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The Herlihy farm was one of 15 Dairygold suppliers that started a pilot programme on farm in 2017. Dairygold has trained 200 staff in lean management and the plan now is to roll this out to other Dairygold suppliers.
The concept of ‘lean’ is essentially to create a written procedure for various processes around the farm and organise work practises and tools.
Less time looking for implements and clear guidelines on milking and calf rearing, etc, effectively reduces the time spent doing daily chores.
Lean farming essentially is an effort to try to make dairy farming more efficient. Labour is scarce, so making the best use of the time we have is important.
We need to think about the next generation of farmers and we need to make it attractive for new farmers.
Dairygold milk adviser Sean Crotty and dairy farmer Liam Herlihy showed me around and illustrated why this Dairygold farm is a lean pilot farm.
Organised fencing posts and reels on the farm of Liam Herlihy, Granagh, Co Limerick. Low cost and cheap to set up. Instead of wasting time looking for equipment, it’s clear to everyone where it should be.
Locked medicine store room and locked storage units mean everyone knows where medicines are kept and they are safe.
Locked spray storage cabinet and associated shelves and drawers organise sprays and they are safe.
Spray mask in drawer beside where sprays are stored safely.
When power goes, the light switch is pressed which it is linked to a wall light so when the power comes back, it is easy to see that it’s back.
Visual display management (white board with black magnetic tape) showing the herd health plan.
Space is at a premium in many dairies, so, in this dairy, the hose is popped in through a hatch to minimise disruption and the hatch door is safely closed after.
The inside of the hatch where the hose from the lorry comes through.
A map of the farm showing paddock numbers, weekly chores and key warnings. Again, a simple organisation tool that saves time and helps communication.
The scraper often slips off the rail just inside the wall where the cows are. Hence a small steel crowbar hangs on the outside wall, available when needed.
Workshop with storage space and organisation so finding something is easy.
Tools with red tape indicate they belong to the weanling shed.
Shed tools with yellow tape belonging to the dairy, crush and collection yard.
Display board showing animal health plan and key tools hanging beside crush where they are used.
A large hose for washing the yard, but a smaller more direct hose for cleaning boots reduces waste water, which saves time spreading waste water.
Written washing instructions so everybody knows what needs to happen.
A vent in shed in front yard - it’s tidy, safe and well finished.
Tools hanging in orderly fashion on the Dairygold lean farm means less time spent looking for tools.
Standard operating procedure (SOP) for milking process up on a wall in the dairy so if Liam or Geraldine are not present, it’s easier for someone to come in and do the job.
Spare parts arranged in orderly fashion again means finding parts is easier and more efficient.
Camera monitors on top of the wall showing the milker what’s on the road. Prior to installation, Liam had to follow each batch of cows out across the road once finished milking.
Dairygold leanfarm signage at launch event in Limerick.
Minister Creed gets shown around the dairy by Liam and Geraldine Herlihy at the Dairygold leanfarm launch event.
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