This document summarizes a Six Sigma project to improve the throwing distance of the Katapult toy. Customers had been complaining about distances being less than 135 inches. The project aims to increase the capability of hitting targets to 185 inches, reduce process variability by 20 inches, and reduce complaints about setup by 10%. Goals include increasing revenues by $138,000 by the end of 2008. The document outlines the problem statement, objectives, inputs/outputs, process mapping, analysis including gage R&R and process capability, identification of factors using fishbone diagram and failure mode effects analysis, design of experiments, and project schedule.

1. Six Sigma Project: Katapult

2. Assembly process

3. Problem Statement Customers from Los Angeles Area have been complaining about Katapult throwing distance (current < 135 inches) beginning with September 2007. Complaints have increased by 15% compared with previous quarter according to the Customer Service Department reportWhereWhatWhenExtentHow do we know

4. Capability of hitting a target: 185 incReduce process variability: 20 incReduce complains about Katapult set up procedure by 10% (from 15% to 5%) by the end of the year 2008. Increase Katapult revenues by $138,000 by the end of the year 2008.Objectives

5. SIPOCSuppliersA Wood Expression Inc

6. Automoblox

7. Bajo Toys USAInputsMan Power

8. Specifications

9. Material

10. MinitabProcessOutputsKatapult Optimum Set UpCustomersMarketing Department

11. Final CustomersVoice of the Customers (VoC)

12. Process Map

13. MetricsThe distance where the ball hits the ground.Primary Metric:Height from where the Katapult is placedSecondary Metric: Height 31 inchesDistance

14. Gage R&R (ANOVA) for MeasureGage R&RGage Run Chart of Measures By Part, Operator

15. Gage R&RGage R&R (ANOVA) for Measure

16. Process CapabilityWeibullProbability PlotProcess Capability Analysis

17. Fishbone DiagramMETHODMATERIALSWOOD QUALITYRUBBER BAND ON BRACING ARMRUBBER QUALITYRUBBER BAND ON THROWING ARMARM WEIGHTANGLE SELECTIONARM DESIGNBALL SELECTIONBALL PHYSICAL CHARACTERISTICSHOLDING CUP ASSEMBLYTHROWING DISTANCEAIRFLOWPROCESS INSTRUCTIONALTITUDEMANUFACTURINGTEMPERATUREOPERATORSHUMIDITYINDOORSENVIRONMENTMANPOWER

18. Cause and Effect Matrix

19. Failure Mode Effect Analysis

20. Key Input & Output Variables

21. Design of Experiment

22. Design of Experiment

23. Design of Experiment