Optimization of productive yield indicators and financial gains in the standard papaya harvesting sector Fazenda Sagarana - Success Case Fazenda Sagarana
Knowing the Company
Fazenda Sagarana was created in January 2021 by a group of partners called Marejo, a company that takes great quality products to Brazilians and offers great opportunities in the city and region.
Company focused on the production of papaya and cereals, in Lassance/MG. The region's climate is highly favorable to its products, which makes it possible to obtain healthy products, with a high level of quality and satisfaction.
Challenge
Fazenda Sagarana stands out in the market through its products with high quality requirements, in addition to adopting the philosophy of operational excellence, strong relationships, fast and effective customer service.
In a scenario where the market is increasingly fierce, the need to improve its production process arose, aiming at reducing operating costs, through productive performance and implementation of Quality control. In this way, in partnership with Avilla Consulting, a project was started, aiming to identify opportunities for process improvements, at first focused on Mamão processing processes.
In the initial mapping carried out by Avilla Consulting, some opportunities for financial gains were identified, but this case study aims to cite one in particular: The optimization of the harvest sector, Sector seen with many opportunities, mainly to eliminate dead time, because it directly affected the employee productivity.
With the opportunities placed in front of us, improvement actions were carried out in the entire method of work that was carried out.
The following improvements were made:
- The diagnosis of the situation (sector);
- Improvement in the process flow;
- Application of metrics and parameters (Indicators) of Utilization, Efficiency and Productivity;
- Empowerment with direct supervision training;
- Adjust the number of teams, using the real need;
- Implementation of SOP “Standard Operating Procedure”.
Avilla, together with Gestão da Fazenda Sagarana, will obtain great results, especially in this sector where we had great challenges. The objective was achieved and has been reaping great results.
Solution
The analysis model implemented by Avilla Consulting, with the objective of eliminating wasted time, was based on Guidance and Continuous Monitoring Methodologies to achieve an effective solution.
Sector Diagnostics
When starting studies and analyzes in the sector, several opportunities were found, such as: Lost time and bottlenecks in direct supervision in the sector.
Application of Improvement in the Process Flow
A continuous flow was implemented in the activity referring to the Mamão loading trailer, it was analyzed that there was a long waiting time since a trailer left the pivot full, took it to the packaged area and returned, with a stop time of 40 minutes in the process for each full trailer that leaves the pivot, we apply the improvement of maintaining two tractors per team, eliminating this downtime, maintaining a stable flow in the activity.
Metrics and Parameters in the Sector
With the beginning of the studies, we applied the first indicators of productive performance, based on the indicators of: Utilization, Efficiency and Productivity, through the Sit system “Integrated Technology System”.
Immediately upon application, we had results well below expectations, as shown in the following image:
Training and Empowerment Supervision
Supervision was also one of the points enhanced with tips and training for better performance, being one of the main pillars for change and engagement in this sector, which has its great responsibility to reap and select the best fruits for customers.
Adjustment in Number of harvest teams
When starting the analysis, it was seen that there was no pattern in the programming of teams in this activity, following randomly, not maintaining an income. Because there were no parameters and metrics to guide Management.
Implementation of SOP “Standard Operating Procedure”
With the improvements applied, the pass-by-pass of this activity and of this harvest format was standardized, having the standard operating procedure, uniform for any new employee who is hired and programmed for this activity.
Results
Fazenda Sagarana achieved great results in this harvesting sector, in several factors, such as: Enhanced indicators, adjustment in the number of teams, according to its production needs, leadership and an excellent cost reduction in this sector.
Income Indicators (Current)
*Productive Yield Indicators: Harvest, credits to the SIT system (22/07/2022).As seen in the image above, compared to the initial indicators of the sector, we obtained an increase of (37%) in numbers of trailers collected by teams.
Obtaining a great individual income of (50%) more than before there was per employee.
In terms of cost savings, we achieved excellent results, with a reduction of (24%) in direct labor in this sector, further enhancing the company, actually using the labor needed in this activity.
In addition to the quantitative results, qualitative gains were observed in this sector through the application of our SIT control system "Integrated Technology System", obtaining important data for decision-making and monitoring of our fruit, the "flagship" of the company.
These improvements, as well as all the others implemented with the Avilla project, will be perpetuated by professionals who are trained and qualified to monitor and identify gaps in the process.
The biggest beneficiaries, with the specific action beyond the company, were the direct employees linked to the process, positively and directly, impacted by the increase in operational efficiency of Empresa Fazenda Sagarana, in the state of Minas Gerais.
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