The Lean Dairy Farmer : Save Time, Cut Costs, Eliminate Waste to Create a More Productive, Profitable and Higher Quality Farm.

Description

the Lean Dairy Farm Contents Acknowledgements Introduction How did this book come about? How will this book help you? Part I The concept of ‘Lean’ Chapter 1 Before we get started … External vs internal locus of control The ‘possible’ mindset A team effort Chapter 2 What is ‘Lean’? What exactly do we mean by ‘Lean’? The history of Lean How did Japanese manufacturing become a leader? A historical timeline of Lean A holistic approach Who uses Lean? Profit Why does your farm need to be profitable? Continuous improvement Competitiveness Change So what is continuous improvement? It won’t happen overnight Chapter 3 Applying Lean to dairy farming Efficiency vs effectiveness The dairy farm business The dairy farming season cycle Benefits of Lean for a farm Part II 10 Lean tools that will transform your farm Chapter 4 The 8 wastes on the farm The three components of work Value (VA) Incidental work Waste A closer look at waste Normal waste and bad waste What is all this waste? Mura: unevenness Muri: overburden Muda: waste The 8 wastes DOWNTIME Defects Overproduction Waiting Non-utilised people, intellect and resources Transportation Inventory Motion Extra-processing Finding waste Stand still and observe Value-added vs non–value added words Day In the Life Of (DILO) . . . Steps to eliminate waste Benefits of eliminating waste Summary Chapter 5 5S workplace organisation How 5S came about What is 5S? Where to use 5S Benefits of 5S The 1st S: Sort Why and what? How to sort Surprise, surprise Don’t forget the electronic stuff! The 3rd S: Shine What and why? How? Shine every day Red tags The 2nd S: Set in Order What and why? How? The 4th S: Standardise What and why? How? The 5th S: Sustain What and why? How? Designing and planning for 5S Summary Chapter 6 Visual management What is VM? Is it in your head? Visualisation How can visualisation be used? Visualisation on the farm Farm problems resulting from poor visualisation You’re not a lone ranger Visual management boards Visual management board rules What do visual management boards look like? Designing an effective team visual management board Setting up your visual management board Benefits of team visual management boards Your farm metrics Visualise your metrics Visual management team meetings Benefits of visual management team meetings What to discuss at visual management team meetings Agenda for visual management team meetings Summary Get your team to think! Chapter 7 Standard work Types of standards Standardisation on the farm Benefits of standardisation Flexibility and standardisation A farm without standardisation Don’t blame the person Never assume The PDCA model How to develop a standardised process 1 Video the existing process 2 Analyse the process 3 Agree on the best method 4 Remove waste steps from the process 5 Balance the work 6 Develop the draft standard document 7 Test the new standard process 8 Improve 9 Finalise the standard document and make it available 10 Train your team 11 Seek continuous improvement The best standard document How to sustain standard work Audits Summary Chapter 8 Value stream mapping What is VSM? Key benefits of VSM The process Current state map Improvements/problem identification Ideal state Future state Action plan VSM symbols Current state map: the how Step 1: walk and understand the actual process Step 2: create the current state map Improvements/problem identification: the how Step 1: open brainstorm (your kaizen bursts) Step 2: the 8 wastes Step 3: other opportunities Step 4: organise Discussing the current state process Ideal state: the how Future state: the how Action plan: the how Step 1: agree on an action plan Step 2: follow up Step 3: celebrate! Continuous improvement Summary Chapter 9 Practical problem solving We love problems When a problem becomes a problem What is a problem? The same problem again? What makes a good problem solver? Problem-solving tools ‘Problem and countermeasure’ sheet The 5 Whys Fishbone diagrams Summary Chapter 10 Built-in quality What is quality? Why should we strive for zero defects? Our interrelated farm processes The cost of poor quality Misconceptions Building a quality culture on your farm Errors and defects We are only human ‘Poka yoke’ (or error proofing) Error proofing systems Andon Summary Chapter 11 Total Productive Maintenance Farm vehicles Why do we have maintenance concerns? Keeping a record The pillars of TPM Design for maintenance Predictive maintenance Planned preventative maintenance Spare parts Autonomous maintenance How to implement autonomous maintenance OEE and focused maintenance What is OEE? Training and knowledge Summary Chapter 12 Creating flow on the farm Spaghetti farm Create a better flow on your farm Information flow Summary Chapter 13 Visual planning The Plan–Do–Check–Act (PDCA) cycle Planning on your farm Strategic planning Annual planning Summary Part III The culture of a Lean Farm Chapter 14 Creating the right culture Toyota’s culture Your farm’s values Chapter 15 People behaviours Understanding people Types of behaviour Psychological filters Chapter 16 Lean leadership Leadership behaviours Where are you spending your time? Empowering people Moving to coaching Motivating people Summary About the authors Index EULA