JANA HOCKEN MAT HOCKEN WITH the Lean Dairy Farm Eliminate Waste, Save Time, Cut Costs Creating a More Productive, Profitable and Higher Quality Farm ‘Succeeding in business is about managing risk, controlling all the factors that are controllable and constantly improving your competitive advantage. At Open Country Dairy we live by this mantra and Lean Management is integral to everything we do. I cannot commend this book enough to all farmers and business people that strive to improve and grow successful enterprises. An outstanding contribution to NZ farming.’ — Laurie Margrain, Chairman, Open Country Dairy Ltd ‘Within GDF we aim to inspire leading farmers. From a personal experience, I am convinced that the Lean approach is very helpful to improve management. So if you want to improve as a dairy farmer, read this book full of practical tools and experiences.’ — Ad van Velde, President, Global Dairy Farmers, CEO, DairyNext, Owner, Hunsingo Dairy the Lean Dairy Farm the Lean Dairy Farm Eliminate Waste, Save Time, Cut Costs Creating a More Productive, Profi table and Higher Quality Farm JANA HOCKEN MAT HOCKEN WITH First published in 2019 by John Wiley & Sons Australia, Ltd 42 McDougall St, Milton Qld 4064 Office also in Melbourne Typeset in 11/15pt Berkeley Oldstyle © John Wiley & Sons Australia, Ltd 2019 The moral rights of the author have been asserted All rights reserved. Except as permitted under the Australian Copyright Act 1968 (for example, a fair dealing for the purposes of study, research, criticism or review), no part of this book may be reproduced, stored in a retrieval system, communicated or transmitted in any form or by any means without prior written permission. All inquiries should be made to the publisher at the address above. Cover design by Wiley Cover image (upper): © Photos by R A Kearton / Getty Images Cover image (lower): Javier Vargas Printed in Singapore by C.O.S. Printers Pte Ltd 10 9 8 7 6 5 4 3 2 1 Disclaimer The material in this publication is of the nature of general comment only, and does not represent professional advice. It is not intended to provide specific guidance for particular circumstances and it should not be relied on as the basis for any decision to take action or not take action on any matter which it covers. Readers should obtain professional advice where appropriate, before making any such decision. To the maximum extent permitted by law, the author and publisher disclaim all responsibility and liability to any person, arising directly or indirectly from any person taking or not taking action based on the information in this publication. Contents Acknowledgements ix Introduction xi Part I The concept of ‘Lean’ 1 1 Before we get started … 3 2 What is ‘Lean’? 9 3 Applying Lean to dairy farming 31 Part II 10 Lean tools that will transform your farm 43 4 The 8 wastes on the farm 45 5 5S workplace organisation 91 6 Visual management 141 7 Standard work 187 8 Value stream mapping 231 9 Practical problem solving 261 10 Built-in quality 289 11 Total productive maintenance 309 12 Creating flow on the farm 339 13 Visual planning 355 The Lean Dairy Farm Part III the culture of a Lean Farm 371 14 Creating the right culture 373 15 People behaviours 379 16 Lean leadership 385 About the authors 397 Index 399 viii