I.»’o. ——‘—-. Marinas. amateurs; AnAmis om. f - was: manna om ms Thai: fa; $094156“ of M8. mcunam m cams: .. Burnt! ,F. J. Cami" I 1952' a— ‘0. n- __ ‘ . _. —--.-———-——- *— -—-_‘-— a..- n o _-.—.—*— This is to certify that the thesis entitled "Methods Engineering.Analyeie of Loose Housing Dairy Barns" presented by Burton F. Cargill has been‘ accepted towards fulfillment of the requirements for Adegree in_£1_'A 101111711111 Engineering Um Maw; Major professor Date ML 0-169 I“ I - —-*nl —__ .I._l. . ‘3 , .1 :, ,L:..T I '1. \; x .’- 'ui’if ‘- .. ‘ f‘ a. " \ W. W "~"T'XI‘S _o“. 1“.- “l ‘H’ "I- ). .‘. ‘ ‘,z . ‘ . m»: .54. It \ 'k-‘.fi""‘ L9 ‘ k.. 4 l A - , Jl ' ‘ ‘ l ._ \. r; .4: xkvul. ii? :33 a ).. l ‘ ' ' Y I . 9’ gr.) .H . - I . 1 , l ,_ -'-l|.,(fig}- -. 3a,. 4 fl: 1- '. 0“ l I ;:‘-‘ y r. ‘ "- ° ‘ ' 3-“ - ' v". t . . , ‘ - Q , ' H‘IV‘..‘ 'V‘o .. I ‘ I‘- It‘;;’r.h9“1’-’.‘~Y ,‘t7"~.-"“V "Y - " ' wfl. v m ' i".-r"\’r “ 1’1: J. .. .I'r ' - {‘1 «.lfi.\.- _ ‘I:, ‘5'; Iifl'ifnlflfiéahfifial .- r I I ‘. .. T 3‘ _ , - " '. «we; r " ‘(l \V;§ I o .- _-. ‘7' :1 1' ‘5 L v ;_' .1. “‘3‘: Y. 4 I ‘ 1. J‘ \J. VQ ; ~51 l‘k- i“??\§l. ' I_ ‘ . . - ' “‘5‘? ~t—i) 55mg; ~ 5.4 V1 0. ' , ,. 1;.) if fitg‘l'M‘lf‘l'f ‘7 “.73 I‘ r‘.‘ L . t' "n ‘ u s x l I r ' ._ . ' . ~ ..\ . a .‘ . :1. ‘ 4 fl . I ’ . H I n -‘ .. - a. r.‘- .n . v _ , N . 4 e . . . . i" . f 'v . .l " . .l .‘h. I, I . . ‘4‘, . . ‘. . ‘ ‘ . > x '. u ‘I . . a r -- . .. v ,‘. ‘ u . 61 . . . '-.. .u . . r .' . '. . .3 I 'V . - l . .y' ‘7 _. . ."‘ . . . h. . . v r - a“ .f’ _ . '.' . I v.. . v' ‘ . ' . ‘- n , . . .' ‘ . | . ,l .. ‘ _‘ . - llv.-llln'.| .tr METHODS ENGINEERING ANALYSIS OF LOOSE HOUSING DAIRY BARNS By Burton F. J. Cargill AN ABSTRACT Submitted to the School of Graduate Studies of Michigan State College of Agriculture and Applied Science in partial fulfillment of the requirements for the degree of MASTER OF SCIENCE Department of Agricultural Engineering Year 1952 f .r ‘7 f.” . " 3""?- A .’,' 44.-.. - Approved f? < i5; __ ~ .- ll[[ [ l \ IIIII.P|| .Tll ‘ r. f I'll lr \rll. . I .‘ll \Q A ‘ (II [.l. Lilll r .\. r Lilla-.[f THESiq iv BURTON F. J. CARGILL ABSTRACT Farm power and machinery have greatly reduced both the time and work on field crops. However, dairying time require- ments have been reduced very little over the past twenty years. Dairying is important to Michigan farmers because it averages about 40 percent of their cash farm income; yet a review of literature reveals that the dairy farmers are not receiving a satisfactory return for labor and management. A check on milk production costs shows that labor amounts to one third and feed about 45 percent of the total costs. Feed costs have been investigated; however, literature re- veals that very little research has been done on the re- duction of labor costs. A substantial reduction in the dairy cow time requirement could net the farmer a satisfactory in- come for his labor and management. A methods engineering analysis of any Operation is necessary to determine the relative importance of the various Jobs and their Job elements. Previous literature revealed an analysis of stall barns, but no publications were found that gave the relative importance of the Jobs in loose hous- ing barns. The major objective of the research was to determine the relative importance of the dairy chore Jobs and determine the value of operating efficiency on return for labor and manage- ment. [{[Ill I‘ll #1.?! ’lllilll‘ [.[ lllllvc BURTON F. J. CARGILL ABSTRACT A representative group of farms with loose housing barns were selected for a methods engineering analysis and it was determined that the relative importance of the Jobs were as follows: Milking and care of milk equipment 80% Bedding the cows 6% Feeding silage (once per day) 6% Feeding hay (hay self-fed) 2% Miscellaneous 6% The work methods and barn arrangements on the farms analyzed were responsible for a variation in financial return. The average return on the 21 farms was $.91 per hour and on one third of the more efficient farms, $1.86. Therefore, the degree of efficiency with which an Operator performs his work is responsible for an unsatisfactory labor return ($.91) or a satisfactory return ($1.86). Further research was deemed necessary after milking was found to have such a dominating time requirement. The addi- tional research was conducted in two well-arranged milking rooms (elevated double tandem) with two operators who had better than average milking time requirements. The work places were not changed; only the milking units and work methods were altered. An annual saving (based on milking twenty cows) of only 63 man hours resulted from the changes in milking room "A". However, the changes enabled the operator to milk with greater lllxlllll>llllkrllkfllkr [[.Ir|ll\.llf\rlll. [[(Ill.lull\.’l.[rl\./dlrll (JI.\I|I.\ (ll .(lllll/llln‘l‘lln‘rll‘rll .[.(lll\ I‘ll :lll‘ Ill (J1 (II II. I! vi BURTON F. J. CARGILL ABSTRACT ease and used better milking practices, which in themselves require more time, after the changes were made. Work on the 21 farms and the additional experience gained from further research in two milking rooms made possible the development of a recommended milking procedure for a double tandem milking room. The procedure will enable one operator, using recommended milking practices, to milk at the rate of 28 cows per hour. METHODS ENGINEERING ANALYSIS OF LOOSE HOUSING DAIRY BARNS BY BURTON F. J. CARGILL A THESIS Submitted to the School of Graduate Studies of Michigan State College of Agriculture and Applied Science in partial fulfillment of the requirements for the degree of MASTER OF SCIENCE Department of Agricultural Engineering 1952 L‘IIIIP.)|\.r\rl?l [lg/IA l .(>. Ill. L[f\.[[[[[|{llll’s‘ll ll-lll||l\. lllll-[(l\l'lll\.[r‘l|.fl‘[ {[.[ Ill ACKNOWLEDGMENTS The author wishes to express his sincere thanks to Professors James S. Boyd and Walter M. Carleton for their guidance in the preparation of this manuscript. The writer appreciates the splendid cooperation received from the many farmers upon whose farms the data were taken; and also to Mr. Harry DeLaere, Chore-Boy Milking Machine Company for the use of his farm and equipment in the de- velopment of an experimental milking machine. Il‘v'lIEIlLII’Itfl-l. fl TABLE OF CONTENTS Page INTRODUCTION...... ..... ..... ..... ................... 1 REVIEW OF LITERATURE................................ 3 Historical Background........................ ..... 3 Current Literature on Relative Importance of Dairy Chores...................................... 23 JUSTIFICATION....................................... 27 INVESTIGATION....................................... 31 Objectives of the Research Project................ 31 Procedure......................................... 31 Results........................................... 34 Hay Feeding... ...... . ..... ...................... 34 Silage Feeding..................... ..... ........ 37 Bedding Cows.................................... 39 Milking and Care of Milk Equipment.............. A2 Caring for Dairy YOung Stock and Calves......... 49 Value of Operating Efficiency................... 49 Further Research................................ 53 CONCLUSIONS......................................... 61 APPENDICES.......................................... 64 Appendix I -- Glossary of Terms................... 65 Appendix II -- Justification Tables............... 70 Appendix III -- Preliminary Forms and Time Study TrialsOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOO 75 viii Page Appendix IV -- Survey Data Forms.................. 77 Appendix V -- Time Data Sheets.................... 90 Appendix VI -- Example of Photographic Record on Farms Analyzed................................. 101 Appendix VII —- Examples of Sketches Prepared on Farms Studied............................ ...... 108 Appendix VIII -— Basic Data Tables................ 112 LITERATURE CITED. ........ ........................... 118 OTPER REFERENCESOOOOOOOOO ..... OOOOOOOOOOCOOOOOOOOOOO 122 \.[Il -lt[[..[.l [ [ ‘Ulv Figure 1. LIST OF FIGURES Page The floor plan of a loose housing barn referred to by W. J. Fraser [12]........... 5 The floor plan of the loose housing barn used at the Maryland Agricultural Experi- ment Station............................... 6 Loose housing barn with outdoor hay feeder used by Dice [8] in l926................... 10 A recommended floor plan for a milk house in 1915. Two rooms were considered necessary, a milk storage room and a washing room..... 12 The milk house requirements changed by 1921. Illustrated is a one room milk house rec- commended by Kelly [21] in l921............ 14 A loose housing barn floor plan illustrated by McColly and Dice [24] had a milk house directly attached to the barn.............. 15 A releaser type milking machine developed by R. R. Graves delivers the milk directly from the cow to the milkroom............... 17 A portable field milking barn described by Long [21].................................. 19 The "Rotolactor" developed on the Walker- Gordon farm, Plainsboro, New Jersey, was put into operation in October, 1950........ 21 Figure Page 10. Dumping or straining in open air is not necessary with this experimental milker.... 57 11. Two cows on each side of an operator area provide an arrangement designed for maximum efficiency with one man.................... 57 12. An interior view of the milking room on the farm selected for a trial detailed time analysis. The arrangement is classed as an elevated abreast walk-thru type......... 102 15. Shows a cow entering the milking room from the holding pen area....................... 105 1A. A ramp aids the cows when entering the elevated milking stall. Cows are handled in pairs with this milking room arrange- ment....... ..... ........................... 105 15. The udder of each cow is washed and the strip cup used previous to milking......... 104 16. The operator puts a milking unit on a cow that has been previously prepared. One operator handles two long tube milking machines in this four stall elevated milking room............................... 105 17. Each cow is machine stripped to stimulate the let-down of the last portion of milk... 106 xi Figure Page 18. Cows leave the milking stalls through doors located in the front of each stall. The doors are roped controlled (opened and closed) from the operator area............. 107 Table II III IV VI VII VIII IX XI XII XIII XIV XV XVI LIST OF TABLES Dairy Chore Jobs In Stall Barns.............. Milk Production Costs........................ Analysis of Hay Feeding Time Requirements.... Analysis of Silage Feeding Time Requirements................................. Analysis of Bedding Time Requirements........ Relative Importance of Feeding and Bedding Time Requirements.................... Analysis of Milking Room Operating Efficiency....... ........... ................. Analysis of the Complete Milking Operation.................................... Relative Importance of Daily Time Requirements................................. Relative Importance of Time Requirements In Stall Barns............................... Annual Per Cow Time Requirements............. Labor Return on Operating Efficiency......... Milking Method Comparisons, Farm "A" ......... Milking Method Comparisons, Farm "B” ......... Recommended Milking Procedure........... ..... Nutrients Contributed by Livestock Products.. Page 26 29 35 38 no 41 43 45 2+7 48 50 52 55 58 6O 71 xiii Table Page XVII Value of the Farm Dairy Industry............. 72 XVIII Numerical Comparison of Farm Dairy Industry ...................... ............... ‘75 XIX Cow Removals................. ..... ........... 74 XX Hay Feeding Data............................. 113 XXI Silage Feeding Data.... ..... ................. 114 XXII Bedding Feeding Data.............. ........... 115 XXIII Milking Data...OOOOOOOOOOOOOOOOOOOOOO0.0.0.... 116 XXIV Young Stock Chore Time....................... 117 INTRODUCTION It is not out of the realm of imagination that loose housing* had been practiced previous to the 20th century. In fact it is possible to imagine that loose housing was the first method of handling the domesticated cow. Perhaps the method started by tieing the cow to a post and progressed to crude shelters where the cows were milked; convenience prompted the farmer to partition off a corner of the barn -— thus the milking room*. A limited amount of research pertaining to loose housing has been published over the past half century. An intensive review of the literature shows that the investigators were_ only concerned with obtaining information relative to the "effects of cold housing" on dairy animals and presenting the advantages and disadvantages of loose housing over the con- ventional stall barn‘. The author's intention is for the reader to receive a clear picture of the relative importance of the Job and the effectiveness of various work methods and arrangements. The author chooses not to devote any Space in the investigation to a discussion of the advantages and disadvantages or the effects of cold housing. An extensive review of literature *Defined in glossary, Appendix I. is deemed adequate. Information regarding the relative importance of the dairy chore work is available for the stall barn and the results of this research can be compared to this data to determine the relative importance of the Jobs in one barn with reSpect to the other. REVIEW OF LITERATURE Historical Background The first reported work in the United States on turning cows loose in a barn, confining them only for milking, was done at the University of Illinois. This work at Illinois was carried on by W. J. Fraser [12], in July, 1905. A preliminary survey of eighteen dairy barns in the state where the method was in use, showed that in some instances the cows were either: (1) milked in the feeding barn or (2) taken into an adjacent stable for milking. In the first, the cows were allowed to run loose, except at milking time when they were confined in stanchions and fed concentrates. An example of the second was on a farm where a three stall, walk-through milking room was used for a herd of thirty-three cows, Figure l. A few years after the work at Illinois, Buckley and Lamson [5] of Maryland Agricultural Experiment Station ran a three year comparative test on the 'open stable"* versus a stall barn of standard design. The open stable had concrete walls, 5'-O" high with 5'-6" posts above supporting the roof. All the spaces between the posts were left open except where a milking barn* was attached. The barn was divided in two parts by two mangers and a gate, Figure 2. At milking *Defined in glossary, Appendix I. time the lactating cows were driven to one end of the barn, "B" Figure 2, and the gate connecting the two mangers closed. The cows were then passed through the milking barn emerging on the opposite side of the mangers, "A" Figure 2. Buckley made significant statements relative to temperature. The experiences gained in the open and closed stable comparison indicate the evil effects of low temperature have been greatly over estimated....there is no instance in this experiment in which there has been a decided de- crease in production of milk, temporary or permanent, which can be attributed to low temperatures or to sudden fluctuation in temperature unless at the same time exposed to rain. Minimum temperatures recorded in the open and closed stables were -14° and 11° reapectively. The advantages claimed for the open stable were: (1) economy of construction, (2) economy of labor, (3) fewer stanchions and mangers, (A) better manure, (5) cleaner cows, (6) greater comfort of cows, (7) slightly cheaper cost of feed in production of milk and (8) production of milk of lower bacteria content. On the other hand, there have been only two disad- vantages suggested against the use of Open stables which it has not been possible to refute by the results of actual experience. One of these is the low temperature of the milking room in extreme weather in winter....and the second is the arrangement for feeding the roughages to the cows. It is interesting to note that the loose housing barn was not generally adopted by the Maryland dairy farmers, deSpite the favorable results of the experimental work. Maryland Experiment Station discontinued the use of the Open barn for dairy cattle after the experiment. Long [22] stated that a ‘F ”W 4‘ . 52.1w F’ 63,- " Maltr- . C‘ . 5 9 ‘ {‘lfiugvhan/hhqyer* * ‘0 r r r J " Figure 1 The floor plan of a loose housing barn referred to by W. J. Fraser [12]. Li 58",0 ” k] Iflhqyer Mb" - 3444* _. Figure 2 The floor plan of the loose housing barn used at the Maryland Agricultural Experiment Station. 7 recent letter received from Dr. H. J. Patterson, Director of the Maryland Agricultural Experiment Station, had comments as follows: We still continue to use the open barn described in our Experiment Station Bulletin 177 for young stock, but have not used it for several years for cows in the manner described in the bulletin....due to the fact it was not as well suited to some Of the experimental work in hand as the other types Of stables. This type Of stable did not con- form tO the arbitrary regulations of City Boards of Health and consequently it is not adopted to any extent for the dairymen in our state. In the changes of personnel in our own staff I have found it difficult in the case Of this barn, as with many other things, to overcome the prejudices which seem tO be instilled in people according to the en- vironment in which they were raised....I believe that all Of the points set forth by Dr. Buckley in favor of the open type barn still hold true....I feel quite certain that if I had the planning and management Of a practical and commer- cial herd I would use some modification Of the barn described in bulletin 177. Davis [4] was conducting research on loose housing in Pennsylvania about the same time as Buckley [3]. The United States Department Of Agriculture also recognized this new loose housing system and in 1914 undertook experiments to determine its worth and general practicability. Woodward [35] reported that in general practice the loose housing barn included a loafing barn* which was enclosed on three sides and Open on the south or east. Roughage was usually fed in the loafing barn. The floor space ranged from 35 to 150 square feet per cow. The United States Department of Agriculture con- ducted their experiments in a 35'-0" x 58'-0" frame barn. An area 18'-0" x 35'-0" was partitioned Off in one end of the barn *Defined in glossary, Appendix I. for an eight stall milking room. Sixteen cows were housed in the barn, an area allowance of 75 square feet per cow. Woodward reported the average daily bedding consumption at 8.3 pounds per cow but did not mention the kind of bedding material used. He also stated: On damp, rainy days more bedding was needed than in dry weather....regard1ess Of climatic conditions, however, the more space allowed each cow the less bedding will be required. In 1924 Fraser [13] wrote that the loose housing barn and the round barn were gaining a little public favor. It is Of interest of note here that a round barn was built on the W. Jensen farm Grant, Michigan, in l9lh. Although considerable experimental work had been conducted on loose housing, college bulletins published around 1924 gave very little Space to this new system for handling dairy cows. Fish [11] stated that the lack Of published material indicated that the farmer acceptance of loose housing had not arrived, at least in the northern states. However, Mac Innes [23] stated that in new South Wales loose housing was generally accepted but chose to use separate structures for milking and feeding. He stated, 'The parallel walk-throu milking barn is in favor." Long [22], in 1931, said that California had been advo- cating the dual structure system for the past eight years and in various forms it is now widely accepted. Due to the varying conditions in the state, climatic and otherwise, the dairies during the past years have exhibited a hodge-podge of structural design. A barn with a central hay mow extending from the ground and sheds on either side has been most widespread. When health author- ities prohibited whole milk production in these barns the trend swung to one-story stanchion barns* large enough to contain the entire herd at milking time. Concentrates were fed in the barn and roughages in the Open corral. The cows spent about six hours of the 24 in the barn during the two milking periods and the remainder Of the time in the open, in the mud or the hot sun Of the feedlots. Long also stated that Animal Husbandry men believe this exposure is detrimental to economical production, and tests and data secured from practical dairymen substantiate this view. Either the production dropped as the cows suffered ex- posure and required additional heat units to maintain their body temperature or additional feed, as high as 25 per cent in some estimates, was required in order to maintain their production. Preliminary shelter studies by Dice [8] in 1926 refute the statements previously made in Long's report. The purpose of the studies was to demonstrate the assumed folly of turning milk cows outdoors all day during cold winter weather. Comparisons Of warm and cold housing were conducted on two similiar groups Of dairy cows. Feed consumption, temper- ature and milk production records were kept during October, November and December 1926, and January 1927. Both groups were handled identically during October and the record for this month was used as the "check". Identical rations were fed to the groups except that the cows in the loose housing group had access to hay at all times from an outdoor feeder, Figure 5. The cows in the loose housing group gained more *Defined in glossary, Appendix I. 10 Figure 5 Loose housing barn with outdoor hay feeder used by Dice [8] in 1926. 11 weight (207 pounds compared to 184 pounds), produced more milk (84.7% of the check as compared to 78.1%) and consumed more hay. The temperature range was —22° to 560 for the loose housing group and seldom below 500 in the stall barn. Based on data collected on numerous experiments from 1928 to 1942 Dice made the following conclusions: Both Observation and data assembled indicate that in the cold dry climate Of North Dakota milk cows can stand considerable exposure tO low temperatures. The idea that dairy cows receiving an adequate ration need to be kept in a warm barn to be comfortable seems to be an assumption rather than a fact. Provided dairy cows are liberally fed on adequate rations, have shelter from wind, snow or rain, and have a dry place to bed down, they can withstand exposure to cold temperature and pro- duce practically the same in a cold shed as in a barn where the temperature is about 500 F. Apparently milk cows on full feed, when housed in a cold place while masticating, digesting, and assimilating their ration, produce sufficient surplus heat over usual maintenance requirements to maintain body temperature without using additional nutrients for that purpose. In these experi- ments cows housed in a cold shed required no more nutrients for milk and butterfat production than other cows, or the same cows, when kept in a standard dairy barn. These results indicate producing dairy cows in a cold shed tend to gain somewhat more weight than cows in the dairy barn. The comfort and convenience of the caretaker and the protection Of the watering system rather than the need Of the cow are apparently the only Justification for the type of barns that are common today. About a third more bedding is required in the shed than in the dairy barn. More trouble with frosted teats may be expected from ex- posed cows when the udder is tightly distended with milk and when udders are pendulous. The cows exposed to long periods Of fall and winter weather developed heavier hair coats than the cows which were kept in the barn. It is significant that none Of the descriptions of early- day loose housing mention the existence Of any kind Of a milk- handling room, therefore, it is evident that the common practice 12 of the day was to have a milk house* entirely separate from the building where the cows were milked or housed. Kelly [20] states in 1915 that, For convenience the dairy house should be near the barn, yet so far from it that no barn Odors can be detected in the house....The principle purpose in building a dairy house is to provide a place where dairy products may be handled apart from anything else. To carry out this idea it is necessary to divide the interior Of the building so that the utensils do not have to be washed in the same room where the milk is handled. Figure 4 is a floor plan Of the milk house recommended by Kelly. r——-——— odd—g...b—-_ Eben. . . I. T , ’ . / F . l ? é _._ 5m , é . . 2: rue: 8”“, ¢; __7 cxwunw; zawx 5/ / o / —“ - / l a z .9 § \ / . \ g \ I, \ / ! ’y I, aamzw'xxxwv , womsw ”cow! - “‘7‘" Vi~~ ”‘7‘?" . I L “IOiF-l' COOLE ] (liyrzunmc V gfy - owuwagw <§g } .uuwaonwii' l- ‘ d I ”l fill? L J \\\)/ JTEP \\\>” Figure 4 A recommended floor plan for a milk house in 1915. TWO rooms were considered necessary, a milk storage room and a washing room. *Defined in glossary, Appendix I. 13 In 1921 Kelly [21] changed his requirements on milk house location and illustrated a one room milk house, Figure 5. Building the milk house adjacent to the stable is not Objectionable....if the milk room is far removed from the stable it will take much additional labor to carry the milk. McColly and Dice [24] continued with Dice's preliminary work started in 1926. They illustrated a milk house attached to the dairy barn in tfio Of their plans, Figure 6, and made the following conclusions regarding their loose housing studies, About the same amount of labor is required in the pen barn as in a barn with stalls. The difference is that in the pen barn the labor involved in cleaning out the stables can be centered at one time during the month and the job Of bedding the cows and even feeding the hay and roughage can be done in more Of a wholesale way....The cost of building a pen barn is about the same as for building a standard barn, altho in some details the pen barn will require less expensive construction. The great saving is in the equip- ment of the pen barn. Stalls and concrete floors are not necessary except in the milking room and with the cows loose, ventilating the barn is a simple problem....Work done at the North Dakota Ex eriment Station and elsewhere indicates that they (the cows are not 'thin skinned' and that they will adapt themselves to varied conditions, eSpecially low temperatures, provided their stable is dry and free from drafts. Therefore, the cow stable does not need to be kept above freezing temperature and cows that are loose will adjust themselves far more comfortably under any conditions than cows tied in stalls or stanchions. Research on loose housing in Michigan started in 1928. Jefferson and Weaver [19] report that, When Michigan State College began a study Of pen barns* in 1928 there were only a few such barns in rather closely confined areas in Michigan. Today (1945) we have records of 159 pen barns. Jefferson and Weaver sent questionnaires to 157 people Operating pen barns, and an analysis of the returned questionnaire *Defined in glossary, Appendix I. l4 Portable Buffer Worker .Draln //l 9" Tesier ll'- 0" X l3'- 0" Heater I Figure 5 The milk house requirements changed by 1921. Illus- trated is a one room milk house recommended by Kelly [21] in 1921. 15 Wm?“ i - Pen YOUNG $100K LITYER ALLEY Tempomxv PAR- “AWE” RACK IITION Fdfl Box NOR 9.51 LLs MANGER on x , HsNGto DooRJJ FEE-D ALLEY MANGER MANGhR '00. .000 Figure 6 A loose housing barn floor plan illustrated by McColly and Dice [24] had a milk house directly attached to the barn. 16 was made. One dairyman reports that loose housing has been used in the vicinity of Hamilton, Michigan, Allegan County for more than 80 years. They also stated that several farms had used a pen barn for more than 25 years. Two common arrangements for milking were mentioned, the tandem* and the abreast*. "The one chosen will depend upon the individual preference. Long [22] stated in 1931 that there was considerable in- terest in the parallel walk-through milking barn (abreast stalls) and also a developing interest in the tandem walk- through milking barn. The parallel walk—through milking barn was introduced to California from New Zealand and Australia. Long stated that along with the walk-through barns came the original releaser type* of milking machine. The original make of releaser milker caused mechanical difficulty, even to the extent of flavoring the milk, and had no facilities for production testing*. The entire system was generally condemned for years in California. A few converts, however, have demon- strated that the structure could be used with hand or bucket milking and "successful releaser milkers are now being built", Figure 7. Long stated also that in the walk-through type milking barn the cows are admitted one at a time from the holding corral and find their way to a vacant stall. Until they are accustomed to the system the cows are held in a stall by chains passed behind them. In the door, which forms a *Defined in glossary, Appendix I. 17 front wall of the stall, there may be placed a feeding bucket. It may be filled from the feed alley or by the milker from a small grain supply kept in the space between each pair of stalls. An interesting feature which is being suggested is placing of the milker (operator) on a level below that of the cow to minimize the stooping necessary. In 1932, Strahan [32] discussed the increased interest in the use of barns for milking only, shelter and feed being pro- vided elsewhere. The principle impetus to the latest trend (separate milking barns) was contributed by Dr. R. R. Graves. " Graves said, "Bring the work to the machine, a well known principle in factory management. . * ' ,/ —‘ HM:;1—x~. O , 1 , I . {D J .‘_ ,_ - .I . H‘s. ‘ , v. ‘ ‘u. . ,‘4 hot/*6 - m “rug—gut..-» - F l K. § 2' t if g ' f}: V -# . ’1. ;; Figure 7 A releaser type milking machine developed by R. R. Graves delivers the milk directly from the cow to the milkroom. l8 Strahan wrote in 1932 that a revolutionary trend -- the milking barn -- was coming into the dairy industry. He stated that for larger herds there were two types: (1) the elevated tandem stalls and (2) the floor level abreast stalls. He even had visions of the future And now, what of the future? In the realm of speculation one man's guess is as good as another's, and the man with the weirdest imagination often wins the game. But it is not unreasonable to expect even the smallest herds ultimately to come under the in- fluence of this revolutionary trend. He also foresees the day, Suppose three or four milking stalls were mounted on a truck - the owner might buy the milk in the cow. In his article Long [21] mentions a portable field milking barn (Figure 8). He states, Another type of dairy management which is bidding for attention and which involves different structural designs is that wherein the herd is kept continuously on pasture and the buildings consisting of a portable walk-through barn, parallel stalls and milk house are moved from place to place in the pasture as frequently as may be required for feed, water and soil conditions. It might be expected that this method originated in England, probably as a descendant of New Zealand and Australian methods. The chief advantages claimed for the open air system were (1) decreased cost in production, (2) improved pastures and (3) improved herd health. 1900 to 1930 was a period when loose housing was con- sidered only as a means for greater production by increased cow comfort. Labor efficiency had not been emphasized. Farrell [10] in 1931 mentioned labor saving designs and 19 4-; i 5/0: END ...... rfi-"“""1 F lifif“) I I I III iii 'iii‘ III '.. '"I \u " g ll ' ,E Z IIE l § § § § 9 m... .e .2 .3 ~s :: '4 v) H H § I. § ‘ '5‘.“ .,—' I“. r I ' ’flflflf : L ............ .J ............ J FLA/v Figure 8 A portable field milking barn described by Long [21]. 2O discussed a revolutionary design - the rotary milking platform - the "Rotolactor" (Figure 9). One complete revolution of the platform in 12-1/2 minutes enabled the operators to prepare and milk 50 cows. It was developed on the Walker - Gordon farm, Plainsboro, New Jersey, and put into operation in October 1930. Huff [18] reported that the milking barn was introduced into Missouri about 1932. Some of the early systems employed old barns as loafing barns, and built two or three stall milking barn - milk house combination structures to handle the milking operation. The tandem walk-through type of milking barn was used, without having an elevated platform. In 1939 Huff predicted that for Missouri the future for loose housing was good. It has been gaining in popularity and acceptance since it was first introduced. In 1944 Morrow [26] of New Hampshire reported on eleven years of experience with a pen type barn*. Later Woodworth [36] conducted an efficiency study on dairy barns in New Hampshire. He states, The study is only on stanchion barns. Pen barn studies are not possible because there is little oppor- tunity in the State to observe chore work....The problem of bedding has restrained farmers from developing this type of housing. An article about Washington State in 1941 [14] reported that loose housing barns had been used in that State for 20 years and were well developed. A later report from Washington 4 '— *Defined in glossary, Appendix I. 21 " ' 'Ffi'IUIIII llilfll! v -§-h’ul!lfll 2...!” :: . -1'1.‘ sun» an un i-rrvr 1 II In. W " -I iiil [III] e u- up Figure 9 The "Rotolactor" developed on the Walker-Gordon farm, Plainsboro, New Jersey, was put into operation in October, 1930. 22 State by Smith [31] stated that there was a trend toward separate open areas for feeding and housing. The Montana State College developed an elevated stall in 1945-46 [33]. The cows stand abreast in pairs on an elevated platform with an operator area* between each pair. This milking room was called the "Montana Type". Eugene [9] in 1948 reported that the "Montana Type" milking room was being used in Minnesota. He also said, Cold housing is considered entirely feasible in non- insulated, freely ventilated barns with open windows and doors. This brief review of the historical background has been prepared from reports of research conducted during the past 45 years (1903 - 1948). The literature cited includes all the major publications and a few popular articles that could be found in the Agricultural Engineering Library and the Michigan State College Library. Literature on loose housing research in the United States previous to that reported by Fraser [12] in 1905 could not be located. There is some evidence that loose housing was introduced into this country from New Zealand and Australia. The in- fluence upon dairy farmers of the United States came about the turn of the 20th century. The popular belief that lactating dairy animals need warm barns and the unwillingness of health authorities to approve of loose housing have retarded the widespread acceptance by dairy farmers. *Defined in glossary, Appendix I. 23 Current Literature on Relative Importance of Dairy Chores Previous loose housing investigations have been concerned only with providing data which showed that: (1) Cold or open housing has very little or no effects on dairy animals. (2) Increased milk production is due to increased animal comfort. (3) Fewer animal diseases and udder injuries occur. (4) Higher quality milk is produced. (5) Better quality manure is produced. (6) Bedding consumption is greater than in stall barns. In January 1948 when the collection of data started for this thesis no previous research, to the writer's knowledge, had been completed on the relative importance of the various dairy chores or the total labor requirements for loose housing barns. Munger [27] in 1921 mentioned labor as an item in the cost of milk production. He made a study of 58 farms in Cerro Gordo County, Iowa, and found that the average stall barn labor requirements were 147.4 man hours per cow per year. He said that the labor involved in the production of milk was milking, feeding and hauling. Headley [15] wrote on the efficiency in dairying in 1930. He mentioned that loose housing existed in Nevada, but did not attempt to determine the labor requirements. He stated that the average labor consumed per cow per year was 14} man hours, 24 but he did not attempt to determine the importance of each Job. Woodworth [36] in 1933 made some efficiency studies in dairying, but again as with previous studies he was concerned only with the stall barn. However, his work appears to be the first attempt at determining the relative importance of the various dairy chores. He gathered his data from 38 stall barns in New Hampshire. The average man hours per cow per year were 129. He divided the dairy chore work into milking, feeding, cleaning stables and watering. A dairy cost study was made in Michigan in 1956 [6]. Dairy chore labor was mentioned as milking, feeding and other work. The data were based on a survey of 123 stall barns and the average man hours per cow per year were 147.3. Buck [2] in 1940 determined the average annual per cow labor requirement on 10 Iowa farms with stall barns. The average was 14} man hours per year. Carter [4] in 1942 made a detailed time analysis of one stall barn in vermont. He developed new work methods from the analysis. But not until 1946 did researchers actually start analyzing the dairy chore work with a definite goal in mind for determining the relative importance of the various Jobs. Previous work except for Carter had not been time and motion analysis work, but merely survey type investigations. 25 Bookhout [l] in 1946 analyzed the dairy chores in 10 Michigan stall barns. His time and motion analysis was a definite step toward determining the relative importance of each Job with respect to the total hours spent (Table I). Smith [30] analyzed the dairy chore time on 15 farms with stall barns in Maryland during the summer of 1946. Milking time averaged 68.7 per cent; whereas it was 48 per cent for Bookhout. However, hay was not fed during the summer when Smith made his study. Woodworth [37] analyzed a series of stall barns. It is interesting to note here that the work by Bookhout and by Woodworth are very similar (Table I). Comparable data, such as obtained by Bookhout [l] on the relative importance of the dairy chores, are necessary for the loose housing barn. Witzel [34] in February 1948 prepared a report after an inspection trip of milking rooms in the western United States. He analyzed the time Spent milking in various types of milking rooms. Witzel's report is the first published data, to the author's knowledge, on the analysis of the milking operation in a number of milking rooms. Previous literature cited illustrates the lack of avail- able information pertaining to loose housing work methods and arrangement. Perhaps Long[2l] when he said "loose housing barns had grown by 'hodge-podge' methods" realized the lack of design data. DAIRY CHORE JOBS IN STALL BARNS (Percentage distribution of winter chore work TABLE I 26 on dairy farms with stall barns in Michigan and Maryland) Item Michigan Maryland Milking 48 49 Care of milk equipment l3 12 Care of milk 6 l Feeding and cleaning mangers 16 13 Cleaning stables and bedding l3 l4 Cows in and out of barn 4 4 Miscellaneous 7 Total per cent 100 100 JUSTIFICATION Dairying is one of the most important industries in the United States. In value, the product is second only to iron and steel [15]. The capital wealth of our Michigan dairy in- dustry is 2-1/2 billion dollars [28]. In Michigan dairying utilizes a huge physical production plant spread over 105,990 [5] dairy farms and extensive processing and marketing facilities. Together these constitute one of the state's largest industries, providing 39.6 per cent of the total farm cash income [25] and an important and dependable share of the income of city people. Michigan's annual milk production of nearly six billion pounds would fill a line of milk tank trucks from Detroit past Denver. This production creates 300,000 Jobs and supports 600,000 peOple on an annual payroll of over 2-2/3 million dollars [28]. The Public Health Service [29] states: Of all the factors of man's environment none is more important to his welfare than food. Of all foods, none is more important than milk. Dairy products make up over 30 per cent of the food we eat, yet cost only 15 per cent of our food dollar. (Table XVI, Appendix Page 71.) Michigan ranks fourth among the states in the number of milking machines, and sixth in value of cows, number of heifer calves kept for milk, value of whole milk delivered to plants and value of cream sold as butterfat. Michigan ranks seventh 28 in farm value of milk produced, number of milk cows, value of dairy products sold, and number of heifers one to two years old. (Tables XVII and XVIII, Appendix Pages 72 and 73). The above figures paint a very impressive picture re- garding the Michigan dairy industry, farm, and otherwise. However, an analysis of the average Michigan farmer with dairy animals reveals that Q; is not receiving a satisfactory labor income. The average farm has a herd of 7.5 cows pro- ducing 5,910 pounds of milk containing 230 pounds of butterfat. A cow must produce 200 pounds of butterfat to pay for her food, housing, veterinarian and other expenses leaving little or no return for labor and management [17]. Labor, the second largest cost item in producing milk, makes up 31 per cent of the total costs per cow. (Table II). Labor, buildings and equipment make up approximately 40 per cent of the total milk production costs without regard for the effect of management's choice of feed and cow removals (Table XIX, Appendix Page 74). A review of literature reveals that Michigan, the location 1 of the original Dairy Herd Improvement Association has con- ducted research on increased production by animal selection l"01d Newaygo", the first cow testing association in the United States was founded on August 10, 1905, in Newaygo County, Michigan. Jens Mogensen, a Danish-trained cow tester being hired by the association. The first year's records listed 31 herds and 239 cows. The cows averaged 5336 pounds of milk and 215 pounds of butterfat. "Old Newaygo" was so successful that it prompted the organization of four more associations in 1906 at Coopersville, Bay City, Caro, and Lapeer, Michigan. TABLE II MILK PRODUCTION COSTS 29 (Costs per dairy cow and percentage distribution on 83 herds in the Detroit milk shed in 1948 - 1949 [16]) Item Cost Per cent Feed $169.44 48 Labor 106.76 31 Building and Equipment Use Electricity Bedding 28.88 8 Other Miscellaneous 44.86 13 Total $344.94 100 30 and improved feeding. However, very little research has been conducted on increased labor income by improved arrangement and management practices. The author believes that considerable improvement can be brought about if (1) a methods engineering analysis is made of the various work methods and (2) the relative time requirements for the dairy chores are known. The importance of the dairy industry to Michigan, along with the shortage of competent farm labor and rising farm wage rates, Justifies research directed at improved work methods, reduced man hours per cow, and improved barn arrangement on increased labor income. INVESTIGATION Objectives of the Research Project To determine the variation in time requirements for feeding hay and silage and bedding with different work methods and arrangements in loose housing barns. To determine the time requirements for the various Jobs of the complete milking operation. To determine the time Spent caring for young stock and calves. To determine the relative importance, with respect to the time requirement, of all winter dairy Jobs. To determine the value of operating efficiency (work methods and arrangement) to the dairy farmer's income for labor and management. Procedure I. Preliminary Survey (Appendix III for sample forms) -A. Prepare a questionnaire to be sent to County Agri- cultural Agents in Michigan (page 76) 1. Request names and addresses of farmers operating loose housing barns 2. Request estimated number of loose housing barns in the county Bo C. H 32 Visit each farm mentioned by County Agent (page 77) and note: 00 CDKICNUTSWMH General comments of the farmer Size of the herd Size of the barn area provided Type of hay fed and bedding used Length of feeder Ceiling height General barn arrangement Number of milking stalls and position with reSpect to the operator area Number of men milking Number of milking units Analyze information obtained from farm visit 1. 2. To locate twenty to thirty farms for intensive analysis a. Group must have a variety of work methods and arrangement b. Group must use different forms of hay, bedding and silage To reduce mileage and travel time on final visits II. Preparation of Field Work A. Make detailed analysis at one farm (Appendix III) saw RDH To gain experience in recording time data To determine the Job elements that could be timed To set up standard procedure for recording time To prepare a code for taking time data Prepare final forms (Appendix IV and V sample forms) 1. Survey data forms Farm data form, page 81 Questionnaire on loose housing, page 82 Job analysis form, page 83 Farmstead information, page 84 General barn information, page 85 Barn space allotments, page 6 Storage space allotments, page 87 Milk house information, page 88 Milking room information, page 89 HUOQW€DQOUN III. IV. 33 2. Time data sheets Time recording sheet, page 91 Individual cow time analysis, page 92 Coding and recording sheet, page 93 Evening and morning coded record, page 94 Evening and morning analysis, page 95 Twenty-four hour Job record (other than milking), page 96 Space and area analysis, page 97 Job analysis hay), age 98 Job analysis silageg, page 99 Job analysis bedding), page 100 c—kt—“D'UQ "DQQOO‘W Notify Farmers of the Visit Date. Field Work A. Make time record of all dairy chores over a twenty- four hour period B. Complete survey forms C. Take photographs when possible (Appendix VI for examples) D. Record temperature 1. 'Interior of barn temperature 2. Open lot temperature 3. Manure pack temperature Office Work A. Time study analysis 1. Milking operation a. Cows milked per man-hour b. Machine efficiency in percent equals actual total machine time 100 total possible machine time Actual total machine time equals a total of all of the machine minutes for each cow Total possible machine time equals actual clock time the machine was taken off the last cow minus the actual clock time the machine went on the first cow multiplied by the number of milking machine units 34 c. The total time Spent on various Job elements for evening and morning milking 2. Other dairy chores a. Estimate the manure hauling time b. Determine the percent of time the various Job elements of the chores are of the total dairy chore work B. Sketches prepared for each farm (Appendix VII for examples) 1. The milk area*, pages 109 and 110 2. The barn area, page 111 C. Motion study analysis 1. Milking -- the distance traveled per milking determined by retracing the path of the farmer on a scale drawing of the area 2. Other dairy chores -- the distance traveled per Job determined the same as for milking D. Master data sheets prepared combining data from all farms Results Hay Feeding. In seventeen loose housing barns with an average of twenty cows per farm, feeding hay required an average of .77 minute per cow per day (Table XX, Appendix page DJ). The range in time per cow was .1 to 1.9 minutes. The difference was due to the feeding interval and type of feeders. The daily per cow average on farms where hay was fed twice per day was .94 minute with 45 percent of the time Spent after the hay left the mow (Table III). ,The total hay feeding time was reduced to .50 *Defined in glossary, Appendix I. 35 ooH s.m em. ooH o.oH om. ooH m.ma am. Hopoe b :. NO. ON o.m 0H. 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Econ wcfixaaa wcficmoao MA on o.H me an S.H esosaesoo weasfiee can xHHE no came Hm omH o.m ms sod m.m msexfiaz ucoohom ppm: 300 no ucooaom upon zoo son. .11 zoolom. :00 ON Nonfinpuoco pcmfioauho Hmoospoa owwe 90h once on» go owmpm>¢ confisdon mouscfiz Amanda wcamSon omoofl Spas manna mcouhpcozp so coaumnoao HHH> Hands 20H9- --—-§——_- --o—--- ---I—--- --- O~ --- r 0.-..- -. ..> -p ,‘w--_.- _ .a- .. .p_;—--~-_.... “uh.-. -o- ,. i J'.’-~w~.‘ ,., . id. iii: L;;i.;.i;..f. '_ T1 llable , r ~ww ~ w' ~~ 228 xxxxxxx 8 -v sww 68 A.» t, 0.1 L.) . JL‘K‘. I i-f“ .:'...J. _. .1. y L.— A... .u. .._. _...u_ .-——.wo..—4_4 —-.--.—-- --...-n-._a u * m-A.—-..—..--o- .- .._..-..1 h... .. "A n-‘—.- . . \ m A " 'n ‘ c - 1.- . . ' , \ ‘ I : o _ -. ‘ ’, ‘ ;(\.' u \ ' L . I ' 5 03 “I”. A_ h, v a: j r; '_, .) ._.. _ , ~. _ . __ z .‘ .‘ a1,- Oam _ e‘re " H "' ' u..oo- .m... _ . .- ...—. —- o 1 . . . . . - -‘~-. ._....._ u .u— _.-i *.- “a-.. -. *--* -¢—-u¢- "~ . .’. I" ' I ‘ V . '. \t .. I ‘ ”J; .. — '-._._ -o-.----.-.a_..-._- ._.._ Awh~1-fl_~.__i_ ' . MM- .- —- .—q ~- -~ -...a~-.--.»’ .- .._...-. .. .,...... n. - -.- --—.--. -. '-~.-. .0-.—- .l‘ -— —- 5 _.. u , - . I - .~ 4 -.. , . n ‘ ‘ l~ v J l ‘I' I 7' I “- ' -.- I ‘ A a A -7 . . ‘ ¢a . , . . l . D.L_. \ .J ( ersey) 4 ,,l . , 33 u -. ' -n.- , - -A “a... Vi " “-5 -.a .: . |.- -— ‘u»-| ,v . ‘ ~ 1‘ . . . . ' ... , L ; ‘ ‘ ‘ l) 1- ,. ,, l .. I s - o-D -'- -— ' ---J-v-.... . — .oh _ .A . g s .. v..-..~l..... ._,__.,,. _- . _-. .. ~. ._ ~ ' ‘ . .5 t Barley. .. _. 5. _- I.“ w_, RY¢_I. U fln__7. H“. 325 , A “s- r w..90~5m.. Beets A ‘HHMHAQS Beans “M w37 Buckwheat ‘ 10 166 ~.40“ d5 ~.228 Fatherw- 60 years old , H _ . _ . a . a Son - 30 years old, married, 5'. h, 150 pounds, Short_course at M.S.C. -, None 'x 82 Trial 194} Old stable inconvenient - we built it to ‘save,steps. Mr. Ruehs (Caledonia, Mich.) and other barns. Yes_ Put hay mangers on the_side instead of_the _ middle, milking platform 7'-6" instead of 7'- O", stall 289 or .50" instead of 20" ‘,_. can-c .._- Saves labor, cleaning is easier, cows more comfortable, cows are cleaner. less injuries, cheaper to construct, flexible (can_change to other livestock).w Cows have to be dehorned - boss cow bothers a little. Cows don't need to be . _warm. ;dYes _m,pg“'”77‘ Racks_are filled, _0nce per day direct from the mow..-“ my.-_. .h.il_r .“955.w “-3094w__ H A .h§°3“5;5.u 81+ Trial West side of road None Drainage ditch on south side (county ditch) a flat farmstead in the barn in the barn p.160iu_q_ connected 85 Trial Frame - low gambrel ‘ . _ 1943 fair Dirt in resting area A Wood 8'-6" Fiber wallboard on parts See plan. 18' . 39' Low gambrel Steel Window Xiifieiézfii‘én Natural .Drainage ditch on south side of barnyard - open lot on south side of barn - yard not paved. Doors are closed during extreme cold weather 1. " ’ 7 Glazed tile . 10 feet 30 . ' " 5 -- ' 35 2. 10 x 35 concrete stave - no pit (located at another farm) 86 ' ”33y Trial s. M a”- cum—.— Av. cum-m —o. M ..._..‘,.,‘..,.. *me W- H 1' oc- «'M.—O -‘.‘-“‘l.—” .7».- ‘u-wwflwfl N- g... H, . ‘ Q t . _. 2.. - ..¢..fi 7 _ . --.... . .- -— . _- ...- ._.—.. _... u-‘ ‘ ." l .. . _ a . -u 1‘. ..A A - . a- . .-, _. - ”— .,.—4-v_. . ,- L _‘ . r~ .. . L . , .. u t f ' . l . . . .:. air « v4 _, v "“ I L . l ‘1 ~ ) v I . z I ’ . ,( A. L . ‘ . l ' -‘ ‘ ‘. ‘~ - - . . . f _ . . n _ . t, 4* ‘7». p u— A, -v _ 7 A S 7 ‘ ‘ ‘ ' ‘ VA , _. . < 1 . > ‘ _ ' A; ‘v ‘ . s ' .. tau .. - x 4 ._. _ l t \ ' ' - V 1 . l . ~ , x i.- .A . 14 ~ = c J 140 1 ‘*- .,196 - _ A a- , . - _ . 103 .. .2249 ,f , fl 87 ;;M36{_x 64lwaverage.depth_l3fuw__ ” [.3o,ooo _ overhead” chopped_v_. g Overhead in’a wing of the main barn 55' x 40{ depth 15' 18,000 See above ChOpped Would like to have a granary above the milking.room. _BarnMA , 800 crates plus some temporary 2 - 10 x 55 .. .fl‘ri 3,1. _ M. W--- - -_ .Yx i“ Concrete block ._.2 _ _h5_ug -_.h, U.-d FLTZZ'"xi.i":;;mConcretehfl;fjnl,1',\._.54 w,.u_fl '*\ ,WT.L.WU‘ (' fi'-- r’} ' ‘rfl . ,‘ ' r' " ' ' w:.,a :Hn.:--. 10'-1o' x 9'-6' _. Floor drain_under sink _ 2 (east & west.wa11) 4 light 10 x 12 windows tip in from top - screens on outside None”, ,_None except ceiling is_covered Yes Yes _ ' 10 gal. electric heater 4 can Esco Rite-way .2 bucket units Sink (24 x 16), teat cup rack By entrance door One duplex outlet south wall .,u.6 1t: 8.X_10.wdu9fihabove_f1003 89 LlflfiiflflTrial” L‘ *7: Ju*-‘. ..0‘--H‘H—~‘va-—.——r~ui Che . \ ‘fi‘a‘m .- M- d —l —..‘ .— g— s h...- — “- h !\, ' l r. r - - _. _L_._..... .. ugdu_.s_ -_...... .. a ' " - l '. k ~ _. .4. ,_ - __ W .x 1-, r“ "7‘. . L“ ‘v- ,Y“.“ ”I *y _ .‘ I ~ ‘ 'I e \l ‘-t ’-’,;- 'IJ...'-J .,......_. . _. . . __..._..- _ . - :31. 557,. . .E'LFJJC‘anr‘etg ___._ ..._ '7 p H“ '- -- 2.14-56 x- 13 '__.-6" . - ‘ ’ ‘. -1943 .. “ “(1; _sloped concrete floor __ .gyynyl MTWQ windows north wall“ "i-7? ,h__ None Windows tip out at top ,No Lime_with broom and shovel. .4 stall elevated abreast 30" . ,_ _ 7‘ ' _ 7,-0" 5 '-6ll 20". - , ‘ 24" LIA-O", - 7'-O" . 30" - 5'-6" Center back Operator area 2 - 60" above operator area Radio APPENDIX V Time Data Sheets Time Recording Sheet, page 91 Individual Cow Time Analysis, page 92 Coding and Recording Sheet, page 95 Evening and Morning Coded Record, page 94 Evening and Morning Analysis, page 95 Twenty-four Hour Job Record (Other Than Milking), page 96 Space and Area Analysis, page 97 Job Analysis (Hay), page 98 Job Analysis (Silage), page 99 Job Analysis (Bedding), page 100 _ 91 THE AND MOTION STUDY Sheet No- Fat: Farm No. and firms -__.>c-. -a-r-‘ta “ma-u—w “a!“ *— :5 ¢.§ .. . - .,_ . . _ h~ '-' .~ . “ .' 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's.u.._~ .‘ -_——--—-- .-V . .--.~_ .....u.‘.-....~.n... - a-._4-. 4 .- -- v m. ~.‘--o_¢-—.—-.... -..__.A‘_... _.— .u.-—‘ . - -~ -. . .2. .- ‘ . r ‘ . . > .. v ... .1 a - ..-. . ._ --. ‘, ... .-. .—, . - _ .. . ‘ , ... ... - . . , . ._\-r-- .V-._- ..--..n. . ‘. , ., H , _.. _ ,_ . - - r M. . . . »..---- .... . '\ . 7 .. o .. . . .. . . _ . , - . . hr - V" LL 131.1"? A i! or \ I A—' 7A- ‘ x “'(3 J_5.J‘.;_LJ $"h \ 1 o. t, ‘\ q u ‘7 . 1.1 ' .fi . ' n I -, I. . .-. , K» I . A; ‘ ‘4 ILL» h. - v7- - I . _;.',. l A.“ . It - A . v . I ,l I I. \— -. n UT” 04'. 1" g. l I.-3n"h. ._’I 4 = "‘ ~ 5 L) '. ..v I I. v . . ‘ . . M ,1 I c 7 .. -. .. 3 ~ ' - \ .4 I" ' I . I} ll‘ - ' I -n b l .»0 l a. \.; . ‘. -. A, ... . 1 . .. -‘ -' , 1 ) . ' I‘. . J \ . _ 4 ‘ ‘J . I . i. I- . r ‘- ‘. I. _. ’1’ r. ‘ I‘5 u o ‘- .- P‘K . , -'- u \ n - . .‘ . b “- ~_. - s ‘ I K., ‘ l. v. .. I us“ -I-~.-H~-— "‘o- .-- .- E ..U& 4- “anu‘. .- ..., m. . 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' L- V ..- w I. - ' — I) ’ ’1 n... v .- .J—-—~._.-.I- .. .. .-._— — —_—-—- - .-.—.,.—-‘_~_.-_...-_ ......I I _¢._..._I~——— -_ - .‘-« --., - -—- _ -.. . I t . ‘ I 3 -- _ . . . - I I , _ _ I I _ I . I I n . . I . , I _ "" ‘ v I APPENDIX VI EXAMPLE OF PHOTOGRAPHIC RECORD OF FARMS ANALYZED 102 Figure 12 An interior view of the milking room on the farm selected for a trial detailed time analysis. The arrangement is classed as an elevated abreast walk-thru type. Figure 13 Shows a cow entering the milking room from the holding pen area. Figure IN A ramp aids the cows when entering the elevated milking stall. Cows are handled in pairs with this milking room arrangement. 104 Figure 15 The udder of each cow is washed and the strip cup used previous to milking. Figure 16 105 The operator puts a milking unit on a cow that has been previously prepared. One operator handles two long tube milking machines in this four stall elevated milking room. 106 Figure 17 Each cow is machine stripped to stimulate the let- down of the last portion of milk. .. m... V O. . Jim 9 .0. -.. I ‘Juil . . ’ Q $27..Ii.: x U '1 34.. 9....1..0.§.v. /..... .‘ 00 I . v.5 0.0" 94..fl-._W.I. ‘0‘ WWW - It]: '1. . ‘- Figure 18 107 Cows leave the milking stalls through doors located in the front of each stall. The doors are roped controlled (opened and closed) from the operator area. APPENDIX VII Examples of Sketches Prepared for Motion Analysis on Farms Analyzed Milk House Floor Plan, page 109 Milking Room Floor Plan, page 110 Barn Floor Plan, page 111 How .‘1‘!.(l0.4 . ‘ . yu-cIJl‘a i4 O (\CL ,x ,. \II‘ ‘c 3.1.3. ...JIm. -‘Jt 1~Iv1il~l ‘77E.r'f£\l 41\§.«4( ‘I‘i’ initiL Iliad-Q l... .11”"'\I|a.lciivu(i6 i .v .Alvvtogfi ... {Ala-Elwin .| :ziil‘lJ 4 M///< Coo/er . u I; ‘ ' vol...‘7.i)nl\ot(l /. \ ’.-c;‘\a~¢_ '3.) . w. ~J~—§.W:u£mwai W‘o-g.*éi‘ . I C /V7/’1l,. /’< H008 E {3,4LLX’XVGE-R FARM «2 " r. . P- a‘. :‘g. r. u . '. __... ! \- .i‘5.‘¥.\uyi} $0.4 ‘ O . . ~'2- . . ~ _ ' ' 9 4 ' .2. . .. - 3' *~ - _-, ‘ I o. o . . .., 13H£§ no. {. v . 47E\xn.aw48 . a: 9L _ Lt. ._ u . i... ... «bl . 4.- . . 21.... r! . .. .2.» ..- a. ‘ 3’ ..... p .. \ t r . _ . r. I I .e \ r . _. Ill. 1'4 b v /. x . x. . \ 4 x _ ( IL! ... / l / .1 / z ,/ ¢ ,1 .v. . l6 1 a A 4 _ . > _ u _ l n , 1.}.‘ninn‘. .brL f ,. .. in A u ANA Oh? FLA/V -r~.'4 I H FA R /‘7 - a, l ,,. l T. ./ ,. S E 1 _/ . 9. \» I . m . ...... 1 a {any .1 .1”): I V ...”9 A . killfi A” / /./ ...- .., ixvfi.bm.:. u. . an... _ , /... w / “\\, flnuJ. ' 4 N . 5&4 t ,. II... /lt /.~ 1... . . I: \V- d o x . 4. . .04-v»: A /.I W... v‘lfi. Mb . K 7. v 3 ... / A.) _ » w . a . r ./. Fina /\ [ .NJ... II. . lab L J \ill. . .I I q...(\/ __ if # y .9”! V , .. /1. h— .. . . _, . .b . . . I. . I‘QI - - - t -- --(l .. ...l. : - - w Ft! / V. . . n 4. , x . . I l. A, l l _ / u, A x _ i T f -—47 a. l.” l m _ --...-) .. 0....- . W.~~_.——-.—.— . ~ . h u . i u . . _ x .. _ . H _ i l a. i . .. . w . \ . . l _ . _ . l, \ - _ V I , _ W 1 W \ . \\ H _ . _ \.I _ F g M v _ _ r _ r \.\ \\\\ ¥ M m M U . _ . \\\.\ _ i . _ . _ a .\\ . . .. . M _ , La _ \ l . x m . . . , _ \_ _ w l . r m . 3 . H w . w x _ _ _ t/ . , r q u x _ . _ . A . _ h ,_ m 1 V v _ w _ I / . M a H . _ _ .. w _ \ l V . . . .r a _ W ...\ . _ . M x , . _ ” n x. l . . .. w i _ . l _ ,\ , . . . _ _ . _ r u . _ . . , i l u . _ a n e . . . \. i .l w ~ — 9 ,rvI/f/ \ _ .— m _. _ _ . ‘ ll 1“ _. i . _ . . ,,,../ l ,. _ l . _ 9. \. m _ . ., _ , x l m H, . , , ,- . . ..-. . . :4.\ f a _. W _ .i a M M _ Fin ...... % rlllh If. 15.0-...5. -Lllrl..rnll_; {9! .OI'.IOL . t, , . .. . ._ 9 __ . P7 . ., . ... , . .l. . .. . . l . .m y l . g l _ I , I b l u . ._ _ I . . . ’ _ . . ~ . h 0 L _ luflll 0.. A. . 1itw‘t1 {ill .{i‘l‘lj 1.. ... a m _ , . . v i . I .. .1 ...-......_..v_. .... ‘-- c- I - - ......a . -—-—- «J " ' ’ ”‘1 --1 — --- ~*-- ————4 ! ”--.—....— -.»A... ~..........-- — .— .~- ......- 115.1... 6 a 5//d/n q I Q I l..l!.'cl:ll.‘|lli.'\1|l. 1‘4. I. A} . #/,, ,,,,,, ___ ‘ ' -~—~‘ « ,, -'~ . :—'__, r x I 7’ ~ - -—--——~ >— - x -— ~ 1 I r—-——>—--— —-‘l . v". —— — ——— — O- w — .... ‘—' I I I I l I . I ' I 5 . i t I I ; i . ' " V. ’ J ) x I 1 I I q : v I 7 Y ‘ u {I I I I I r ‘ . I 1 I I ! , I I ? 0 I 3 I I l I ' i i I I i '« I ( f ’ - I 0 - V I ‘ _ f . 1‘ . fl V. a E - I H ’ Ax 1 7 . k. s i + 5 I 3 . 7 7 _ .... - .1, .. .. _ ...- __ _ -.. ...—...”.-. ...—J ‘ \__ l - ’ - ”...—...; I ‘. I . I“ I ' 7" I \ ‘_-.~ _"_ _ _ __ ___*__ _~ __ 1 - ______ I ‘ I \ J i \ ‘ I [ x _ -__..-..-.._.. '_—~I , ”'5 "" i'::_".__._ ..._,____,-,,,. ,_, f’f ‘ ' ' ' " ' ' I .\ \. \ \ \ - \. / l I I I I I I l "‘ '\ \‘. I k H \ H .. 4‘ _ r “J . A _ .... ~A—V . D I ‘ 1“. ~‘ ~.‘mm‘.-.L-L'£mx‘mw~ i was“. 3mg COLLEGE AGRECSLTURALINHHNEERING DEPT.‘ ASTLANSING,MICH. I E -— .5: A /Q ,I'Av': /: Z. O 1:) IQ /"3./_ A [s/ v w I i ' ‘ .' ”R .""' "‘ : j . - III/Ia" ‘13 .5" I”? (FA Q M l ’ I ' ELAAAHHTEE ’ l P‘ ‘ /&//// AP? BY tRAwa<3XLCi ..w. .1 _ . l. ‘maufi U Iflfi?§agfzwsjsmxt-x3ga v—v' vv . '- C'.‘ ‘4 _,‘_ - “— ... vCHEflfiifl jSSéiE§"<,/’ .NO. / APPENDIX VIII Basic Data Table Table XX Hay Feeding Data Table XXI Silage Feeding Data Table XXII Bedding Data Table XXIII Milking Data Table XXIV Young Stock Chore Time TABLE 22 113 Avata ge 10 A“ Farms 3'33" $3299 Fug-1.3 Hm. 'I. Hm. '7. Km. % Hm. ”l. Hm. V. .I9 I34 .32. 4L6 .36 36.3 .19 58.0 .09 33.3 I“ ”NIL-.. ._ .37 65.9 .32 44.6 .43 “.7 .II 11.0 J‘ 59.3 ".25 19.7 .I: we .15 no .10 2.0.0 .02. 7.4 L32 "10.0 .77 IBM] .94 "30.0 .50 I001) .27 “30.0 914 2.0 10 I7 18 J 1 - _{l .I l _i M. Loose .jaa, Overhead ”noble. [enlet H 5.3 3.2. 3.6 3.2. .9 i—I _Al _FTII: L 4»— 4h. «M K I ‘>-‘ 1K 114 TABLE 211‘ {-32de Ildi N "1. .lo ' .04 4..8 .28 33. 3 .45 53.6 ' 0°, .0 3 .54. 100.0 '4- 2.3 AvezagI Ian Fozm: L Wu “F“ .13 17,1 “_‘ Avezage All FatMS. 0,. .13 2.7.1 .40 47.0 .45 51.9 J? 1.0. O .85 10 TABLE x 115 r \ 2: ELL. I TABLE XXIII I6rri[l7el7ml8el8m]l€- 20.5 22.5 2|.6 23.4 19.3 19 $13.0 11.2 10.9 23419.3 9 IO.2 Il.2 IO.8 ”.7 9.6 S 4.3 4.3 4.0 4.1 4.9 4 L3 .6 .4 .8 .9 I 74.4 88.0 92 83.5 84.0 83 3.! 3.0 3.4 2.2 3.2 2 6.7 5.8 6.7 7.9 8.9 1 O I I I2 AIL PAIL PAIL 7.. 2 2 .5' 2 I LEVEL ELEVATED ELEVATED Fl. 121191 71111105515313“: TANPNEM'C'SJIEGLE ‘ 'HROUGH SIDE ENTERING SIDE ENTERING WAI 4 3 3 117 TABLE XXIV YOUNG STOCK CHORE TIME (Average winter chore time Spent for the care of youn stock and calves on 18 farms with loose housing barns? Farm I Number of I Total Average minutes required Number number young stock time Based on 'Based on of dairy and calves required number of number of cows on young stock dairy cows farm 1 9 6.2 .69 .48 13 3 11 1.2 .10 .09 14 4 19 733.0 1.74 1.74 19 6 15 11.4 .87 .60 19 7 21 22.8 1.56 1.43 23 8 21 23.2 1.10 1.01 23 9 6 10.1 1.68 L51 20 10 18 45.1 2.50 2.65 17 11 21 14.1 .67 1.76 8 12 10 41.1 4.11 I 1.52 27 13 9 6.5 .72 .54 12 14 52 45.2 .86 1.56 29 15 9 11.4 1.26 .88 I: 16 13 11.2 .86 1.02 11 17 10 915 .95_ .73 13 18 15 32.9 2.19 2.19 l5 19 29 89.6 3.08 3.90 23 2O 15 29.9» 1.99 2.14 14 Everage 17 25.2 1.48 1.31. 17 LITERATURE CITED Bookhout, B. R. Reducing Chore Labor on Dairy Farms. Michigan Agricultural Experiment Station Quarterly Bulletin 30:1, 15-20, 1947. Buck, R. K., Hopkins, J. A. and Malone, C. C. An Economic Study of the Dairy Enterprise in North- eastern Iowa. Agricultural Experiment Station Iowa State College of Agriculture and Mechanic Arts. Research Bulletin 278, 1940. Buckley, S. S. and Lamson, R. W. Open Shed versus Closed Stable for Dairy Cows. Maryland Agricultural Experiment Station Bulletin 177, 1913. Carter, R. M. Labor Savin Through Farm Job Analysis (I. Dairy Barn Chores . vermont A ricultural Experiment Station Bulletin 503, 19 3. Census of Agriculture for Michigan (Preliminary for 1950) United States Department of Commerce. Bureau of the Census, 1951. Dairy Costs (1936) Michigan State Agricultural Experiment Station Bulletin F. M. 205, 1937. Davis, H. P. The Effects of Open-Shed Housing as Compared with Closed Stables for Milk Cows. Pennsylvania Agri- cultural EXperiment Station Annual Report, 1913- 1914: 183-226, 1916. Dice, J. R. Some Effects of Types of Shelter Upon Dairy Cattle. North Dakota Agricultural Experiment Station Bulletin 344, 1947. Engen, S. A. Loose Housing for Dairy Cattle. University of Minnesota Agricultural Experiment Station Folder 146, 1948. 10. 11. 12. 13. 14. 15. l6. 17. 18. 19. 20. 119 Farrall, A. W. Engineered Dairy Production and Machinery. American Society of Agricultural Engineering Journal 12:6, 241-242, 1931. Fish, N. S. Building the Dairy Barn. Wisconsin Agricultural Experiment Station Bulletin 569, 1924. Fraser, W. J. Should Dairy Cows Be Confined to Stalls. Illinois Agricultural Experiment Station Circular 9}, 1905. Fraser, W. J. Suggested Plans for Running Cows Loose. Hoard's Dairyman 66:12, 665, 1924. Gasser, J. Washington Milking Parlor and Lounging Barn. Hoard's Dairyman 86:4, 279, 1941. Headley, F. B. and Venstrom, Cruz Efficiency in Dairying. University of Nevada Agricultural Experiment Station Bulletin 118, 1930. Hodge, T. L. Factors in Dairy Costs and Income. Michigan Agri- cultural Experiment Station Quarterly Bulletin 32:2, 208-212, 1949. Hoglund, C. R., and Christian, R. W. How Can Upper Penninsula Dairymen Reduce Costs. Michigan State College Quarterly Bulletin 52:4, 598-605, 1950. Huff, K. B. The Milking Parlor for Small Dairy Farms. The American Society of Agricultural Engineering Journal 20:12, 462, 1939. Jefferson, C. H. and Weaver, Earl The Pen Barn and Milking Room in Michigan. Mich- igan Agricultural Experiment Station Circular Bulletin 195, 1945. Kelly, Ernest and Parks, Karl E. A Plan for a Small Dairy House. United States Department of Agriculture Farmers' Bulletin 689, 1915. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 120 Kelly, Ernest, and Parks, K. E. Farm Dairy Houses. United States Department of Agriculture Farmers' Bulletin 1214,1921. (Revised 1932). Long, J. D. Present Trends in Dairy Management Methods and Structures. American Society of Agricultural Engineerinngournal 12:11, 399-405, 1931. MacInnes, L. T. and Brooks, A. Dairy Farm Buildings. New South Wales Defiartment of Agriculture Farmers' Bulletin 149, 192 McColly, H. F. and Dice, J. R. The Pen Barn and Separate Milking Room. North Dakota Agricultural EXperiment Station Bulletin 283, 1935. Michigan Agricultural Statistics (1950) Michigan Department of Agriculture, Bureau of Agricultural Industry, 1951. Morrow, K. S. Eleven Years Experience With a Pen-Type Barn. Hoard's Dairyman 89:1, 38, 1944. Munger, H. B. The Cost of Producing Milk. Agricultural Experiment Station Iowa State College of Agriculture and Mechanic Arts Bulletin 197, 1921. Paul Bunyon' s Mammoth Michigan Milk Pail. American Dairy Association of Michigan (undated). Public Health Bulletin United States Public Health Service Bulletin 220, 1939. Smith, H. D., Hamilton, A. B., and DeVault, S. H. Labor Utilization in Dairy Buildings. The University of Maryland Agricultural Experiment Station Bulletin A46, 1947. Smith, L. J. The Loose Housing and Feeding of Dairy Herds. Washington State Agricultural Experiment Station Popular Bulletin 190, 1948. Strahan, J. L. A New Method of Milk Production. American Society of Aggicultural Engineering Journal 13:12, 313-316, 1932. 33. 34. 35. 36. 37. 121 Tretsven, J. O. and Monson, O. W. Montana State Agricultural Experiment Station Circular Bulletin 186, 1946. Witzel, S. A., Smith, U. R., and Wilkins, J. W. Milking Parlor Studies Where Used in Conjunction With the Loose Housing System. University of Wisconsin Department of Agricultural Engineering, 1948. Woodward, T. E. The Open Shed Compared With the Closed Barn for Dairy Cows. United States Department of Agri- culture Bulletin No. 736, 1918. Woodworth, H. C., Harris, C. W. and Rauchenstein, Emil Efficiency Studies in Dairy Farming. New Hampshire Agricultural Experiment Station Bulletin 275, 1933. Woodworth, Harry C. and Morrow, Kenneth S. Efficiency in the Dairy Barn. University of New Hampshire Agricultural Experiment Station Bulletin 387’ 1951 o 10. OTHER REFERENCES Agricultural Statistics 1951. United States Department of Agriculture 1951. Approved Washington Milking Parlors. The State College of Washington Extension Bulletin 410, 1950. Ashby, Wallace United States Department of Agriculture Farm Building and Rural Housing Activities. American Society of Agricultural Engineering Journal 27:10, 471-472, 1946. Barnes, Ralph Mosser Motion and Time Study. 3rd Ed. New York. John Wiley, 1949. Barre, H. J. and Sammet, L. L. Farm Structures. New York. John Wiley and Sons, Inc, 1950. Bartlett, R. W. and Caskey, W. F. Milk Transportation Problems in the St. Louis Milk- shed. University of Illinois Agricultural Experiment Station Bulletin 430, 1937. Bartlett, Roland Willey The Milk Industry. The Ronald Press Company. New York, 1946. Baxter, Eleanor 8., Clarke, Pamela M., Dodd, F. H. and Foot, A. S. Factors Affecting the Rate of Machine Milking. Egg Journal of Dairy Research (Great Britain) 17:2, 117-127. 1950. Bendixen, H. A. and Smith, L. J. Approved Milking Parlors for the State of Washington. Washington State Agricultural Experiment Station Bulletin 461, 1945. Boss, William Why Build Better Farm Buildings. 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H. Dairy Chore Efficiency (Timely Economic Information for Washin ton Farmers). State College of Washington Bulletin 5 , 1946. '1 W M v ' ' 1‘ . .. s‘ ’fi' 0 1 o . I ' t K ‘ J I ‘ ' O N» I .' 3' l Yr ' \ ' A .7 ~ L \ . * " r, -. . ' D . r. 9' . .v 0;; it} ‘ '_ .. . «F ‘ v. . . ,7; (A. ’. v _‘ ‘ ’ '1. '{2 f. r) ‘ 2 \ .7 I z ', _ u . r" :9 's 1. .‘4' ’~ ‘ h ... ‘ . 1 \ I ... ’ ’ ‘ - - ’ 9“. :3; 7 ‘ ' . . I ' , j .’ ~ . .‘I I s . l . . l , , . I I‘ ' ‘5’”.- ‘ h v '* .‘ . a . it" .: mi - .V ' 'x -1 7. "“9 3, f I ‘ 1' 8* '- .J. ' t '\ / 4,, 3 ~. . 0‘ if .0 ’ :4 ‘- . ‘- w _ (I- l-,~ (' ." f, A) q “_ . b‘ {:0 ’ 'V-r «a m: I L 1" 4.. r -’ i. t- n ‘ - 1 \l. . r ' 3" L' . v x: 4' -‘ 4' E'I",'J" \ " I L ‘vg 5’“.‘ C.,! "' \" . .' f... 3"! I t .1 f‘ - I f. ’ .. ' l *5" .‘L‘ 314%; "x , '9 .- v1. .3 t -4, fifta 42' o " " - r § 5‘.3 V.‘_;-..t’ rn' .' limiter TIL-5755 "“‘ M 'V-Iu CH GAN STATE UNIVERSITY Ll BR