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Evolution of a Process Flow Diagram

Some examples for Production Agriculture

Click your mouse throughout this slide show to advance the slides and animations

Overview
1. What is a Process Flow Diagram (PFD)? 2. Why do you need a PFD? The ISO 9001:2000 requirements.
3. Varying degrees of PFD complexity It depends on what you do! 4. Getting Started: Define your business processes.

5. Categorizing your business processes:


Management Responsibility Resource Management Product Realization Measure-Analyze-Improve.

6. The ISO 9001 Process Model.

7. How to build your own PFD.


8. The evolution of your PFD. Some examples of PFD for production agriculture.

What is a PFD?

Process flow diagrams are illustrations of key business processes and their interactions.

Planting

out
Young crop (with weeds)

in

Crop Management

out
Mature, healthy crop

in

Harvest

This simple PFD contains 3 general Processes The output of one process is often an input to The You interaction between processes is of the the next. could also think of the a PFD in terms sequence, or order, which they occur. material flow throughout the in production line.

Why do you need a PFD?


Reason #2: A #3: #4: ByPFD creating is your also a an PFD road organizational for map your to operations continual tool. Ityou may improvement must be used actively as .athink With checklist all about ofto your each The Bottom Line of ensure business your that business processes you have processes and all interactions of individually, the human in plan and andmaterial view as part you of resources should a system. be your able This need to is see often to where produce referred to Reason #1: The ISO 9001:2000 standard requires you to identify all of your business Your PFD is a roadmap of your business and QMS. It will help you to meet all of the as your measurement process products. evaluation and analysis will most likely lead to improvements in your system. processes and their interactions. general requirements of ISO 9001:2000. ISO 9001:2000 Clause 4.1 - GENERAL REQUIREMENTS
The organization shall establish, document, implement, and maintain a quality management system (QMS) and continually improve its effectiveness in accordance with the requirements of this International Standard. The organization shall:

a) identify the processes needed for the quality management system and their application throughout the organization (see 1.2);
b) determine the sequence and interaction of these processes; c) determine criteria and methods needed to ensure that both the operation and control of these processes are effective; d) ensure the availability of resources and information necessary to support the operation and monitoring of these processes; e) monitor, measure and analyze these processes; and f) implement actions necessary to achieve planned results and continual improvement of these processes.

PFDs for Production Agriculture:

We are going to build on the previous example by adding some pre-planting and post-harvest processes.

Tillage

Planting

Crop Management

Harvest and conveyance


SHIPPING TO CUSTOMER

The complexity of the PFD depends on

WHAT YOU DO!!!

Storage
In this example the color coded arrows distinguish product that is shipped: Immediately after harvest, OR click Packaging Processing

Following a period of storage, OR click

Following packaging (and possibly storage), OR click Following processing (and possibly packaging and/or storage)

Slow Down?!?!

Dont worry, you are going to start with the basics Lets get rid of the fancy stuff for now

Tillage

Planting

Crop Management

Harvest and conveyance

Storage and/or processing and/or packaging.

SHIPPING TO CUSTOMER

Storage
Packaging Processing

Thats better. This looks like a good starting point, but


there are a few things missing

Tillage

Planting

Crop Management

Harvest and conveyance

What about
Seed Purchases Crop planning Hiring seasonal staff

Storage and/or processing and/or packaging.

SHIPPING TO CUSTOMER

Financials

Equipment Maintenance

Just to name a few. You are very busy. Take some time to
make a list all of the things that you do as part of your farming operations.

YOUR list may include some of the processes shown below. Your
processes may then be grouped into categories
Resource Management Management Responsibilities planting Harvest and conveyance Product Realization Measurement and Analysis pest control

customer communication product quality analysis purchasing

financials
Processing and packaging storage and shipping

infrastructure
crop planning

fertilizer application

Equipment maintenance hiring seasonal staff Staff training tillage

Look Familiar? These categories are also illustrated in the ISO


Process Model for a QMS.

Management Responsibility
Customer communication Crop planning

Resource Management
Purchases Equipment/infrastructure maintenance hiring staff/training

Measurement and Analysis Product Realization


tillage planting apply fertilizer/pesticide harvest and conveyance process and package storage and shipping product quality analysis financials yield/profit maps

Building your own PFD: Our first example PFD included only Product Realization Processes. What do you do before your start farming?
What Hmmm category There may from be the another ISO Process interaction Model of a QMS these do these processes. processes belong maysome set to? Good But Now wait that You How you need know do a you plan! what decide you what are working tobetween produce? towards, You will youneed probably toYou have some Hint: Who of your is responsible objectives based for each on your customer requirements (e.g., delivery objectives gather in mind this information with respect before to step? your planning cropping your season crop. (e.g., yields, profits). dates). Tillage ISO Planting Crop Harvest and Remember, requires you to establish and document measurable objectives. Management conveyance SHIPPING TO CUSTOMER

Determine your customers product requirements

Crop Planning
Identify legal requirements with respect to the product and/or production processes

Set Objectives

OK now that you have a plan, what do you still need to do before the growing season?

What You need will Section also to obtain have of the to RESOURCES ISO manage for Model HUMAN in order do RESOURCES, to these produce processes your which belong includes according to??? hiring to and your plan, and taking care of the Process equipment/infrastructure that you crop already have your customers requirements, and your objectives. This requires purchasing material training resources

Purchasing
(supplies, seed, equipment)

Equipment and Infrastructure Maintenance

Acquire qualified staff

Provide Staff Training

The next Section of the ISO Process Model is the PFD that we started with earlier. What is this section called???

Tillage

Planting

Crop Management

Harvest and conveyance

Storage and/or processing and/or packaging.

SHIPPING TO CUSTOMER

At theSection What end of the of the growing ISO Process seasonModel you all of should these do these be evaluations evaluating processes should belong the: beto??? part of your MANAGEMENT REVIEW. This will help you to plan and IMPROVE your QMS for next year!
b) efficiency of your processes a) quality of your products

c) effectiveness of your QMS.

Product quality analysis

Review Customer Feedback

Corrective Actions

Process Evaluation, Preventive Actions

Internal Audit of QMS

MANAGEMENT REVIEW

Put the whole model together

customer requirements

Crop Planning
legal requirements

Set Objectives

Purchasing

Equipment and Infrastructure Maintenance

Planting Crop Management Harvest and conveyance

Tillage

Staff Training

hiring

MANAGEMENT REVIEW

Storage and/or processing and/or packaging.

Product quality analysis

SHIPPING

Product quality analysis

Internal Audit of QMS

Process Evaluation, Preventive Actions

Corrective Actions

Review Customer Feedback

Customer and Schedule KEY POINTS Contract Set Objectives cropping Crop Planning establishment Services Crop Plan

Assemble Supplies/Equipment

Hire/Train Staff

XYZ Farms Process Flow Diagram

The PFD Purchase includes seed, processes Equipment (boxes) and their interactions supplies and maintenance Hire/Train Staff (arrows). equipment Your PFD should be unique to your farm business Make sure Plant Crop Provide contracted Tillage and you include what you do! Crop Management The level Pest of detail is also dependant on your needs:
management
Transport

Fertilize Harvest

service Planting (plant/combine/spray)

Internal It may be simpler that our 1st example (i.e., a linear Audits Harvest chronological flow of processes Customer Crop yield data

Or a more complex web of Product and Process Conveyance Shipping Internal Audit of Evaluation and services QMS products Or it may be fancy
Packaging Storage Processing

Receipt and feedback process interactions


Management Review

and multiple

Management Review

scrap

Financials

Corrective/Preventive Actions

Return to top

Precision Ag data Analysis

ID Contact and/or Customer Requirements

ID Legal Requirements

ID Environmental Aspects

Use the information to plan Objectives and Targets Alternatives Evaluation Emergency Preparedness

Collect the information

Human Resources Employee training Acquire qualified staff/services

Set-up and maintain equipment

Acquire supplies, equipment, materials.

Production Resources

Crop Planning (ID mgt zones, variety selection, etc.

Planting Seedbed preparation Crop management (fertilize, pest control) Harvest

Conveyance Storage Shipping

Management Review

Internal Audit

Process Evaluation and Preventative Action

Product Quality

Product Receipt, Customer Feedback

Corrective Action

TIPS for Constructing Your Farms PFD


1. Write down a list of what you do throughout the year 2. Categorize the processes under the headings of Management Responsibilities, Resources, Production, and Measurement Analysis - Improvement. 3. Evaluate your list. Did you leave anything out? 4. Draft the PFD by putting the processes into order (on scrap paper). 5. Look for process interactions (other than the chronological sequence that was done in the above step) and draw them in. 6. Re-examine the examples in this slide show. Is there anything that you could borrow from them? 7. Complete Exercise #3 in the Ag-ISO Workbook to generate an electronic version of your PFD. 8. Accept what you have (for now). Your PFD will time especially when you put it to work!

evolve and improve over

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