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 resourcesTransportation; 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: StandardiseWhat 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 metricsVisual 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
