Getting Things Done! Lean Introduction –

Principles, Rules, Tools of Lean

Dr Richard Keegan

Maximum Benefit – Least Effort

Basis of Lean

Leadership team that builds the capability and

capacity of their people to be able to identify and

fix problems - constantly

Why go “Lean”?

Because it Works…….Two Pilots 2018 and 2019:

Serious savings identified - Euro

Saving of time and effort

Better quality pigs

Feed Conversion Efficiency

Looking at systems, layouts, feed, water, space use

QUICKER

BETTER

CHEAPER.........TOGETHER

Focused on Effectiveness and Efficiency

Doing the right things well!

A War on Waste!!!

What is the alternative?

What is Lean?

Lean Principles:

Identify value

Map Value Stream

Create Flow

Establish Pull

Seek Perfection

Hearts and Minds

Tools and Techniques

Roy Coleman VP

Advanced Manufacturing Systems,

Harley-Davidson (retd)

Principles

Rules

Tools

Questions

• Time

• Money

• Effort

• Respect

• Challenge

Some Lean Principles….

Must want to compete…..

1. Fairness

2. Firmness

3. Consistency

1. Look

2. See

3. Understand

4. Think

5. Do

Dealing with People

Dealing with Processes

Rules

• Process Mapping

• Physical Flow mapping

• Check Sheets – What is going wrong?

• Run Charts – Is it getting better or worse?

• Teams – People working together to improve their business

Five Fundamental Lean tools…..

• What are you doing?

• How are you doing it?

• Why are you doing it?

• Who is going to improve it?

• When?

Key Lean Questions…..

Capture the FACTS!

Make things better…..

• Transportation

• Inventory

• Motion

• Waiting

• Over Processing

• Over-production

• Defects

• People

War on Waste- Absolutely Focused & Relentless

The 7 Key wastes + 1

TIM WOOD s

Benchmarking = Diagnosis

Real Facts – Real Data At the core of all Lean Improvement activities

Lean - Action based on FACTS

No matter how good you think you are there is another level to go to……can you see yourself?

Why Lean does not work?

People don’t believe it will work

Think it is too simple

Think it is too sophisticated

Get blocked by having to KNOW the answers

Afraid to experiment

Afraid to be seen to not know all the answers

Wanting to be seen to know all the answers

Always wanting to know more

Never knowing enough

Wax On... Wax Off...

A question of levels of commitment……

Maximum Benefit – Least Effort

Case Studies – Lean Pig Project

• Case Farm 1: Work Place Organisation

• Case Farm 2: Feed Management

• Case Farm 3 & 4: Feeder Trials

• Case Farm 5: Slaughter Weight

Case Farm 1: Work Place

Organisation

Problem: Disorganised work place

• Time wasted looking for tools/equipment

• Ad-hoc mineral sample and medicine storage

Lean Procedure: 5S Lean Plan (Sort, Set-in-order, Shine, Standardize, Sustain)

• Applies standard house keeping practices to the

workplace high level of workplace organisation

Lean Procedure (5S Plan)

• 5S for maintenance, mineral, medicine &

weaner mixing areas

• Map areas

• Train staff

• Develop & implement plan

• Monitor (checklists and audits)

• Address areas for improvement

Lean Procedure (5S Plan)

• Kanban System to organise and store mineral

samples by month

• Control chart, numbered and colour-coded

• 1-6 Red: substantial action needed

• 7-8 Amber: minor correction needed

• 9-10 Green: acceptable

Outcome

• Saving 30 minutes per person per day

• Waste and poor processes will continue to be

exposed

• Will generate further savings of €10,000 to

€20,000 per year

Before 5S After 5S

Maintenance Store

Case Farm 2:

Accommodation

Plan

Accommodation plan

Outcome:

Full map of unit’s

maximum capacity &

identification of future

building requirements

Problem:

Gradual increases in sow output has resulted in additional

pressure on available weaner & finisher accommodation.

Lean procedure:

Map all accommodation based on feeder & floor area

identify stocking rates pressure points per pen

Accommodation plan

30

Section House Name Room Pen

Pigs /pen Space

Pigs /pen Feeder

1st stage Punched 2 8 20 20

1st stage Flat D 4 8 20 18

1st stage New 4 8 20 20

2nd stage old T/B 1 1-4 20 17

2nd stage old T/B 2 1-4 20 18

2nd stage Old Cavan 4 1-8 20 20

2nd stage New Cavan 4 1-12 20 20

Case Farm 3&4

Feeder Trials

Feeder trial

Problem:

Variable growth rates

between weaner pens

Lean procedure:

Carried out trials

comparing growth rates

on 2 different first stage

feeder designs

Feeder trial

Problem:

Variable growth rates

between weaner pens

Lean procedure:

Carried out trials

comparing growth rates

on 2 different first stage

feeder designs

Outcome:

For this unit, 4ft feeders provided additional

feeder space when compared to swing feeders

& higher growth rates as a result

Wet/Dry Feeder Guards Problem:

Finishers given a break from feed, pre-slaughter transport

Finishers started rooting at the feeders & caused damage. This

results in regular repairs required for finisher feeders.

Lean procedure:

Investigate the cost associated with the fabrication of a feeder guard

& carry out a cost benefit analysis.

Outcome:

Fabrication of 10 feeder guards to be fitted across wet/dry feeders in

pens of pigs ready for sale to prevent damage.

Case Farm: 5

Slaughter

Weight

Supplying out-of-spec product: under/over weight pigs

€7,250 1.7%

of pigs

sold

Small

Volume Significant

Loss

Problem

9,373

Lean Procedure

3 Week

Pre-sale

‘Tops’

Selection

Outcome - All Pigs supplied

Outcome - Pigs Outside Wt. Specification

Total % Outside Weight Spec. = 0.86 %

50% Annual Saving = €3,200

Biggest contributor to

sale weight variation is

birth wt & weaning wt

20% 25%

Outcome - Now going after the other 50%.......

Acknowledgements

• Our Partners

• Lean Consultants

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Further Activities

Webinar Series:

Episode Date Guest Topic

1 26/06/2020 Richard Keegan Becoming Lean – A Guide for Pig Farmers

2 10/07/2020 Jeroen Dewulf

Biosecurity - the first step to excellent health &

performance

3 24/07/2020 Peadar Lawlor Latest advances in weaner pig nutrition

4 07/08/2020 Mirjam Lechner Rearing pigs with intact tails

5 21/08/2020 Jens Sorensen Antibiotic use & reduction

6 04/09/2020 Charlotte Lauridsen Supplementary milk in the farrowing room

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• Booklets:

• Introduction to Lean for Pig Farms

• Lean Pig Farm Case Studies

• Trinity College Dublin training session

• Lean Pig Farm Program – Start & Plus

• Call to action: contact Teagasc PDD

Further Activities continued…