Marmi Zenatelli: production costs allocated with precision

The context

Founded in 1954 by Luigi Zenatelli and partners in Volargne (Verona), the company works, trades and contract-saws marble and granite. Across a total of 11,000 square metres, with latest-generation machinery, it has a production capacity of 200,000 square metres a year and supplies customers with everything from the rough slab to the finished product.

Alongside the workshop for finished marble and granite pieces, Marmi Zenatelli runs a substantial sawmill site where half a century of experience produces rough slabs, semi-finished and finished products. To improve order management and allocate costs precisely to each job, the company was looking for a way to analyse, control and attribute production costs. With specialist staff in house, it chose to run IDA entirely on its own.

The project

The goal was met by centralising into IDA the data from the latest-generation multiwire machines that cut the stone blocks. The application shows in real time how raw material, energy, tooling and labour consumption is distributed across each individual order.

Operators are supported by clear charts, automatic reports and screens showing in real time the path of the blocks along the production lines and the progress of each order. Monitoring of the photovoltaic panels' output was added, along with data collection from 2 block-cutting frames and consumption monitoring through energy meters, with the associated CO₂eq output under Scope 2.

The results

Today the cost items of each operation are allocated automatically and managers can consult the data at any time. Administrative processes have moved from a traditional spreadsheet-based model to systems that offer greater reliability, speed and accuracy of information. IDA also met every requirement on bidirectional data exchange and reporting during the checks for 4.0 certification.

What comes next

The next step is performance monitoring and predictive maintenance on the multiwire machines. Keeping them efficient means reading the energy consumed and the hours worked, in order to track remaining tool life, cutting sequence, greasing and maintenance in general. With IDA it will be possible to identify the most efficient cutting sequence and trigger notifications and alarms telling staff when a tool needs servicing, replacing or reordering from the supplier.