The lean dairy farm: save time, cut costs, eliminate waste to create a more productive, profitable and higher quality farm

the Lean Dairy Farm......Page 5
Contents......Page 9
Acknowledgements......Page 11
 How did this book come about?......Page 13
 How will this book help you?......Page 15
Part I The concept of ‘Lean’......Page 19
  External vs internal locus of control......Page 21
  The ‘possible’ mindset......Page 23
   A team effort......Page 24
  What exactly do we mean by ‘Lean’?......Page 27
   How did Japanese manufacturing become a leader?......Page 30
   A historical timeline of Lean......Page 32
  A holistic approach......Page 34
  Who uses Lean?......Page 36
  Profit......Page 37
   Why does your farm need to be profitable?......Page 38
   Competitiveness......Page 41
   Change......Page 42
   So what is continuous improvement?......Page 43
  It won’t happen overnight......Page 47
  Efficiency vs effectiveness......Page 49
  The dairy farm business......Page 52
   The dairy farming season cycle......Page 55
  Benefits of Lean for a farm......Page 57
Part II 10 Lean tools that will transform your farm......Page 61
   Value (VA)......Page 63
   Waste......Page 65
  A closer look at waste......Page 66
   Normal waste and bad waste......Page 70
  What is all this waste?......Page 71
   Mura: unevenness......Page 72
   Muri: overburden......Page 73
   Muda: waste......Page 74
   DOWNTIME......Page 75
   Defects......Page 76
   Overproduction......Page 80
   Waiting......Page 81
   Non-utilised people, intellect and resources......Page 83
   Transportation......Page 85
   Inventory......Page 88
   Motion......Page 89
   Extra-processing......Page 93
  Finding waste......Page 94
   Stand still and observe......Page 97
   Value-added vs non–value added words......Page 98
   Day In the Life Of (DILO) . . .......Page 100
  Steps to eliminate waste......Page 102
  Benefits of eliminating waste......Page 103
  Summary......Page 104
  How 5S came about......Page 109
  What is 5S?......Page 111
  Where to use 5S......Page 113
  Benefits of 5S......Page 115
  The 1st S: Sort......Page 117
   Why and what?......Page 118
   How to sort......Page 119
   Don’t forget the electronic stuff!......Page 122
   What and why?......Page 127
   How?......Page 130
   Shine every day......Page 131
   Red tags......Page 133
   How?......Page 135
   How?......Page 143
   How?......Page 147
  Designing and planning for 5S......Page 152
  Summary......Page 153
  What is VM?......Page 159
   Is it in your head?......Page 162
  Visualisation......Page 163
   How can visualisation be used?......Page 165
   Visualisation on the farm......Page 168
   Farm problems resulting from poor visualisation......Page 172
   You’re not a lone ranger......Page 175
  Visual management boards......Page 177
   What do visual management boards look like?......Page 178
   Designing an effective team visual management board......Page 180
   Setting up your visual management board......Page 184
   Benefits of team visual management boards......Page 187
  Your farm metrics......Page 188
   Visualise your metrics......Page 191
  Visual management team meetings......Page 193
   Benefits of visual management team meetings......Page 194
   What to discuss at visual management team meetings......Page 196
   Agenda for visual management team meetings......Page 197
  Summary......Page 198
   Get your team to think!......Page 199
 Chapter 7 Standard work......Page 205
  Types of standards......Page 207
  Standardisation on the farm......Page 208
  Benefits of standardisation......Page 215
   Flexibility and standardisation......Page 218
   A farm without standardisation......Page 220
   Don’t blame the person......Page 222
   Never assume......Page 224
   The PDCA model......Page 227
  How to develop a standardised process......Page 229
   1 Video the existing process......Page 230
   2 Analyse the process......Page 231
   4 Remove waste steps from the process......Page 232
   5 Balance the work......Page 233
   6 Develop the draft standard document......Page 235
   8 Improve......Page 236
   11 Seek continuous improvement......Page 237
  The best standard document......Page 238
  How to sustain standard work......Page 241
   Audits......Page 242
  Summary......Page 245
 Chapter 8 Value stream mapping......Page 249
  What is VSM?......Page 250
   Key benefits of VSM......Page 251
  The process......Page 252
   Improvements/problem identification......Page 253
   Ideal state......Page 254
   Action plan......Page 255
  Current state map: the how......Page 256
   Step 1: walk and understand the actual process......Page 257
   Step 2: create the current state map......Page 259
   Step 1: open brainstorm (your kaizen bursts)......Page 268
   Step 2: the 8 wastes......Page 269
   Step 4: organise......Page 270
  Ideal state: the how......Page 271
  Future state: the how......Page 272
   Step 1: agree on an action plan......Page 273
   Step 3: celebrate!......Page 274
  Summary......Page 275
  We love problems......Page 279
  When a problem becomes a problem......Page 282
  The same problem again?......Page 285
  What makes a good problem solver?......Page 289
  Problem-solving tools......Page 290
   ‘Problem and countermeasure’ sheet......Page 293
   The 5 Whys......Page 294
   Fishbone diagrams......Page 297
  Summary......Page 302
 Chapter 10 Built-in quality......Page 307
  What is quality?......Page 309
   Why should we strive for zero defects?......Page 310
   Our interrelated farm processes......Page 311
   The cost of poor quality......Page 312
   Misconceptions......Page 313
  Building a quality culture on your farm......Page 314
  Errors and defects......Page 315
   We are only human......Page 318
  ‘Poka yoke’ (or error proofing)......Page 319
   Error proofing systems......Page 320
   Andon......Page 321
  Summary......Page 323
 Chapter 11 Total Productive Maintenance......Page 327
  Farm vehicles......Page 329
   Why do we have maintenance concerns?......Page 330
   Keeping a record......Page 331
  The pillars of TPM......Page 334
  Design for maintenance......Page 335
  Predictive maintenance......Page 339
  Planned preventative maintenance......Page 340
   Spare parts......Page 344
  Autonomous maintenance......Page 346
   How to implement autonomous maintenance......Page 347
  OEE and focused maintenance......Page 349
   What is OEE?......Page 350
  Training and knowledge......Page 352
  Summary......Page 353
 Chapter 12 Creating flow on the farm......Page 357
  Spaghetti farm......Page 360
  Create a better flow on your farm......Page 362
  Information flow......Page 366
  Summary......Page 367
 Chapter 13 Visual planning......Page 373
  The Plan–Do–Check–Act (PDCA) cycle......Page 374
   Strategic planning......Page 378
   Annual planning......Page 381
  Summary......Page 384
Part III The culture of a Lean Farm......Page 389
 Chapter 14 Creating the right culture......Page 391
  Toyota’s culture......Page 392
  Your farm’s values......Page 393
 Chapter 15 People behaviours......Page 397
   Types of behaviour......Page 398
   Psychological filters......Page 400
   Where are you spending your time?......Page 403
  Empowering people......Page 406
  Moving to coaching......Page 408
   Motivating people......Page 410
  Summary......Page 411
About the authors......Page 415
Index......Page 417
EULA......Page 427