Solnechny Dar greenhouse complex introduces improvements within the “Labor Productivity” national project

An article dedicated to the results of the “Labor Productivity” program, implemented in one of ECO-Culture’s greenhouse facilities, was published on the website of the FCC (Federal Center of Competence in Labor Productivity, the national project’s coordinator).

Lean production tools allowed the Solnechny Dar complex located in Stavropol Krai and ranked among the leaders of indoor vegetable production in the region, to double the harvesting and packing rate along with the optimization of some other work processes.

The expanded support received from the FCC enabled the company to join the national project in 2021. As a result, the primary “harvest-packaging-shipment of medium-sized red tomatoes” flow output has increased by 26%, with the process turnaround time reduced by half.

Red medium-sized tomatoes account for 90% of the greenhouse complex’s overall yield. Consumers love the eco-friendly vegetable for its aesthetic appearance, excellent organoleptic properties, and unsurpassed taste of its juicy flesh.

According to Eduard Natsibulin, the FCC project manager, the working group analyzed the greenhouse complex’s production processes in order to identify any losses and implement measures to eliminate them. Lean production technologies allowed to increase the output by 22%, with the amount of end product rising from 30 to 50 thousand packs per shift. Beforehand, the experts came up with a visual diagram of the entire production process to clearly demonstrate the sections of the production chain that require readjustment, i.e. the ones experiencing losses of productivity and time.

The improvements made it possible to minimize interruptions in the production capacity of the conveyor lines. The ultimate result was halving the time from product arrival at the distribution center to packaging. This means that the tomatoes harvested in the greenhouses now reach the end consumer faster.

With the ongoing introduction of efficient technologies at Solnechny Dar complex, another step is focused on the “creation of a nutritious irrigation formula”.

The specialists also elaborated on further improvements to be taken by the greenhouse complex on its own. Those include, for instance, daily harvesting instead of scheduled harvesting three times a week. According to experts, this will ensure optimal average ripeness of the products while reducing the number of transportation runs to the distribution center.

Lev Berlin, the CEO of Solnechny Dar greenhouse complex, notes that apart from optimal solutions to specific optimization problems, the FCC provides managers and staff with valuable skills to improve the work processes efficiency. The entire management team, as well as a few rank-and-file employees, has already undergone training. This process was synchronized with the implementation phases of the project inside the complex’s greenhouses and distribution center. It was the balance of theory and practice, as well as the systematic implementation and expansion of lean production practices that provided convincing measurable results to confirm the high efficiency of the “Labor Productivity” national project for the enterprises participating.

For the full text of the article, please visit the News section of the FCC’s website.