Case Studies of Cannabis Businesses We Transformed

Challenge

The Laughing Goat, an outstanding cannabis cultivator in Oklahoma, was driven to refine their growing operations. They wanted to make their growing process better. One big problem was how hard it was to deal with the plastic trellis netting during harvest time. Their team would cut the netting and leave it to pick up later. This method caused a few issues - it took a lot of time, was not safe, and it was tough to separate the netting from the irrigation systems and plant pots. Also, trying to twist and squish the netting to save space in their trash bin was a tough job. 

Solution

To help solve The Laughing Goat's problems, our team recommended the Trellis Trap™. We went to their place during harvest time and showed them how it works. The Trellis Trap™ has a special comb design and rubber part that catches and holds the trellis net effectively. 

Result 

In the beginning, The Laughing Goat team used the Trellis Trap™ after all the plants had been removed from the room and then returned to each table to pick up the trellis waste and stuff it in the Trellis Trap™ like their usual harvest routine. But they quickly saw how much better it was. 

The Trellis Trap™ lets them get rid of the netting quicker and in a smaller, less in-the-way container. This means they didn't have to spend time twisting and squishing the netting, which saved them a lot of time and effort. Remember the customer isn’t paying you extra money to dispose of the trellis. 

For the next harvest, we suggested a change in their process to make the most of the Trellis Trap™. The recommended change would use the Trellis Trap™ immediately as they removed the trellis from the plant canopy which required them to touch the trellis waste only once. The team saw the potential benefits and decided to follow our recommendation.

The result of using the Trellis Trap™ when cutting away trellis was:

•  They could get rid of the trellis netting easily and quickly, which made the whole harvest go faster. [one touch and done]
• It was safer because the trellis never fell on the floor.
• They saved time because they didn't have to untangle the netting from the watering system and pots.
• By compressing the trellis, they reduced the amount of trash and spent less time handling waste.

Customer Review:

"This tool brings real value to our grow just like it would to others. We estimate our annual savings to be up to $4k so it was a no brainer for us.” 

Mark O. - Operations Manager

Laughing Goat, Oklahoma

Objectives

Our client requested help to reduce a 40-45 min process from harvest to freezer in <20 minutes.

Observations

Hours of observation and interviewing exposed numerous waste types; transportation, motion, waiting, inventory.

Solutions

• We suggested layout changes that were implemented immediately. We introduced Lean thinking to reduce wasted motion and transportation at a macro and micro level. 
• We introduced 5S and provided options for the client to experiment with over the next few days.

Benefits (after 2 weeks)

• Improved productivity
• The harvest to freezer time was reduced to 15 minutes per ~1,000 grams.
• Reduced floor space by 60%
• Utilizing lean tools and our guidance the client reduced their space requirements.
• Lowered labor cost ($21,600 annually)
• Through our coaching, their intelligent and highly motivated manager transitioned from a batch and queue process to a more continuous flow.
• Return on Investment (ROI) of 1,250%
• Accounting for a one-day engagement and annual cost savings of $21,600.

Customer Review:

"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

Objectives

Introduce Lean thinking to the team and provide quick wins for their harvest routine.

At A Glance:

Harvest Challenges

• Inefficient process
• Lengthy and variable time
• Significant wasted motion
• High work-in-progress inventory

Benefits

• Reduced harvest time: 2 days to 1
• Reduced staff required by 0.5 person
• Introduced "standard work charts"
• Continuous flow with no chaos
• Reduced injury risk and strain on employees

Observations

Hours of video revealed opportunities to reduce significant waste in the grow room and the pre-dry trim/breakdown operation.

Solutions

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. 

Benefits:

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.

Customer Review:

“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)