Quarrying & aggregates · Tamil Nadu, India
Closing the production-to-billing gap at a multi-pit aggregate operation
Client: A leading aggregate producer in Tamil Nadu
Product deployed: Quarry360
Summary
A three-pit aggregate producer running manual weighbridge slip books could not reconcile production against sales. After deploying Quarry360 with direct weighbridge capture, ANPR at the gates and GPS on the fleet, unrecorded dispatch effectively stopped and diesel reconciliation identified a second, separate loss.
Measured results
- Near zero
- unrecorded dispatch after go-live
- 3 pits
- consolidated onto one system
- Same day
- production-to-sales reconciliation
- Separate
- diesel loss identified and closed
The challenge
The operator ran three pits with a combined fleet of owned and hired vehicles. Each pit maintained its own weighbridge slip book, and slips reached the head office in batches, sometimes days later.
The consequence was a persistent, unexplained gap between crusher production estimates and invoiced sales. Management suspected leakage but could not prove where it occurred, and every attempt to tighten manual controls produced arguments rather than data.
Diesel was issued at each pit against a register. Nobody had ever compared issue volumes against what the trips those vehicles performed would actually require.
What we built
Quarry360 was deployed across all three pits with a local server at each site so weighing and dispatch printing would continue through the connectivity outages the remote pit experienced regularly.
Weighbridge indicators at each site were connected directly, so gross and tare readings wrote into the transaction rather than being typed by an operator. Dispatch slips became non-editable after printing, and customers received an SMS confirmation with the weight at the moment of dispatch.
ANPR cameras at each gate matched departing vehicle plates against expected dispatch. GPS units on owned and hired vehicles recorded route history, and trips deviating from the billed destination were flagged automatically.
Fuel issue was moved into the system and reconciled against recorded trip distance and load. Vehicle maintenance, tyre lifecycle and insurance were brought into the same records so cost per vehicle became visible for the first time.
Tally integration was retained so the finance team continued statutory filing from a familiar system while operations moved onto the ERP.
The weighbridge integration was the whole reason we bought it. Within two months the gap between what we produced and what we billed had effectively closed. We had been arguing about that number for years.