Lean Practices in Our Alphonso mango Farming and agriculture ecosystem

1. Value Stream Mapping

• Purpose: Identify and optimize the flow of activities from planting to mango harvesting and mango distribution.
• Application: Map out the entire alphonso mango online development process, from seedling preparation to market delivery. Identify bottlenecks, waste, and inefficiencies. For example, if there are delays in irrigation or excessive time spent on manual labor, these can be pinpointed and addressed.

2. Continuous Improvement (Kaizen)

• Purpose: Foster a culture of ongoing improvement.
• Application: Encourage farmers and workers to suggest small, incremental changes that can improve efficiency and quality. For instance, using more efficient irrigation techniques or improving the layout of the farm to reduce travel time for workers.
• Example – www.alphonsomangoes.online workers always empower for kaizen activities, one simple input like box dimension changes saves Rs120 per order

3. Just-In-Time (JIT) Production

• Purpose: Minimize inventory and reduce waste by producing only what is needed, when it is needed.
• Application: Implement JIT principles in the supply of inputs like fertilizers, pesticides, and water. This ensures that resources are used efficiently and reduces the risk of spoilage or overstocking.
• Example – The peak inventory at www.alphonsomangoes.online farm is not more than 50 dozen. Rest daily harvest of 250 dozen sold daily through online and offline channels

4. 5S Methodology

• Purpose: Create a clean, organized, and efficient work environment.
• Application:
  • Sort: Remove unnecessary items from the farm and storage areas.
  • Set in Order: Organize tools and equipment for easy access.
  • Shine: Keep the farm and equipment clean and well-maintained.
  • Standardize: Develop and maintain standards for cleanliness and organization.
  • Sustain: Ensure that the 5S practices are consistently followed.

5. Standardized Work

• Purpose: Ensure that tasks are performed consistently and efficiently.
• Application: Develop standard operating procedures (SOPs) for tasks such as planting, pruning, and harvesting. Train workers to follow these procedures to maintain quality and efficiency.
• Right from harvesting to dispatch everything is standardised, Alphonso Mangoes in terms of weight, Boxes in terms dimensions and workers in terms of SOP and Control plan.

6. Total Productive Maintenance (TPM)

• Purpose: Maximize the efficiency of equipment and reduce downtime.
• Application: Regularly maintain and inspect farm equipment to prevent breakdowns. Train workers to perform basic maintenance tasks, and establish a schedule for more comprehensive maintenance.

7. Pull System

• Purpose: Produce and deliver products based on customer demand.
• Application: Use a pull system to manage the harvest and distribution of Alphonso mangoes. This means harvesting and delivering mangoes only when there is a confirmed order, reducing the risk of overproduction and spoilage.

8. Visual Management

• Purpose: Use visual tools to communicate and manage processes.
• Application: Use visual boards to track the progress of planting, growth, and harvesting. Display key performance indicators (KPIs) such as yield, quality, and customer satisfaction in a visible location.
• Weighing chart of mangoes / Different location for each boxes are unique features at our farms.

9. Root Cause Analysis (RCA)

• Purpose: Identify and address the underlying causes of problems.
• Application: When issues arise, such as a drop in yield or quality, conduct a root cause analysis to determine the cause. This could involve examining soil conditions, water management, or pest control practices.
• We also applied this methodology for customer complaints and resolve within 48 hrs.

10. Employee Empowerment

• Purpose: Engage and empower employees to contribute to the improvement process.
• Application: Encourage workers to take ownership of their tasks and provide them with the training and tools they need to make informed decisions. This can lead to more innovative and efficient practices.
• We believe in woman empowerment, and support them in earning more through BACHAT GAT with Alphonso Mango products manufacturing

11. Supply Chain Optimization

• Purpose: Ensure that the supply chain is efficient and responsive.
• Application:
  • Supplier Management: Build strong relationships with suppliers of seeds, fertilizers, and other inputs to ensure timely and reliable delivery.
  • Logistics: Optimize transportation and storage to reduce costs and maintain the quality of mangoes.
  • Customer Feedback: Regularly collect and analyse customer feedback to improve the product and service.

12. Technology Integration

• Purpose: Leverage technology to enhance efficiency and accuracy.
• Application:
  • IoT Sensors: Use Internet of Things (IoT) sensors to monitor soil moisture, temperature, and other environmental factors.
  • Data Analytics: Analyze data to make informed decisions about planting, irrigation, and pest control.
  • Automation: Implement automated systems for tasks like irrigation and pest monitoring to reduce labor costs and improve accuracy.

13. Sustainable Practices

• Purpose: Ensure long-term viability and environmental responsibility.
• Application:
  • Water Management: Use drip irrigation and other water-saving techniques to reduce water usage.
  • Pest Control: Implement integrated pest management (IPM) to reduce the use of chemical pesticides.
  • Soil Health: Use organic fertilizers and crop rotation to maintain soil health and fertility.

14. Quality Control

• Purpose: Maintain high standards of product quality.
• Application:
  • Regular Inspections: Conduct regular inspections of mango trees and fruit to identify and address issues early.
  • Training: Train workers on quality standards and best practices for handling and storing mangoes.
  • Feedback Loops: Establish feedback loops with customers to continuously improve the quality of the product.

15. Customer Focus

• Purpose: Ensure that the product meets customer needs and expectations.
• Application:
  • Market Research: Conduct market research to understand customer preferences and trends.
  • Customization: Offer customization options for different customer segments, such as organic or sustainably grown mangoes.
  • Customer Service: Provide excellent customer service to build loyalty and repeat business.

By implementing these lean practices, Alphonso mango farmers like us can improve efficiency, reduce waste, and enhance the quality of their product. This not only benefits the farmers but also ensures that customers receive the best possible mangoes, leading to a more sustainable and profitable agricultural ecosystem.