Enhancing Efficiency and Empowering Students: How Lean Reshaped the Horticulture Farm

By Jena Armstrong

Understanding the Issue

At the Berea College Horticulture Farm, the balance between education and productivity is crucial. The farm exists not only to provide safe, certified organic produce and plants for the community but also to serve as a hands-on learning environment for students, particularly those in the Agriculture and Natural Resources (ANR) major. However, inefficiencies in the Plant Sale Planning Process were making it difficult to meet these goals effectively.

One of the primary challenges was the time spent planning seed orders. Without a structured approach, rework and delays became common, often resulting in a rushed final stage. The lack of visual management tools, disorganized workstations, and unclear communication only added to the confusion, making it difficult to track progress or ensure timely completion. This inefficiency pulled staff and students away from other critical farm operations, creating a domino effect of reprioritization and lost productivity.

Lean in Action

Horticulture Farm Manager Ema-leigh Forbes partnered with the Office of Continuous Improvement to tackle these challenges using Lean methodology. The goal was to standardize the process, create clarity, and increase student ownership. By introducing structured checklists, the Ema-Leigh significantly reduced wasted time and effort.

Countermeasures:

Measurable Results of Lean

Before implementation, the process required 1,210 minutes (20 hours) of touch time, with a cycle time of 51 days and a Rolled Throughput Yield (RTY) of 51%. After Lean improvements, the touch time decreased to 1,010 minutes (17 hours), saving 200 minutes (3 hours). The cycle time improved to 49 days, reducing the overall process by 2 days, while the RTY increased to 73%, an improvement of 22%.

Cultural Shift: More Engaged Labor Students

Beyond the numbers, the most significant transformation was seen in the students. With clear guidelines and better organization, they now have greater ownership over their work. The new structure allows them to take initiative, engage more deeply in the process, and develop critical problem-solving skills. Students have expressed enthusiasm for the improvements and are eager to pass down the new systems to future labor students in the Plant Sale Planning Process. The checklists are so thorough that new students can confidently step into the process with minimal guidance.

This project strongly aligns with the Berea College’s Great Commitment of “Educational Opportunity.” By giving students direct involvement in an essential farm operation, they gain hands-on experience in project planning, teamwork, time management, and communication. These skills extend beyond the horticulture farm, preparing them for leadership roles in various industries.

Personal Transformation: The Impact of Lean on Leadership

This transformation not only benefited the farm’s operations and students but also had a profound personal impact on those leading the changes. Ema-leigh Forbes reflected on how implementing Lean reshaped her approach to management, emphasizing the importance of effective systems for both operational success and personal well-being.

"My time working with the Office of Continuous Improvement has been incredibly beneficial, not only for our operation but also for me personally. Through our collaboration, we’ve implemented a variety of techniques that have made our work more streamlined and efficient. More importantly, these improvements have given students greater autonomy, an active voice, and a more engaging role in the process, something I cannot understate.

On a personal level, this experience has profoundly shaped my perspective on management. The tools and strategies I’ve gained have allowed me to restructure operations in a way that made it possible for me to truly take the holiday break as a time of rest and rejuvenation. After implementation, I was able to step away, visit with family, and return to this role refreshed and ready for the spring term. That time of rest has had a lasting impact, reinforcing just how valuable effective management structures can be, not just for the operation, but for the people within it."

Looking Forward: Empowering Students

As demonstrated by the improvements at the Horticulture Farm, Lean methodology can transform not just processes, but also the way students engage with their work and develop critical skills. We encourage other departments across Berea College to explore similar opportunities for process improvement. By adopting structured systems and empowering students to take ownership, we can create more efficient operations, foster a culture of continuous improvement, and better prepare students for future leadership roles. Together, let's continue to enhance learning and ensure that every aspect of our campus thrives. Reach out to the Office of Continuous Improvement to start your own Lean transformation today.