MSE 618 Project

Team 3
Ravinder Singh
Allen Giragosian
Simon Psavko
Jidhin James
Rijul Dhruv
Chirag Contractor
 Introduction
Team 3 is an international catapult
manufacturing company, supplying IVY League
Universities for their annual Catapult Fair Party.
Recently a batch of 100,000 pieces supplied to
these universities did not perform according to
specification, creating dissatisfaction and a
reduction in sales. A Six Sigma Process has been
employed to rectify this situation
 DMAIC
The DMAIC methodology has 5 main phases:
Define Phase where the problem is defined and the desired goals
specifically
Measure Phase where the key aspects of the current data and the
relevant data is collected
Analyze Phase where the data is investigated using detailed process
map and verify the cost and effect relationship. Determine what the
relationships are, and attempt to ensure that all factors have been
considered.
Improve Phase where the optimization of the current process
based on the data analysis obtained in the Analyze phase using
technique of DOE(Design of Experiment) and the FMEA (Failure
Mode Effect Analysis) is prepared.
Control Phase where controlling the future state process to ensure
any deviation from the target are corrected before they result in
defect
Define Phase
Problem Statement
The catapults used by the IVY League Universities in their
egg toss competition every spring experienced an X percent
error in the distance travelled, this caused the sales order to
decrease by Z percent

Problem Objective
The objective of this project is to increase the efficiency of
the catapult in such a way that it travels a distance of XYZ
99 percent of the time and thus causes a 25 percent
increase in sales
 S.I.P.O.C.
Supplier Input Process Output Customer
Oregon Wood Material Catapult IVY league
Company
capable of universities
Home Depot Labor
shooting egg
National Blue Print
Rubber
99% of the shooting
Industry time. teams.
Shell co. Cutting
Machine

Cut wood to Assemble Fix Pins and Fix

Punch
specific base side Rubber shooting
Holes
dimensions and arms Band shell
Primary Metric
The primary metric is the shooting range of the catapult.

Secondary Metric
The secondary metric is the Height of the catapult, this will be
constant throughout the project.
Measure Phase
 A set of 90 different readings collected using
three different operators utilizing 10 parts and
3 trials per parts provided the data for this
phase.

The collected data was input into Minitab, this

process provided the MSA analysis; Gage R&R,
Normality, Capability Analysis.
 Gage R&R
Two-Way ANOVA Table Without Interaction
Source DF SS MS F P
Parts 9 64207.4 7134.15 85.7586 0.000
Operators 2 356.1 178.04 2.1402 0.124
Repeatability 78 6488.7 83.19
Total 89 71052.2

Gage R&R
%Contribution
Source VarComp (of VarComp)
Total Gage R&R 86.350 9.93
Repeatability 83.189 9.56
Reproducibility 3.162 0.36
Operators 3.162 0.36
Part-To-Part 783.440 90.07
Total Variation 869.791 100.00

Study Var %Study Var

Source StdDev (SD) (6 * SD) (%SV)
Total Gage R&R 9.2925 55.755 31.51
Repeatability 9.1208 54.725 30.93
Reproducibility 1.7781 10.669 6.03
Operators 1.7781 10.669 6.03
Part-To-Part 27.9900 167.940 94.91
Total Variation 29.4922 176.953 100.00

Number of Distinct Categories = 4

Normality Test
Capability Test
The following things can be inferred from the capability graph:

Cp of 0.84 indicates a process whose average is not centered and

whose parts may not be conforming to the specification.

Cpk of -2.02 indicates that the average is outside the specifications.

While the Pp and Ppk are similar to the Cp and Cpk it relates to the
overall process rather than subgroups (within). The slight difference
in values is due to the way the mean is calculated.

PPM Total (Exp. Overall Performance) indicates that there will be 1

million out of 1 million shots outside the specifications.

We are not meeting customer's requirements and should improve

the process by reducing the variation.
Primary Metric
We have a target distance specified by the customer
of 58 +/- 4 inches.

Secondary Metric
The secondary metric, which should remain constant
throughout the process, is the height of the catapult
Primary metric
 28.35

Shooting Height

Number of trials

Secondary metric
Analyze Phase
 Detailed process map

Ys: Components Ys: Partially assembled Ys: Partially assembled

cut to size catapult catapult with holes
Pre-
CUT Drill
Assembly
Xs: Material (C) Xs: Operator (N) Xs: Tools (C)
Operator (N) Components cut to size (C) Operator (N)
Blueprint (S) Fasteners (C) Blueprint (S)
Tools (C) Tools (C) Partially assembled catapult (C)

Catapult without Ys: Final product

Ys:
bowl
Pin Final Assembly
Assembly
Xs: Operator (N) Catapult bowl (C)
Tools (C) Blueprint (S)
Partially assembled catapult Fastener (C)
with holes (C) Tools (C)
Operator (N)
Catapult without bowl (C)
 Fish Bone Diagram
Cost and Effect Analysis

Machine Environment
Fabrication Tools (C) Temperature (N)
Assembly Tools (C) Airflow (N)
Inspection Tools (C) Humidity (N)

Shooting
Range

Wood (C) Pin on Shooting Arm (C) Inspector (N)

Rubber band (C) Pin on Base (C) Designer (N)
Fasteners (C) Pin on Fixed Arm (C) Operator (N)
Shooter (N)

Material Methods People

Cost and Effect Metrics
Cost and Effect Analysis
 Shooting Arm Pin

Fixed Arm Pin

Base Pins
FMEA
Improve Phase
Design of Experiment
 Design of Experiment
DOE RECCOMENDATION

GOAL IS 58 INCHES 4

Pin Fixed Arm Location : 0

Pin Movable Arm : 0

Pin Base: 5
Control Phase
Using the new and improved Catapult, obtained
through the improve and analyze phase, we re-
ran the experiment to validate that our catapult
is now within client specification.
Control Charts
Normality Test
Capability Test - Before
Capability Test - After
 Conclusion
Through the utilization of the Six Sigma Process;
variation has been reduced and the catapult is
now within specification.

The Catapult Fair Parties may now continue!