Customer Overview

A leading marble manufacturing company engaged in the production of artificial marble slabs and the processing of natural marble slabs required complete material traceability, inventory visibility, and production tracking across its manufacturing operations.

The organization wanted to eliminate manual tracking processes and establish end-to-end visibility from raw material receipt to finished goods dispatch.

The Challenge

The company faced several challenges in managing inventory and production operations.

There was no real-time visibility of raw material inventory, making it difficult to accurately monitor stock availability and material movement.

Tracking batch-wise and lot-wise consumption of granules was challenging, while manual recording of production and material movement transactions increased operational effort and the risk of errors.

The organization lacked complete traceability from raw materials to finished marble slabs, resulting in delays in locating finished goods and conducting stock verification activities.

Inaccurate inventory records and production reporting further limited operational visibility and made it difficult to maintain reliable inventory and production information.

The Solution

A barcode-based Inventory and Production Tracking Solution integrated with ERP was implemented to provide complete traceability and real-time visibility across inventory, production, and finished goods operations.

1. Artificial Marble Manufacturing Process

Raw Material Receipt
Granules and additives received from suppliers were assigned barcode labels containing Material Code, Batch/Lot Number, Weight, and Receipt Date. Materials were stored in designated warehouse locations and made available for tracking throughout the production process.

Stores Management
Barcode scanning was implemented during putaway activities to enable real-time location-wise inventory visibility, batch-wise inventory tracking, and accurate inventory records.

Production Issue to Silos
Materials were scanned before being issued from stores to production. This enabled batch-wise consumption tracking, accurate material issue recording, and real-time inventory updates.

Marble Block Manufacturing
Raw materials were processed into artificial marble blocks. The system linked production batches with the corresponding raw material lots, ensuring complete genealogy and traceability throughout manufacturing.

Gang Saw Cutting
Marble blocks were scanned before cutting operations. Each slab generated during the cutting process remained linked to its parent block, maintaining traceability.

Polishing Process
Slabs were tracked throughout the polishing stage, while production status was updated in real time through barcode scanning.

Resin Application
The resin coating process was recorded and monitored to maintain production traceability and support quality control requirements.

Finished Goods Management
Finished slabs were assigned barcode labels capturing Slab Number, Batch Number, Dimensions, Grade, and Weight. This information enabled accurate inventory management and dispatch planning.

2. Natural Marble Processing Flow

Block Receipt
Natural marble blocks received from suppliers were assigned unique barcode identities for tracking throughout processing.

Gang Saw Cutting
Blocks were cut into slabs while maintaining traceability between the finished slabs and their original marble blocks.

Polishing
Barcode scanning enabled status tracking of slabs throughout the polishing process.

Resin Application
Resin treatment activities were recorded, and quality inspection updates were captured for future reference.

Finished Goods Storage
Finished slabs were barcoded and stored with complete location-wise visibility, grade-wise visibility, and inventory availability information.

Results

The implementation significantly improved visibility, traceability, and operational efficiency across the organization's inventory and production processes.

By introducing barcode-based tracking throughout the manufacturing lifecycle, the company achieved complete batch and lot traceability of raw materials while gaining real-time visibility into inventory across stores and production areas.

Production teams were able to accurately track material consumption at every stage, creating complete genealogy from raw materials to finished marble slabs.

Warehouse operations became more efficient as barcode scanning enabled faster stock verification, improved inventory accuracy, and reduced the time required to locate materials and finished goods.

The solution also minimized manual errors in production and dispatch processes while strengthening quality control and audit compliance.

With accurate inventory records and complete product traceability, the organization was able to fulfill customer orders more efficiently and make better operational decisions based on real-time information.

Business Impact

The implementation provided complete visibility across both artificial and natural marble manufacturing processes.

By digitizing inventory and production tracking activities, the organization achieved improved inventory management, stronger material traceability, faster order fulfillment, and better control over manufacturing operations.