Responding to this question submitted in a separate article about "5 examples of big production problems and effective ways to overcome them" it is necessary to know a little about the conditions in his workplace so that the solution is right on target. Due to very little data, we will come up with some approximate solutions with the aim of ultimately increasing the daily volume of milk.
1. Problems with milk supply from dairy cows
A standard dairy cow produces 8 liters of milk per day. To produce 20,000 liters of milk every day, the number of dairy cows is at least 20,000 divided by 8 to become 2,500 dairy cows.
If this amount is less then the cow's milk will be less than 20,000 liters per day. Complete the number of dairy cows according to the standard calculation to get at least 20,000 liters of milk every day.
Another way to increase cow's milk production can be pursued by raising superior types of cows so they can produce more lactation every day.
Several superior types of dairy cattle include:
- Ayrshire cows from Ayr Scotland are capable of producing 24.7 liters of milk a day
- Swiss Brown Cows from Switzerland can produce 24.6 liters of milk every day.
- Holstein - Friesian cows from the Netherlands can produce 21 liters of milk a day.
- British Milking Shorthorn cattle are capable of producing 19 liters of milk a day.
- Guernsey cows in the Guernsey Islands can produce 16.4 liters of milk per day.
- Jersey cows from Jersey are capable of producing 16 liters of milk a day
- Red Poll cows from England are capable of producing 12 liters of milk a day
It is also important to pay attention to the delivery of cow's milk from the farm to the factory to ensure that it meets quality standards, for example the temperature during delivery must be at 4°C before the pasteurization process removes harmful bacteria.
2. The problem of inefficient production processes
The target of 20,000 liters of milk a day was not achieved while we assume that previously this target has been achieved but there has been a decline in yields.
We assume that supply from dairy farms is not constrained by volume demand and timely delivery. This means that the next process will be seen in the factory in the form of pasteurization, heating and packaging processes.
The dairy processing factory uses high technology and the production process is controlled automatically and does not require a lot of people.
The next question is is it possible that the input volume of the milk process does not match the output volume of this high-tech machine and causes a loss of 2,000 liters of milk every day?
One way to ensure this is by calculating the OEE of a milk processing machine. For a high-tech machine like this one should achieve a standard OEE of 85% and even an optimal OEE value of 95% because of the small hidden loss factor in a capacity of 20,000 liters of milk a day.
OEE is affected by the six big losses, so it is necessary to observe carefully whether there are big loss points that affect both the availability, performance and quality rate of OEE.
Availability
In a day the milk processing machine will work non-stop 24 hours to produce a volume of 20,000 liters of milk. If there is machine damage, machine settings and maintenance, the machine operating time is under working time or machine availability is not 100%.
The target of 20,000 liters of milk cannot be achieved if availability is below 100%.
The solution for 100% availability is by creating zero breakdown and zero machine settings because machine settings are only set once at start up and the maintenance schedule has been coordinated to prevent downtime during the production process.
Performance
The performance of the milk processing machine according to the machine specifications is the standard time base for the process of the machine so that it can produce 20,000 liters of milk a day. Engine performance decreases if there is a momentary error or low speed.
Momentary errors can be caused by
- Overload and overheat
- Unstable power source causes under voltage.
Examples of low speed prevention by ensuring the setting parameters are appropriate or maintaining the availability of process input supplies so that the processing machine continues to operate.
Quality
The difference with other types of production, when there is inappropriate quality in the results of milk processing, the number of rejects is 100%. All dairy products that do not meet quality standards must be destroyed and replaced with the next batch of processed milk.
For example, in 1 day there is a quality problem causing the loss of the daily production target of 20,000 liters of milk. The next impact is the problem of carry over having to catch up on the target shortfall and causing over capacity.
Detect quality problems from the first process to avoid the impact of greater losses.
3. Daily target increase
The increase in consumer demand is directly proportional to the production target. Initially the daily target was only 18,000 liters of milk but now it must be able to produce 20,000 liters of milk a day.
If the conditions are ideal without any downtime from six big losses or without wasting work (a very efficient process), then the following options are available as an effort to increase daily production capacity:
- Milk supply: Increase the number of dairy cows or superior cows so that they can increase the supply volume of milk to factories as mentioned in point 1.
- Machinery: Increase the capacity of the milk processing machine or make the cycle time shorter if possible to compensate for the increased supply volume of milk from dairy farms.
- Working method: Adding to the process time base by setting shift work. This only applies if the current condition is that the 3 shift 3 group work system is then changed to 3 shifts 4 groups so that the production process is non-stop.
- Look for other outside dairy processors to help offset the demand for increased milk volumes.
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