Forty Holstein cows were used in an 8-wk randomized block design trial to determine the effects of theoretical length of cut (TLC) and kernel processing (KP) of whole plant corn silage on nutrient intake and digestibility, milk yield, and milk composition. Corn was harvested at three-quarters milk line stage of maturity at TLC of 1.90 or 2.54 cm. At each TLC, corn was KP at either 2 or 8 mm roll clearance. The control was harvested at 1.90 cm without KP. Corn silage provided 38% of the dietary dry matter (DM) in the experimental diets. Intake of DM and nutrients was similar among treatments. Apparent digestibility of DM and acid detergent fiber (ADF) increased with increasing TLC. Fiber digestibility was improved by KP compared with unprocessed corn silage. Starch digestibility was greater for corn silage KP at 2 vs. 8 mm. Apparent digestibility of DM, crude protein, and ADF was lowest for the diet containing silage harvested at 2.54 cm TLC and KP at 8 mm, resulting in an interaction of TLC and KP. No differences were observed in DM intake (DMI) among treatments. An interaction of TLC and KP was observed, however, for yield of milk protein and energy-corrected milk (ECM) and efficiency of converting DMI to ECM because of lower yield for diets containing silage harvested at 2.54 cm TLC and KP at 8 mm. Results of this trial indicate that as TLC increases, aggressive KP is necessary to maintain nutrient digestibility and performance of lactating dairy cows. cm with 2-mm kernel processing, 2.54 P=corn silage chopped at 2.54 cm with 8-mm kernel processing.