Lean dairy farming: making it happen · Farm hours worked: Jan - June 1883 2157 2558 32303500 0 500...
Transcript of Lean dairy farming: making it happen · Farm hours worked: Jan - June 1883 2157 2558 32303500 0 500...
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Lean dairy farming: making it happen
A. Ryan1, A. Ahearne2, P, O’Connor3 and M. Beecher1 1Animal and Grassland Research and Innovation Centre,Teagasc Moorepark, Fermoy, Co.
Cork, Ireland. 2 Scart Dairy Farm, Cappagh, Dungarvan, Co. Waterford.
3Animal and Grassland Research and Innovation Centre,Teagasc Grange, Dunsany, Co.
Meath, Ireland.
National Dairy Conference
3rd and 5th December 2019
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Lean focuses on cutting out waste, whilst ensuring quality
• Henry Ford
• Toyota in Japan
Many farmers are already implementing Lean without realising it
• Measurement
• Small steps - CHANGE
Why implement Lean? Where is your waste?
• Reduce costs
• Too much work
• Fire fighting – no plan or structure
Introduction
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Farm hours worked: Jan - June
1883 2157
2558
3230
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Farm hours worked: Jan - June
26.2
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Benefits of Lean
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Increase
profitability
– less waste
Improve work
conditions
– satisfaction
Save time
– efficient
practices
Improve
safety
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8 deadly wastes
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WASTE Type Example of WASTE types
TRANSPORT
(materials) Poor farmyard layout resulting in excessive movement of
materials
INVENTORY Excess machinery, keeping cull cows for too long, expired
items
MOTION
(people)
Walking, lifting, searching, moving, carrying
WAITING Meal, vaccines, machinery, people
OVER PRODUCTION Overgrown grass
OVER PROCESSING
Over-cooling, recording too much information, or duplicating
paper work
DEFECTS
(inferior quality) Antibiotic milk, machinery breakdown, low milk solids,
unhealthy cows
SKILLS Not training new employees correctly or at all
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Visualisation Example 1: Large Farm Map
Communication
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Example of a Farm Map
Design
Guidelines: Farm satellite map/
printed on white aluminum
Cost: <€100
How it works: mark paddocks to
be grazed after each farm walk,
for contractor (slurry/ fertiliser/
silage)
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Visualisation Example 2: Workstation
Assess current status of the farm
Communication
Organisation
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Example of a workstation
Design
Guidelines: white board, tape, white
board marker, planner, roster
Cost: <€100
How it works: Weekly 30 min.
meeting, stand up
Key to success: Allow time for
people to get used to it
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Case Study: Aidan Ahearne
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Partnership: Aidan, Lisa &Thomas
Cappagh, Co. Waterford
Craig, Nicky & Stephen,
207 crossbred cows on 82 ha
16 unit herringbone parlour (13 rows)
ACR, manual drafting
Milking Process
• Remove waste using
Lean principles
» 5S, Standardisation
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Measurement Day 1 Day 2
First cluster on 07.08am 07.08am
Last cluster off 08.38am 08.33am
Time taken to treat cow for
mastitis
- -
No. of times exited parlour
pit
14 6
Milking duration 1hr 30min 1hr 25min
Average row time 6min26 sec 6min04 sec
Milking process start time 06.40am 06.32am
Milking process finish time 09.40am 09.10am
Total time: milking process
(hrs.)
3hr 2hr 38min
Case study: Milking process
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5mins
20mins
1. Cow flow: improve cow flow
2. Cow flow: hang gates
3. Reduce times operator exiting parlour pit
4. Teat spraying system
5. Slow milkers
6. Visual mgmt.: yellow tape- 4th cluster
7. 5S board: parlour pit
8. 5S plan: dairy and plant room
9. Fix leaky water pipes
10. Keep large water hose tidy
11. Wash yards immediately after milking
12. Develop a SOP for milking & washing
Recommendations
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Case Study: Milking process
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Cow flow Visual & 5S
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10 13
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79
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5S
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What is 5S? Process for organising, cleaning and maintaining a workplace
Creates a safe, standard, efficient and effective workplace
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Case study: 5S
Before
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After
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Case study: 5S Before After
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Case study: 5S
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Before After
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What is Standardisation?
Standardised work is an agreed set of work procedures
Useful for repetitive processes that need to be done regularly by
different people
SOP
Visual
Location
Update
Training
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Case study: Standardisation – milking process
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Standard operating procedure (SOP)
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Lean lessons learned
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Aidan Ahearne
Perception v reality – some jobs not
as long as perceived
Lean gave the structure needed to tidy
the area
“Walk before you run” start in an area
that is small enough to give you a
‘quick win’
Cleaning is addictive – but first step is
the hardest!
Excellent routine
& low wastage,
high quality
product
Saved: 40 min/ d
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Conclusion
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LEAN
• 8 WASTES
• VISUALISATION
• 5S
• STANDARDISATION
• SAVES TIME
• EXCELLENT
QUALITY
• LESS WASTE
BENEFITS 2020
• REPEAT THIS
EXCERISE ON YOUR
FARM (DISCUSSION
GROUP)
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Thank you to Aidan
for his enthusiasm
and willingness in
this project
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