The lean dairy farm : eliminate waste, save time, cut costs : creating a more productive, profitable and higher quality farm / Jana Hocken with Mat Hocken.

Format:

Book

Author/Creator:

Hocken, Jana, author.

Hocken, Mat, author.

Language:

English

Subjects (All):

Dairying.

Dairy farms--Management.

Dairy farms.

Physical Description:

1 online resource (427 pages)

Edition:

1st ed.

Place of Publication:

Milton, Qld : Wiley, 2019.

Summary:

Make your farm better, smarter, and more productive The Lean method is revolutionising farming globally with its proven approach for reducing waste, improving productivity and sustaining profits.In The Lean Dairy Farm, dairy farmer and Lean consultant Jana Hocken explains why this approach is essential to every dairy farm and how to apply these tools, practices and principles to your dairy operation. The Lean Dairy Farm helps reduce the common problems and stressors faced by farmers every day: long work hours, high staff turnovers, repeat problems, breakdowns, wastage, safety and high costs. Using her own family's dairy farm as a case study, Jana provides insight into how the Lean approach applies to farming, introduces practical tools to help you improve efficiency and reduce waste, and shows you how to create a farm culture that supports Lean thinking. Even if Lean is entirely new to you, this book offers a simple blueprint for applying its principles and practices to improve your farm. * Quickly make use of basic Lean concepts on your farm * Identify and eliminate waste in farm processes * Organise your farm effectively to improve productivity * Standardise your processes to do everything right the first time * Develop an engaged, high performing team If you want a more efficient, profitable and robust dairy farm, The Lean Dairy Farm is for you.

Contents:

Intro

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

How?.

The 4th S: Standardise

The 5th S: Sustain

Designing and planning for 5S

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

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

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!

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

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

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

Chapter 12 Creating flow on the farm

Spaghetti farm

Create a better flow on your farm

Information flow

Chapter 13 Visual planning

The Plan-Do-Check-Act (PDCA) cycle

Planning on your farm

Strategic planning

Annual planning

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

About the authors

Index

EULA.

Notes:

Includes index.

Description based on print version record.

ISBN:

9780730368434

0730368432

9780730368427

0730368424

OCLC:

1089608700