Case Studies of Cannabis Businesses We Transformed

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)