is issued

The storekeeper issues stock to the order number. Cost accrues on the job.

Output is booked

The supervisor enters completed, rejected and reworked pieces by stage. The board updates.

A customer rings

The counter reads the stage on a screen. The reply takes seconds.

Who touches it

The people who open this every day.

Production in-charge

Releases jobs, moves them between stages, and holds the ones waiting on material with a reason typed in.

Supervisor

Marks his stage done from a tablet near the machine.

Storekeeper

Issues material against the job number and sees what is still due to it.

Owner

Looks at what is late, and at what is late for the same reason every week.

How it is set up

From first conversation to daily use.

  1. Name your stages

    Tell us the stages a job passes through, in your words. A stage list comes back to confirm.

  2. Link orders and material

    Sales orders are connected, and so is the bill of materials. A sample work order draws on each.

  3. Set up the board

    A screen shows jobs by stage. The supervisor tries it beside the whiteboard.

  4. Move to the screen

    Supervisors and the store use live work orders. The whiteboard is retired after a trial period.

Measuring it

How you would know it is working.

Record where you stand before it goes live, so the change is measured against your own figures.

  • Jobs late against their promised date
  • Rejection and rework by stage
  • Material issued against material planned
  • Jobs on hold, with the reason
  • Time a job spends in each stage
How it fits

It is one part of a system, not an island.

A module earns its place by what it passes to the next one. These are the connections we set up most often.

  • Bill of materials
  • Production planning
  • Stock
  • Job work delivery notes
  • Quality control
  • Sales orders
Common questions

Questions owners ask about work order management.

What if our supervisor will not touch a computer?

Then he need not. Most shops keep one tablet at the store window, and either he marks the stage or the store clerk marks it while issuing material. If nobody on the floor touches a screen, the board runs a day behind, and it is fairer to say so now.

Is a whiteboard still enough?

For four or five jobs at a time, yes. It fails when jobs run into double figures, when two people promise dates to the same customer, or when nothing on the board explains why a job has not moved since Monday. Share your requirements and we will look at how your board is used and which of those is you.

Can it take our sales orders from our accounting software?

Yes, where the software allows an export or connection. Orders and item masters come across, and finished quantities can go back as stock entries. Your accountant keeps his ledgers where he likes them.

What about work we send outside?

That goes out as job work against the same order. Each load sent to the galvanising plant is booked out on a delivery note, so any pieces still at the plant show as pending on that job.

What affects the price of a work order module?

Stages, products and users matter. Bill of materials, production planning, stock, quality control and job work notes all add work as links, and outside work adds more. Priced separately is the stage board.

How quickly can the floor start working from it?

Your stages and item list decide it. The floor release covers the work order, stage board, material issue and output booking. Stage names and sample orders come from you, and the schedule of work in the proposal carries dates.

Talk to us

Tell us how you handle work order management today.

A spreadsheet, a register or another system: say which, and we will tell you plainly what is worth changing.

What happens after you share your requirements

  1. A senior engineer reads your answers. Nobody phones first.
  2. Within one business day you get a written note: what we understood, what we would start with, and the questions we still have.
  3. If it fits, a proposal follows with the order of work, what we need from you and what you receive at each step.
  4. No call is booked and nothing is paid until you have read the note. Your details stay with us.

Start with your requirements

Seven short steps that tell us what you need. A senior engineer reads them before anyone gets in touch.

Share your requirements