Let’s Keep The Calves Alive and Healthy!

Galih Purboningrum
LEAP Program Batch 6.2
Dairy Farm Operation
METHODOLOGY

D M A I C
DEFINE MEASURE ANALYZE IMPROVE CONTROL
• Problem • Highest Mortality • Causes of • Trial design • Control
statement Causes of Disease • Trial Results method
• Goal Disease • Root Problem • Trial • Action Plan
Statement • Top 3 Major • Potential Conclusion
• TImeline Disease in heifer Improvements • Other
• Project Chater Improvement
Proposals
Define
PROJECT DEFINITION
 DEFINE - PROJECT DEFINITION
“Goal Statement”
“ Improving heifer performance by reducing morbidity
number due to pneumonia case in unwean phases.
Balance In KPI Target 10%”.

“Project Timeline”
Aug Sept Oct Nov-Dec Jan Feb-March

FIELD TRIAL A TRIAL B TRIAL C Continous

OBSERVATION Collecting Data and
Improvement Plan
- Monitoring Analysist
- Current Barn Condition Trial A & B - Collect Data
(showing data) - Presentation
- Day to Day Activity - Next Plan
- Analysist situation Action
Dairy Cow Cycle

Pregnant Cow
7 2

Dry Cow
(Rest Period will start 7
months of preganancy Newborn-Unweaning
periode ) Phases (0-2mo)
Heifer
Raising

6 Lactation 3
Cow
Weaning / Growing
Heifer (>2mo)
Calving
Session Heifer
Pregnant
5
Yearling Phases -
4 Ready to Artificial
Insemination
(13months)
 Heifer Raising
Activity
DEFINE - PROJECT DEFINITION

Vaccination &
Dehorning Medication Deworming Feeding

Taking Care Feeding

Sanitation
Newborn Calf Milk

Barn Condition
2 barn: Average Temp Barn in the morning: 22-23°C
Calfbarn 1 Average Temp Barn in evening(2-3 pm) : 24-25 °C
Average Temp Barn in evening(7-8 pm) : 23-24°C
Windspeed: min 2,5-3
m²/detik -180 x 10 m2
THI (Temperature Humidity - 70 x 15 m2
Index): 80-87
 DEFINE - PROJECT DEFINITION

PROJECT CHARTER

PROJECT SPONSOR Yuliantoni Queen

Head of GGL Operation

PROJECT CHAMPION Yuniantoni Eko N.

Dairy Operation Sub Div Head

PROJECT ADVISOR Syaiful B. Dairy Farm Op. Dept. Head

Arief R. Veterinary Dept. Head

Anggun P. Heifer Raising

LEAP 6.2
PMO Galih Purboningrum

TEAM MEMBER Calfbarn Team

MEASURE
PROJECT MEASUREMENT
 Background

Current Condition
18%
16% 16%
16% “Penumonia are Top 1
14% highest morbidity in calfbarn area”
12%
12%
9%
10%
8% 8%
8%
6% 7% 6%
7%
Target of KPI
6%
4%
Pneumonia are 10%
2% 1%

0%
Jan-21 Feb-21 Mar-21 Apr-21 May-21 Jun-21

Pneu Linear (Pneu) Diare

Scabies Bloat

120

100 98
93 95 92
89 90
80 80 82
72 71
60 57
Amount of
49
40 43
34 34
Pneumonia from
32
20
14
19
26 25
18
24
19 January-Juni 2021
9 9
0 0

Morbidity Population
 MEASURE

“CURRENT FACT”

Estimated ADG Estimated ADG

(Normal) (Pneumonia Case) “Comparison ADG between
Pneumonia Calf and Normal”
0.5 kg 0. 3 kg

100%
90%
80%
70%
60% 0.48
0.42 0.47
50% 0.4 0.39 0.41
0.35
0.3 0.28 Target ADG
40%
0.2 0.37 ADG Per Month
30% 0.36
0.24
20%
10%
0%
21 21 21 21 21 21 21 2 1 21 21 2 1 21 22
an- eb- ar- pr- ay- un- Jul- ug- ep- ct- ov- ec- an-
J F M A M J A S O N D J

**Calculated based on Daily GGL Dairy Database

 MEASURE

“Cost of Pneumonia ”

“Delaying Weaning”

Estimated Value Unwean Calf Estimated Value Unwean Calf

(60days) Due To Pneumonia (70days)
Rp.3.669.931,- Rp.4.129.530,-

Increasing 12,5% or Rp.459.599,- for every

one cycle (10 days) pneumonia treatment

**Calculated based on Daily GGL Dairy Database

ANALYZE
FINDING ROOT CAUSE
Activity of Taking care Newborn Calf
(Calf Management)
Background

Taking Care
Newborn Calf

Feeding Monitoring Managing House Managing transition

Growth and Environment from Milk Replace to
Colostrum
solid Folid

“Royal Veterinary College (2018) has shown that

mortality rates of liveborn dairy heifers in their
first month of life ranged between 0% and 12%”
 ANALYZE

Feeding Monitoring
Colostrum Growth

Quality of Increasing Average

Colostrum Daily Gain

Protect Calves
Immunity
No Ad- Hygiene,
Libitum Feed Sanitation of
Environment

Managing Feed Managing House

Transition and Environment
Knowledge Gap:
• Fluctuative weather (Temperature,
Windspeed, Humidity)
• People Behaviour
*Based on MSD Animal Health United Kingdom • Age of sampled calves
IMPROVEMENT
IMPLEMENT & VERIFY THE
SOLUTION
 IMPROVE (ACTION PLAN)
TRIAL 1

Sanitation Trial and Cost of Trial

Description Before After
Treatment Treatment

Barn Sanitation 3x/Week Every day

(Virkon/Limestone)

Changes Bedding 1x/Week 3x/Week

(Maternity)

Reason:
“Frequency of barn sanitation based on: daily flushing
Changes bedding based on: daily frequency of calving”

*based on daily activity

 IMPROVE
TRIAL 2

Pest Control Trial and Cost of Trial

Description Before After
Treatment Treatment

Zyrox - 3x/week

Neporex -
IMPLEMENT & VERIFY1-2x/week
THE
SOLUTION

Reason:
“Depends on the condition of fly trap.”

**Calculated based on Daily GGL Dairy Database

 IMPROVE
TRIAL 3

Feeding on Newborn Calves

Using 1-1-2 Methods for Standard

BRIX Quality
Newborn Dairy Calves
1. Use Colostrum from the FIRST
milking for the FIRST feed

2. Give colostrum within ONE

hours of the calf’s birth BRIX Scale Average BRIX
14
Quality in GGL

3. 12
12
Give at least TWO litres 10
10
8
8
6
6
4

2 3 3 3 3
2
0 1
*Based on Department Agriculture and 22% 23% 24% 25% 26% 27% 28% 29% 30% 31%
Holticulture Development Board UK, 2021
 IMPROVE
TRIAL 3

Feeding on Newborn Calves

Before After
1. • Newborn calves
give fresh
• New Born colostrum for it’s
mother
Calves give
• CMR Milk add by
frozen
Doxy treatment
colostrum • Daily Feed
Measurement for
unwean by
program

UMUR KEBUTUHAN PAKAN PER HARI

PEN JUMLAH TAG NO. LAHIR

Minggu Bulan KLSRTM SUSU
/ KONST KONST KONST 7-
Hari
MR 0-3 (Kg) 4-6 (Kg) 12 (Kg) HIJAUAN

                         
CB2.28 1 51867 16/10/21 23 3 1 0 6 0,2 0 0 0
CB2.28 1 51869 16/10/21 23 3 1 0 6 0,2 0 0 0
RESULT & CONTROL
SUSTAINABLE IMPROVEMENT
 RESULT

Implementation Result

Pneumonia Trendline Fly Gramation on Farm Area

120 1000
880.6
899.8 900
Morbidity Mayor Disease 2021 100 95.4
800
20% 87 680
16% 16% 700
13% 80 74
15% 12% 600
9% 11% 11% 59.7
8% 8% 9% 8% 58.8
10% 7% 6% 7% 8% 60 500
6%
5% 2% 0% 38.6 400
1% 0% 1% 0% 1% 0% 40 295
1% 30 31.2 300
0% 25 22
20 19 200
1 1 1 1 1 1 1 21 21 1 1 1 2 20
-2 -2
ar
-2 r-2 ay-2 un-2 l- 2 g- p- t-2 ov-2 ec-2 an-2
J an F eb M A p J J u
Au S e Oc
N D J
100
M
0 0
Ja
n
Fe
b ar Ap
r ay ne Ju
ly st be
r er be
r
be
r
Pneu Linear (Pneu) Diare M M Ju ugu m tob m m
A e c e e
pt O v c
Se No de

Calf Barn Maternity SNB Calfbarn 2

- Pneumonia trend line is

decreasing along 2021
“Since the trial of fly pest in October 2021
- Pneumonia rate become 0% in
the gramation was decresing”
the end of 2021
**Calculated based on Daily GGL Dairy Database
 RESULT

Potential Cost Saving

Cost of Mortality Calves Cost of Morbidity Calves

Cost saving from mortality in unwean Cost Saving about delaying weaning
phases : Rp. 3.669.930,-/head phases: Rp.267.000,-/2weeks
treatment/head

Lost cost mortality due to pneumonia Lost cost morbidity and to pneumonia
from July-Dec201: 35 head x from July-Dec201: 146 head x
Rp.3.669.930,- = Rp. 128.447.580 Rp.267.000,- = Rp.38.982.000,-

**Calculated based on Daily GGL Dairy Database

 RESULT

COST IMPACT
TRIAL

Descriptio Doing Trial Cost Before Cost After Differentiation

n Treatment Treatment

Trial 1 Sanitation Rp.185.000,- Rp.2.180.000,- Frequency

Change Frequency
Bedding
Trial 2 Fly Treatment Rp.563.200,- Rp. 2.370.400,- Frequency &
(Neporex) Vendor
Fly Treatment Frequency &
(Zyroxx) Vendor
Trial 3 Feeding - - Change Methods
Colostrum
Feeding Alfafa Change Amounts
 CONTROL
CONTROL

SUSTAINABLE
CONTROL

STANDARIZATION TYPE REFRENCES

Swab Test For Control Form SNI and W-

Equipment QC.09

SOP Procedure Flow Process W-DH. 05

(Feeding Milk) (SOP & WI)

SOP Procedure Flow Process W-DH. 08 and

(Sanitation Process) (SOP & WI) W-DH. 16

“The application and procedure

sanitation and another must follow the
WI issued by GGL Dairy QA & QC Team”
APENDIX
Comment, suggestion and question are welcome!
 IMPROVE

Implementation Result
Potential Cost Saving
Pneumonia Trendline
Total Saving
Morbidity Mayor Disease 2021 Cost Of Mortality Calves Rp. 47.709.101,-
20%
16% 16%
15%
9%
12% 11% 11%
13%
Cost of Morbidity Calves Rp.8.732.381,-
10% 8% 8% 8% 9% 8%
6% 7% 6% 7%
5% 2% 0%
1% 0% 1% 0% 1% 0%
0% 1%

21 21 1 1 1 1 1 21 21 1 1 1 2
a n- e b- a r-2 pr-2 ay-2 un-2 ul- 2
ug- e p- ct-2 ov-2 ec-2 an-2
J F M A M J J A S O N D J

Pneu Linear (Pneu) Diare “Total Estimated Saving from

The Project on Heifer Raising Area Rp.56.441.481,-”

- Pneumonia trend line is

decreasing along 2021
- Pneumonia rate become 0% in
the end of 2021
**Calculated based on Daily GGL Dairy Database
 IMPROVE (ACTION PLAN)
TRIAL 1

Sanitation Trial and Cost of Trial

Description Before After
Treatment Treatment

Barn Sanitation 3x/Week Every day

Changes 1x/Week 3x/Week

Bedding

Cost/Week Rp.140.800,- Rp.592.600,-

Cost/Month Rp.563.200,- Rp.2.370.400,-

“There is increasing sanitation cost

in the amount of 25% or Rp.1.807.200,-”

**Calculated based on Daily GGL Dairy Database

 MEASURE

Attachment 1

Months Cost Per Head Unwean Dead Total Cost

Bcs of Pneumo

Jul-21 Rp3.669.931 7 25.689.516

Aug-21 Rp3.669.931 2 7.339.862

Sept-21 Rp3.669.931 3 11.009.793

Oct-21 Rp3.669.931 7 25.689.516

Nov-21 Rp3.669.931 10 36.699.309

Dec-21 Rp3.669.931 6 22.019.585

Total 35 128.447.580
 MEASURE

Attachment 2
Tanggal Suhu (c) Jam COde Humidity(%) THI Wind Speed
06/06/2021 28 9:00pm pm 87 80,66 2
06/06/2021 27,1 9:00am am 87 79,15 2
06/06/2021 27,5 8:00am am 87 79,82 1
06/06/2021 28,1 7:00am am 88 80,96 1
06/06/2021 28 6:00am am 88 80,79 1
06/06/2021 32,4 4:00am am 70 84,99 1
06/06/2021 31,4 5:00am am 73 83,99 1
06/06/2021 32,2 3:00am am 74 85,39 2
06/06/2021 31,8 2:00am am 74 84,77 1
06/06/2021 30,8 1:00am am 78 83,88 1
06/06/2021 26,1 10:00am am 91 77,94 2
06/06/2021 26,1 11:00am am 91 77,94 3
06/06/2021 25,7 12:00pm pm 92 77,37 2
06/06/2021 25,2 8:00pm pm 95 76,83 2
06/06/2021 23,7 7:00pm pm 96 74,29 2
06/06/2021 24,3 6:00pm pm 94 75,15 3
06/06/2021 24,6 5:00pm pm 94 75,68 3
06/06/2021 24,5 4:00pm pm 94 75,5 3
06/06/2021 24,6 3:00pm pm 95 75,78 3
 MEASURE

Attachment 3
UMUR KEBUTUHAN PAKAN PER HARI

PEN JUMLAH TAG NO. LAHIR

Hari Minggu Bulan KLSRTM SUSU / KONST KONST KONST 7- HIJAUAN
MR 0-3 (Kg) 4-6 (Kg) 12 (Kg)

                         
CB2.28 1 51867 16/10/21 23 3 1 0 6 0,2 0 0 0
CB2.28 1 51869 16/10/21 23 3 1 0 6 0,2 0 0 0
 MEASURE

Picture 1: *Fly Pest Trial and Control

*Based on Agriculture And Holticulture Development Board United Kingdom, 2020
 ANALYZE
Too Many
Poor Hygiene Over Population Intervention

Mixing Age of Too Much

Lacking of Calves Fly Pest
awareness

Influecce to reach
0,3 Kg /day
Rainy Season No Ad- Hygiene of Calves
coming Libitum Feed Transportation

Exposure Draughts Feed Transport Calves

(Weather)
Knowledge Gap:
• Fluctuative weather (Temperature,
Windspeed, Humidity)
• People Behaviour
*Based on MSD Animal Health United Kingdom • Age of sampled calves
 IMPROVE

Potential Cost

Cost of Doing The Program Cost of Not Doing The Program

“For the sanitation and “For the died calves causes pneumonia and
pest control progam is Rp.4.550.400” Pneumonia treatment Rp.56.441.481,-”

- High Mortality
- High Morbidity
- Repetated Case
BACKGROUN
D
Morbidity Major Disease 2021
18% 16% 16%
o Pre-weaning heifer mortality is an
16%
14%
12%
important economic loss to the farm
12% 11% 11%
9%
10% 8%
8% 6% 7% 6%
7% 8%
o Pneumonia cases mostly attack
6%
4%
1%
calves in unwean phases
2% 0% 1%
0%
Jan-21 Feb-21 Mar-21 Apr-21 May-21 Jun-21 Jul-21 Aug-21
Total Population for Heifer Raising
Pneu Linear (Pneu) Diare per Aug 2021 : 325 hd

Average Mortality Number

Average Morbidity Number in
Unwean Phases
Pneumonia Diare
Other Case 11%
32% Pink
3%Eye Lame
Pneumonia 3%
68%

83%

** Average Data from June-August 2021 with total unwean population about 61
 Objectives of the
Project

Preventing Output
Pneumonia

High Growth Rate

Cost Efficiency

Sanitation and Low Morbidity

Hygiene
Healthy Calves Maximum
Productivity

No Delay Weight
Gain

Scope: Heifer Raising especially

in Unwean Calf
Decreasing
Pneumonia Rates
 IMPROVE
TRIAL 2

Pest Control Trial and Cost of Trial

Description Before After
Treatment Treatment

Zyrox - 3x/week

Neporex 2x/week
IMPLEMENT & VERIFY1-2x/week
THE
SOLUTION
Cost/Week Rp.46.250,- Rp.545.000,-

Cost/Month Rp.185.000,- Rp.2.180.000,-

“There is increasing pest control trial in

the amount of 848% or Rp.1.995.000,-”

**Calculated based on Daily GGL Dairy Database

 LOSS COST FROM
PNEUMONIA

ADG (Average Daily Gain) different unweaning

calves is about 40% due to pneumonia case**

Estimated ADG (Normal) Estimated ADG

(Pneumonia Case)

“Daily live weight gains targeting 0.8 kg can 0.5 kg 0. 3 kg

drop to 0.4 kg/day and may never recover
completely increasing lifetime costs and
reducing efficiency of production*”

“Lower ADG will effect delayed the weaning

program. Weight gains is one of
*Based on MSD Animal Health United Kingdom
requirement for weaning”
**Based on Latest 3 Months GGL dairy Heifer Raising Database
 THE COST OF PNEUMONIA

Cost per case minimum Rp.459.599,- of per

sick calf with an added cost if the pneumonia
on calf getting worse**

Estimated Value Estimated Value

Unwean Calf (60days) Unwean Calf Due To
Pneumonia (70days)
Rp.3.669.931,- Rp.4.129.530,-

Increasing cost 12.52% every 10 days for every

pneumonia medication in calf . This cost include
**Based on Simulation Cost Dairy 2021 in GGL Dairy Accounting feed, drugs and milk replacer (all operation cost)**
 ADDITIONAL
COST

Goods Quantity Price Per Total

Quantity Price
Limestone 4 kg Rp. 400,- (kg) Rp.1.600,-
Woods craft 20 Kg Rp. 850/Kg Rp.17.000
Virkon 160 g/1000 Rp.512.600/kg Rp.574.000
Sanitation g
Rp.592.600
“This additional cost will add for calf with
sanitation treatment. The calculation is for
each calves during pre-weaning period”
The additional cost for sanitation are
Rp.100.600 for each 3 days. Until weaning
time (60days) need Rp.2.012.000,-

**Based on Daily GGL Dairy Database

 Timeline Project

TIME
Activity September October November December Januari Februari
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Field Observation
Farm Preparation
Project Implementation
Collecting and Analyze Data
Evaluation Project
Final Presentation

**Based on Daily GGL Dairy Database

Improving Sanitation and Hygiene
Factor Problem Root Cause What Why Who Where When How

Man Less No sense of Training Improve Farm Farm Oct- Do training

Awareness responsibility to and quality of Operation Operation Nov and briefing
their work briefing worker Staff 21 the worker
the worker regarding
SOP and
daily basic
process
Methods Different SOP didn’t Standarize Eliminatio Farm Farm Oct- -Revised
way of mention the how to n variation Operation Operation Nov SOP by
cleaning details stages of clean the of cleaning Staff 21 adding the
equipment cleaning shoe process stage
process equipment cleaning
process
-Standirized
cleaning
for feeding
equipments

Improving Feeding
Factor Problem Root Cause What Why Who Where When How

Methods