To analyze the data in the provided tables and pinpoint the main problem, we need to examine each table

individually and identify any issues or trends. Let's go through each table:

**Table 1 (Raw Material, Crude Oil, and Cake Production):**

- The data in this table provides information about raw material, crude oil production, and cake
production over a 31-day period.
- Some key observations include fluctuations in Moisture Content, Dust, FFA as LAURIC, and Residual
Oil.
- Day 31 stands out due to significantly higher Residual Oil (12.8%) compared to other days.

**Table 2 (Yield Information):**

- This table provides information about the yield percentages for crude oil and cake production.
- Yield percentages for crude oil and cake seem to be within an acceptable range, with fluctuations but no
extreme anomalies.

**Table 3 (Utilities Consumption):**

- This table provides data on electricity, bunker fuel, and water consumption over the same 31-day period.
- Electricity consumption is relatively consistent, but there's a noticeable drop on Day 5.
- Water and bunker fuel consumption fluctuates but doesn't show any extreme anomalies.

**Table 4 (Expeller Running Hours):**

- This table provides data on the running hours of multiple expellers over the same 31-day period.
- There are no extreme anomalies, and the running hours are consistent for most expellers.

**Table 5 (Manpower Shift Schedule):**

- This table shows the shift schedule for three different groups over the month.
- It indicates which shift each group is assigned to on different days.

To pinpoint the main problem:

1. **Day 31**: Day 31 stands out due to the exceptionally high Residual Oil in Table 1 (12.8%). The
spike in Residual Oil on this day is a significant problem that needs investigation. There might have been
an issue in the oil production process or with the raw materials used on this specific day.

2. **Electricity Drop on Day 5**: In Table 3, there is a noticeable drop in electricity consumption on Day
5. Investigate if there was an issue with the electrical supply or equipment on that day.

3. **Manpower Schedule**: In Table 5, it's important to ensure that the workforce schedule aligns with
production needs. Any discrepancies between the shift schedules and production demands should be
addressed.

To analyze the data further and address the main problem:

- Investigate the root cause of the high Residual Oil on Day 31. Check the processing conditions, raw
material quality, and equipment performance on that day.
- For the electricity drop on Day 5, examine if there were any equipment failures or maintenance
activities that affected production.
- Ensure that the workforce schedule is optimized for production requirements and there are no issues
with manpower allocation.

Additional context about production goals, quality standards, and specific processes would be helpful for
a more in-depth analysis.
To analyze the data using the DMAIC (Define, Measure, Analyze, Improve, Control) method, we'll
follow each phase:

DEFINE:

1. Problem Statement:
The problem appears to be related to the production process of raw material, crude oil, cake, and related
performance indicators. Specifically, there are variations in the data, and certain days show anomalies.
We need to identify the root causes and areas of improvement.

**Measure:**

2. **Data Collection:** Data is already collected and provided in tables 1 to 5.

**Analyze:**

3. **Data Analysis:**

a. **Raw Material Processed:**

- Moisture content and dust percentage vary, but no significant issues are immediately evident.

b. **Crude Oil Produced:**

- There is a significant spike in "Residual Oil" on day 31, indicating a potential issue on that day.

c. **Cake Produced:**
- Moisture content of the cake varies but does not show extreme anomalies.

d. **Expeller Running Hours:**

- Data is provided for expeller running hours, which might be related to the production issues.
 e. **Manpower Schedule:**
- Manpower schedules are provided, which could impact production performance.

4. **Root Cause Analysis:**

- Examine the factors contributing to the high residual oil on day 31. Investigate the potential causes,
such as equipment malfunction or operator error.
- Analyze the expeller running hours to see if there's a correlation with production issues.
- Consider the impact of the manpower schedule on production quality and efficiency.

**Improve:**

5. **Improvement Actions:**
- Investigate the high residual oil on day 31, and take corrective actions to prevent it in the future.
- Review the expeller running hours to ensure optimal equipment performance.
- Examine the manpower schedules for potential adjustments to improve overall process efficiency.

**Control:**

6. **Control Measures:**
- Implement regular quality control checks to monitor the quality of raw material and production
processes.
- Establish preventive maintenance schedules for expellers and other equipment to ensure consistent
performance.
- Continuously monitor and optimize the manpower schedule to maximize production efficiency.
- Create control charts to track key parameters such as residual oil, dust percentage, and moisture
content to detect any deviations from the desired standards.
Problem Statement: The yield of crude oil and cake production is inconsistent and variable. influenced by
variations in raw material characteristics and production parameters.

-Optimization: Implement changes based on the analysis. This could involve adjusting processing
parameters, improving raw material quality control, optimizing expeller running schedules, or enhancing
manpower allocation strategies.
- **Training:** Provide training to the workforce to ensure they are following the best practices for
production.
- **Quality Control:** Implement real-time quality control measures to detect and address deviations
promptly.

**5. Control:**
- **Monitoring:** Establish a monitoring system to track yield metrics, raw material quality, and process
parameters regularly.
- **Feedback Loops:** Implement feedback mechanisms to continuously gather insights from the
production team.
- **Standardization:** Standardize processes and best practices to maintain consistency in production.
- **Documentation:** Maintain detailed records of process changes, their impact, and the results
achieved.

By following the DMAIC method with a focus on these areas, you can pinpoint the specific problems
causing yield variations and work toward implementing effective solutions to improve the overall
production process.

 To pinpoint the data's primary issue.

  To come up with a solution to prevent the circumstances that cause the discrepancies to
happen again.

 Inconsistent yield percentage as a result of inconsistent raw material consumption during

the processing period (month of September)
- The moisture content, dust percentage, and color of the raw material (Table 1) vary across different
days. Inconsistent raw material quality can lead to variations in the production process and affect yields.
- Parameters such as FFA (Free Fatty Acids) as LAURIC, residual oil content, and moisture content
after processing (Table 1) show fluctuations. Inconsistent processing conditions that directly impacted the
yield of both crude oil and cake.
- The running hours of different expellers (Table 4) show fluctuations across days. Variability in the
running time of machinery might indicate inefficiencies or maintenance issues, affecting the production
process.
- Manpower scheduling (Table 5) shows rotations between day and night shifts. Shift changes and
different teams might lead to inconsistencies if proper communication and handovers are not in place.
- Fluctuations in electricity, bunker, and water consumption (Table 3) could indicate inefficiencies in
resource usage, affecting the overall process stability.
- There appears to be a lack of standardized operating procedures or clear guidelines for handling
variations in raw material quality and adjusting processing parameters accordingly.

To address these issues using the DMAIC method:

Fordaaaa main problem:

- Inconsistent yield percentage as a result of inconsistent raw material consumption during the processing
period (month of September)
Day 31 stands out due to the exceptionally high Residual Oil in Table 1 (12.8%). The spike in Residual
Oil on this day is a significant problem that needs investigation. There might have been an issue in the oil
production process or with the raw materials used on this specific day.
In Table 3, there is a noticeable drop in electricity consumption on Day 5. Investigate if there was an issue
with the electrical supply or equipment on that day.
In Table 5, it's important to ensure that the workforce schedule aligns with production needs. Any
discrepancies between the shift schedules and production demands should be addressed.
Additionally, cross-functional collaboration and effective communication among production, quality
control, and maintenance teams are crucial to maintaining consistent yields. Regular training programs for
staff can enhance their skills and awareness of quality requirements, contributing to a more stable
production process.