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Our client requested help to reduce a 40-45 min process from harvest to freezer in <20 minutes.
Hours of observation and interviewing exposed numerous waste types; transportation, motion, waiting, inventory.
Benefits (after 2 weeks)
"So (within 2 days) we effectively doubled our processing speed with just the minor changes you suggested... ”
Quinn Rodrigo Processing Lab Manager PHB Growers, Oklahoma
Introduce Lean thinking to the team and provide quick wins for their harvest routine.
At A Glance:
Hours of video revealed opportunities to reduce significant waste in the grow room and the pre-dry trim/breakdown operation.
We defined new work responsibilities to reduce motion sequencing for every job assignment.
We conducted "on-the-floor" coaching for leaders and technicians under new Standard Operating Procedures.
Reduced harvest time
Their harvest times were typically taking 2 days for ~420 plants and the small team was able to reduce this time to 1 day through lean training and the industry's first Harvest Station system.
Reduced staff required
Utilizing Lean tools, we were able to identify reduced staff requirements to free a person to accomplish support tasks which are not typically conducted in parallel to the harvest.
Standard work charts (SOP)
We established a customized "recipe" for most efficient way to complete a task. This approach enables consistent execution, improves performance and makes employee training easier.
“In a very short time you opened my eyes to a new world that I hadn’t thought about. Just in my office the amount of wasted effort is astounding... A simple change in perspective... I’ve been telling everyone about the ahh ha moment. ”
Shawn Freeman TSGP (Oklahoma City)
The largest opportunity for improvement lies in the non value-added tasks (i.e., the wastes)