Greenhouse Increases Packing Productivity By 10% With GLSS
Canada
Agriculture
Operations
10%
- The problem: A greenhouse operation faced a major challenge in its packing process, particularly with hydrangeas. Packing these delicate plants took too long, leading to poor quality, increased labor costs, and dissatisfied customers.
- Determined to fix these issues, the organization partnered with GLSS and their Green Belt Training & Certification. Their expertise in Lean Six Sigma provided the structured approach needed to overcome the bottlenecks and boost productivity 10%.
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Running a greenhouse is no easy task, especially when striving to balance efficiency with maintaining the highest quality of plants. As the greenhouse business worked to deliver top-quality plants, it became clear that their packing processâespecially for hydrangeasâwas causing operational delays. Packing hydrangeas was an incredibly labor-intensive task, and the team was only managing to pack 63 plants per hour. This slow pace was more than just an inconvenience; it was directly impacting plant quality, increasing costs, and upsetting customers.
The extended packing times left the plants vulnerable to heat stress, which diminished their overall quality before they even reached the customer. Additionally, the inefficiency led to higher labor costs, particularly during the peak harvesting season when extra workers were brought in to handle the load. Worse yet, these delays and quality issues were damaging the company’s reputation, as customers were receiving plants that didnât meet their high expectations.
Something had to change if the business wanted to maintain its commitment to quality while reducing costs and keeping customers happy.
The first step was identifying what was causing the delays. Upon closer inspection, it became evident that the greenhouseâs workspace and conveyor layout were the primary issues. All the conveyors were confined to one floor, forcing workers to spend too much time navigating through the space. This setup was far from optimized and was causing major delays in packing.
The workersâ unnecessary movements and the inefficient use of conveyors during peak hours were slowing the process, which ultimately contributed to higher costs and lower product quality. It was time to rethink the packing system from the ground up.
By partnering with GLSS Training & Certification, the business was able to apply Lean Six Sigma principles to address these operational inefficiencies. Using the skills learned from GLSS, the greenhouse analyzed its process, pinpointed problem areas, and implemented changes.
The solution was straightforward but transformative: reorganize the workspace and conveyor layout. With GLSSâs guidance, the greenhouse restructured the system so that conveyors could be utilized across multiple floors simultaneously. This simple change drastically improved the workflow, reducing wasted time and minimizing unnecessary movements. The new layout allowed the team to work more efficiently, cutting down packing time and making the entire process smoother.
- The impact of the new layout was immediate and impressive. Packing productivity improved by 10% (from 63 plants per to hour to 69.5 plants per hour), which meant hydrangeas could be packed and shipped faster, reducing their exposure to heat stress and improving the overall quality of the plants.
- Not only did this enhance the customer experience, but it also helped the business reduce labor costs during the peak season, as fewer workers were needed to keep up with demand.
- Customer satisfaction improved as well. With faster turnaround times and healthier plants, customers began receiving the high-quality hydrangeas they had come to expect, and the greenhouseâs reputation rebounded as a result.
with GLSS
Partnering with GLSS Training & Certification was a game-changer for this greenhouse business. The innovative training approach and expert Lean Six Sigma guidance provided by GLSS allowed the organization to quickly pinpoint the root causes of its inefficiencies and implement effective solutions.
By redesigning its conveyor layout and optimizing the packing process, the greenhouse achieved faster results and improved plant qualityâultimately positioning itself for long-term success. With the tools and knowledge gained from GLSS Training & Certification, the business is now better equipped to continue improving its operations and deliver top-quality products to its customers more efficiently than ever before.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.
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