Case Study: How a Shop Turned $42,000/Year in Dead Remnants into Revenue
This countertop software case study documents measurable results from a real fabrication shop.
A countertop fabrication shop with 180+ slab remnants collecting dust in their yard implemented SlabWise's remnant tracking and AI matching system. Within 8 months, they cleared 65% of their remnant inventory, generated $28,000 in direct remnant sales, avoided $14,000 in fresh slab purchases by matching remnants to incoming jobs, and freed up 400+ square feet of yard space.
TL;DR
- Shop profile: 11 employees, 80 jobs/month, 8-year-old business
- Starting remnant inventory: 184 pieces valued at approximately $42,000
- Remnants cleared in 8 months: 119 pieces (65%)
- Revenue from remnant sales: $28,000 (discounted pricing for small projects)
- Fresh slab purchases avoided: $14,000 (remnants matched to incoming jobs)
- Yard space recovered: 420 sq ft of storage freed for new slab inventory
- Ongoing remnant utilization rate: 58% of new remnants matched within 60 days
The Shop
Cascade Stone Works (name changed) is an 11-person fabrication shop in the Pacific Northwest that processes about 80 countertop jobs per month. Owner Jen has been in business for 8 years, growing steadily through a mix of residential and light commercial work.
The Remnant Graveyard
Every fabrication shop accumulates remnants -- pieces left over after cutting a slab for a job. Some are large enough for bathroom vanities or bar tops. Others are only useful for small applications like fireplace hearths or desk tops. And some are truly too small for anything practical.
Jen's problem wasn't unique, but its scale was uncomfortable. Eight years of fabrication had produced a remnant yard that had become a running joke among her staff: "the graveyard."
Remnant Inventory Audit
Before implementing any changes, Jen's team cataloged every remnant in the yard:
| Category | Count | Avg Size (sq ft) | Estimated Value | Usability |
|---|---|---|---|---|
| Large (20+ sq ft) | 28 | 31 | $15,400 | Vanities, bar tops, desks |
| Medium (10-19 sq ft) | 47 | 14 | $14,100 | Small vanities, end tables, hearths |
| Small (5-9 sq ft) | 62 | 7 | $9,300 | Samples, trivets, small projects |
| Unusable (< 5 sq ft) | 47 | 3 | $3,200 | Scrap/disposal |
| Total | 184 | -- | $42,000 |
Material Breakdown
| Material | Remnant Count | % of Total |
|---|---|---|
| Quartz (various brands/colors) | 78 | 42% |
| Granite (natural stone) | 61 | 33% |
| Marble | 22 | 12% |
| Quartzite | 15 | 8% |
| Other (porcelain, soapstone) | 8 | 5% |
Why the Remnants Accumulated
Jen identified three reasons her remnant inventory had grown unchecked:
-
No tracking system: Remnants were stacked in the yard with handwritten labels that faded, fell off, or became inaccurate over time. Nobody knew exactly what was available.
-
No matching mechanism: When a small job came in (bathroom vanity, bar top), nobody checked the remnant yard first. It was easier to pull a fresh slab than to search through 180+ pieces.
-
No sales channel: Jen didn't actively market remnants to small-project customers. Occasionally, a walk-in customer would buy one, but there was no systematic approach.
The SlabWise Solution
Jen implemented SlabWise Standard ($199/month) and dedicated the first month specifically to remnant inventory and management.
Phase 1: Catalog Everything (Weeks 1-2)
Jen's team spent 2 days photographing and measuring every remnant. Each piece was entered into SlabWise with:
- Material type and color name
- Exact dimensions (length, width, and any irregular edges)
- Condition notes (chips, scratches, edge quality)
- Location in the yard (row and position)
- Estimated retail value
- Photo from multiple angles
Result: 184 remnants fully cataloged with photos and searchable by material, color, size, and condition.
Phase 2: AI Matching for Incoming Jobs (Weeks 3-8)
With the remnant inventory digitized, SlabWise's AI matching system activated. For every new job that entered the system, the AI checked the remnant inventory before suggesting a fresh slab pull.
How the matching works:
- New job enters SlabWise: bathroom vanity, 22 sq ft, White Carrara marble
- AI searches remnant inventory for: marble, white/carrara, minimum 22 sq ft with compatible dimensions
- Match found: Remnant #47, 28 sq ft Carrara marble, good condition
- Team receives alert: "Remnant match available -- saves $1,540 vs. new slab"
Phase 3: Remnant Sales Channel (Weeks 4-12)
Jen created a "Remnant Specials" page on her website linked to SlabWise's remnant inventory. Customers browsing for small projects (vanities, desk tops, hearths) could see available remnants with photos, dimensions, and discounted pricing.
Pricing strategy:
- Large remnants: 40% off retail slab pricing
- Medium remnants: 50% off
- Small remnants: 60% off
Even at steep discounts, selling a remnant generates pure profit -- the material cost was already absorbed by the original job.
Phase 4: Ongoing Remnant Management (Month 3+)
For new remnants generated from current jobs, Jen's team adopted a discipline: every remnant over 5 sq ft gets photographed, measured, and entered into SlabWise the same day it's created. Remnants under 5 sq ft are evaluated immediately -- if they have a plausible use, they're cataloged; if not, they're disposed of.
8-Month Results
Remnant Clearance: 65% of Backlog
| Disposition | Count | Value Realized |
|---|---|---|
| Matched to incoming jobs (avoided fresh slab) | 34 | $14,200 (slab purchase savings) |
| Sold directly to small-project customers | 52 | $28,400 (revenue) |
| Donated to vocational training programs | 12 | Tax deduction value |
| Scrapped (under 5 sq ft, no practical use) | 21 | Disposal cost: -$400 |
| Total cleared | 119 | |
| Remaining inventory | 65 |
Financial Impact
| Category | 8-Month Total | Monthly Average |
|---|---|---|
| Fresh slab purchases avoided | $14,200 | $1,775 |
| Direct remnant sales revenue | $28,400 | $3,550 |
| Disposal costs | -$400 | -$50 |
| SlabWise subscription (8 months) | -$1,592 | -$199 |
| Net financial impact | $40,608 | $5,076 |
Yard Space Recovery
Clearing 119 remnants freed approximately 420 square feet of storage space. Jen repurposed this area for organized new slab storage, reducing the frequency of slab deliveries (she could store more inventory on-site) and improving yard workflow.
Ongoing Remnant Utilization
After the initial backlog clearance, Jen's shop now generates about 35 new remnants per month from current jobs. With the AI matching and active sales channel in place:
| Monthly Remnant Flow | Count |
|---|---|
| New remnants generated | 35 |
| Matched to incoming jobs (within 60 days) | 12 (34%) |
| Sold to small-project customers (within 60 days) | 8 (23%) |
| Added to inventory for future matching | 15 (43%) |
| 60-day utilization rate | 58% |
Before SlabWise, the utilization rate was approximately 15%. The shift from 15% to 58% means fewer remnants accumulate, and the ones that do are tracked and findable.
The Customer Sales Channel
Who Buys Remnants?
Jen's remnant sales attracted a customer segment she hadn't previously served:
| Customer Type | % of Sales | Typical Project |
|---|---|---|
| DIY homeowners | 35% | Bathroom vanities, desk tops |
| Small remodeling contractors | 25% | Single-bathroom jobs, laundry rooms |
| Furniture makers/artists | 20% | Table tops, art pieces, samples |
| Property flippers | 15% | Budget-conscious vanity replacements |
| Other (fireplace hearths, shelving) | 5% | Misc. small projects |
Pricing That Moves Inventory
| Remnant Size | Discount from Retail | Avg Sale Price | Avg Pieces Sold/Month |
|---|---|---|---|
| Large (20+ sq ft) | 40% off | $520 | 3 |
| Medium (10-19 sq ft) | 50% off | $245 | 4 |
| Small (5-9 sq ft) | 60% off | $85 | 6 |
At these prices, remnants sell quickly. The key insight: a remnant sitting in your yard at full price generates $0. A remnant sold at 50% off generates pure profit because the material cost was already paid by the original customer's job.
Operational Changes
Before SlabWise Remnant Management
- Customer calls about a small vanity job
- Salesperson quotes using a fresh slab
- Fabricator pulls fresh slab, cuts vanity, creates new remnant
- New remnant goes to the yard with a handwritten label
- Cycle repeats -- remnant pile grows
After SlabWise Remnant Management
- Customer calls about a small vanity job
- SlabWise AI checks remnant inventory, finds a match
- Salesperson offers remnant option at a slight discount (or quotes from fresh slab if customer prefers)
- Fabricator uses remnant -- no new remnant created, no new slab pulled
- If a new remnant is created, it's immediately cataloged with photos
The cycle breaks because every small job is first checked against existing inventory.
FAQ
How long does it take to catalog an existing remnant inventory?
Cascade Stone Works cataloged 184 remnants in 2 full days (about 16 hours). The process is: photograph, measure, enter dimensions and material info into SlabWise. Budget about 5 minutes per remnant.
Does the AI automatically match remnants to jobs?
Yes. Every time a new job is created in SlabWise, the AI checks your remnant inventory for compatible pieces based on material, color, dimensions, and condition. If a match exists, you receive an alert.
What if the customer wants a fresh slab instead of a remnant?
That's always their choice. The remnant option is presented as a cost savings opportunity, not a requirement. Some customers prefer fresh slabs for aesthetic reasons (seeing the full slab, choosing their specific piece).
How do you price remnants for direct sales?
Cascade Stone Works uses a tiered discount: 40% off for large remnants, 50% for medium, 60% for small. The goal is to move inventory quickly since every remnant sold generates pure margin.
Can I sell remnants online through SlabWise?
SlabWise tracks your remnant inventory with photos and dimensions. You can link this to a page on your website or share the catalog directly with interested customers. The system manages inventory levels so sold pieces are automatically removed.
What about remnants that are chipped or damaged?
Include condition notes when cataloging. Minor cosmetic imperfections can be discounted further or offered for projects where the edge will be hidden (like built-in desk installations). Severely damaged pieces should be scrapped rather than taking up yard space.
How does remnant management affect my waste rate?
Using remnants for small jobs directly reduces your effective waste rate because you're fabricating from material that would otherwise be written off. Cascade Stone Works saw their reported waste rate drop 4% from remnant utilization alone.
Is remnant tracking included in the Standard plan?
Yes. Remnant inventory management and AI matching are included with SlabWise Standard at $199/month. No additional fees or modules required.
How do I prevent the remnant pile from rebuilding?
The key is same-day cataloging of new remnants and active AI matching for incoming jobs. As long as every remnant is tracked and every small job checks the remnant inventory first, the cycle of accumulation breaks.
Should I donate or scrap pieces under 5 sq ft?
Small pieces under 5 sq ft rarely match to real jobs. Consider donating to vocational schools (tax deduction) or scrapping them. Keeping them in inventory creates clutter and search noise without meaningful revenue potential.
Stop Wasting Your Remnant Inventory
Start a 14-day free trial and catalog your remnant yard in SlabWise. The AI will start matching remnants to incoming jobs immediately. No credit card required.
Sources
- SlabWise customer data -- Cascade Stone Works (anonymized), 8-month review
- Natural Stone Institute -- fabrication shop remnant management survey, 2025
- Marble Institute of America -- material waste and inventory data
- Stone World Magazine -- remnant utilization best practices, 2025
- Freedonia Group -- U.S. countertop material cost analysis
- ISFA -- fabrication shop inventory management benchmarks