A marble factory run entirely on FLAPP ERP — every square meter at its real cost
From receiving a block to loading the container and booking it in the accounts, the whole factory runs on one system. Cost follows every block down to the last square meter, AI proposes the sawing plan and a loading engine packs the containers — so prices are set on a real cost instead of a guess.
The system — A whole marble factory on one system
Purchasing, receiving, planning, production, sales, shipping and accounting — every department of the factory works on FLAPP ERP. Each transaction is recorded once and reaches every department that needs it.
- → Receiving — each block enters at its full cost
- → Planning — a sawing plan proposed by AI
- → Production — sawing, cutting and polishing recorded at the machine
- → Sales & shipping — goods reserved and containers loaded
- → Accounting — every movement has its journal entry
The challenge — The block price was known. The cost per square meter wasn't.
The factory buys marble blocks, saws them into slabs, cuts them into tiles and polishes them. Between the price of a block and the price of a finished square meter, a lot of cost went missing along the way — so prices were set by experience.
- ✕ Shipping and customs on the block
- ✕ Material lost to the saw
- ✕ Labour, power and water
- ✕ Machine wear
Cost per m² — Every square meter at its real cost
Each block enters at its full cost: its price, shipping, customs and every approved expense against it. Every saw cut and tile cut is recorded, and cost follows each piece in proportion to its volume — so the material lost to the saw is carried by what remains, and not a pound disappears. On top of material: labour, power and water, and machine depreciation.
- ✓ Block → slabs → tiles
- ✓ Every piece traceable to its block
- ✓ Saw loss carried by what's left
- ✓ A real cost for every square meter, block and slab
Sawing plan — AI proposes, the planner decides
The planner writes to FLAPP's assistant in Arabic: "make a sawing plan for the available blocks". The assistant picks the blocks that are ready, sets the saw and the thickness for each, and works out the expected hours and number of slabs from the block's own dimensions. Nothing runs until the planner approves — then each item goes to its machine and is tracked like any other run.
- ✓ Ready blocks picked automatically
- ✓ Expected hours and slabs from the block's dimensions
- ✓ Nothing runs without approval
- ✓ Plan and execution in the same system
Container loading — An engine that packs the container before it's loaded
For every sales order, the loading engine spreads the bundles and crates across the containers on its own, within each container's weight and area limits and floor size. The team can move any package by hand from one container to another, and the engine refuses any spot that breaks a limit. Once the plan is approved, the goods are reserved on the sales order.
- ✓ Every bundle and crate has a calculated place
- ✓ Weight and area always within limits
- ✓ Moves by hand, limits still enforced
- ✓ Approving the plan reserves the goods
Accounting — Every movement reaches the books on its own
Accounting is linked to sales and production. Receiving a block puts it in stock at its full cost, production charges labour, power, water and depreciation to what it makes, and every delivery and invoice books the revenue and the cost of sales. Every customer and every supplier has an account in their own name.
- → Receiving — stock at full cost
- → Production — cost carried by each piece
- → Invoice — revenue and cost of sales
- → Collection — the customer's balance closes
- → Month end — an income statement from the same numbers
The result — Prices set on a number, not a feeling
- ✓ Prices are set knowing the cost
- ✓ Before agreeing a price, they know whether it makes money
- ✓ Sawing by plan, loading by plan
- ✓ Every department looks at the same numbers
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