Idealmarmi: dead time eliminated and auxiliary line use cut by 40%

The context

IdealMarmi specialises in the precision processing of marble, granite and agglomerate products: thresholds, jambs, window sills and tiles. Its strength lies in combining the artistic vocation of stone with a structured, efficiency-driven production model. Together with Marmobon and Domos it belongs to a group covering the whole stone cutting chain, from buying raw material to finishing.

Its digital journey began several years ago, with the modernisation of the machine fleet along Industry 4.0 lines, the digitisation of information processes and energy monitoring. Steps that built solid foundations, but also exposed a problem: the data was there, spread across different systems with no correlation between them. The real need was bringing heterogeneous sources into a single application, to know at any moment what is being produced, what it is costing, with what energy efficiency and what lead times.

The project

The project connected the ERP, the machines, the energy meters and the solar plant. IDA's infrastructure, built on a continuous real-time data flow, makes it possible to read production end to end: every job is tied to its times, the square metres produced and the energy consumed, so bottlenecks, micro-stops and slowdowns invisible to the naked eye show up immediately. With a real-time dashboard and structured supervision, there is no longer any need to "open the workshop door". IDA became both an operational and a strategic tool: on one side daily monitoring and fast decisions, on the other planning, financial analysis and investment appraisal.

The results

IdealMarmi turned marble processing into an industrial model built on operational continuity and cost control. IDA is used daily as a kind of operating balance sheet for the day, where square metres processed, energy consumed and plant status give an immediate picture. Full traceability cut hidden idle time, and optimisation made it possible to concentrate production on a single line, reducing use of the auxiliary line by around 40%. Monitoring also brought to light apparently minor but high-impact effects, such as the optimal abrasive configuration to reduce changeover times and machine stops: efficiency comes from constant micro-improvements.

What comes next

The company is widening its set of indicators, with attention to OEE, scrap reduction, air quality and the building of predictive models. Next come complete CO₂eq metrics per item and order, precise measurement of labour hours and an even more advanced system for maintenance and production cycles. The vision is a production process with no idle time, fully measurable and optimisable.