IE272 – Manufactoring Processes and Operations

Anlysis
Term Project Spring 2022-2023
Instructor: Yiğit Karpat
Group 5
Berke Kemahlı 22102210
Doğa Aynacı 22102917
Zeynep Erva Dama 22102109
Betül Aslan 22102830
Index:
1. Introduction
2. Application of Lean principles and Operation Analysis
2.1 Operation Purpose
2.2 Catapult Design
2.3 Tolerances and Specifications
2.4 Materials
2.5 Manufacturing Sequence and Process
2.6 Setup and Tools
2.7 Material Handling
2.8 Plant Layout
2.9 Work Design
3. Time Study and Line Balancing
4. Performance Evaluation Studies
5. Conclusion
 1. Introduction:

The aim of this project is to design and manufacture a catapult that can throw a ping pong
ball for a certain distance. The design and manufacture of this catapult were made by using the
lean principles and we prioritize the efficiency of the catapult’s manufacturing process. While
making the catapult, our first priority was to make a catapult that can throw a ball to a target
range at every shot. Then to make this possible, we made some changes in design and created
the final version of the catapult.
In the first stage of our term project, we met and brainstormed together. As a group, the
first thing we decided for this catapult was its design and which materials would be the best fit
for the catapult such as wooden stick (with different sizes), silicon, roller, rubber band and
bottle cap.
In the second stage, we collected the materials and made our first catapult. For the first
catapult, we used wooden sticks for the body, silicon as our glue. The first catapult could throw
a ball to a target distance. However, after particular shots, some parts of the catapult broke up
and we decided to change our glue from silicon to super glue. We collected the data of the
distance of every shot and changed some properties during these shots to make the best
catapult. These properties were the tension of the rubber band, places of sticks, the height of
the spoon and made changes by consideration of these data. We took the measurements for
the placement of the spoon and some specific sticks and marked the sticks for those
measurements to use in our second catapult. Additionally, to make the rubber band more
stable, we notched the sticks, so the rubber band would stay stable during the shots and that
catapult could throw the ball more accurately for every shot.
In the third stage, we made another catapult by considering that data and mistakes that
we did last time We used super glue for pasting the body part of the catapult, because we
thought that the time that we spend on pasting with super glue would be less than silicon since
the time of drying process. Also, we thought that it would be more solid and cannot break up
like the last time. Nevertheless, with super glue the roller’s pasting process took so much longer
and it did not paste so well. Furthermore, roller and stick of the spoon separated several times
because even tough super glue did a good job in pasting wooden sticks to each other, it did not
perform so well with pasting metal to wooden stick. Therefore, we needed to find another
solution for pasting bearing to the spoon and we came up with the idea that we could use 2
different glues for different processes. In the first catapult, we did not face a problem with roller
and spoon. Hence, we decided to use silicon for pasting the bearing to the spoon.
In the fourth and final stage of our project, we did our final catapult. Finally, after two
problematic catapults, our third catapult was satisfactory and ready to make the shots. We did
not face any problems during the trial shots and we were able to collect proper data.
 2. Application of Lean principles and Operation Analysis
2.1. Operation Purpose:
Table 1) Process chart
Step# Activation Description Time Operation Transportation Inspection Delay Storage

Ο → □ D ∆
1 17cm long parts mark at 4.6cm and carve for band 50 sec +
2 11cm long parts mark at 3.8cm and 6cm for band 20sec +
holder and target stick
3 16cm long thrower marks 1cm and 5 cm opposite 20sec +
sides for band and bearing
4 12cm long parts mark 7cm and put a way sign to 12sec +
avoid complications
5 Put marks on 6.2cm and 6.8cm at middle cylinder 20cm +
for bearing
6 Tires of the catapult paste to the 17cm parts with 65sec +
respect to mark side
7 Transport 6th step’s outputs to assembly +
8 Paste bearing to cylinder with respect to marks 16sec +
9 Paste bottle cap to the thrower 15sec +
10 Stick thrower and bearing with silicon 18sec +
11 Delay for the drying time of glue 20sec +
th
12 Transport 10 step’s output to assembly +
13 Paste two 13cm parts to each other 19sec +
14 12cm and 11cm parts paste each other with 24sec
respect to marks (two times)
15 11cm part paste to the step 14’s output (two 35sec
times)
16 Inspection of the 15th step for the 11cm parts are 5sec +
in the right side
17 Two outputs of 15th step paste 71sec +
th
18 Hold the output of 17 to dry 10sec +
th
19 Turn the model for paste the 13 steps ‘s output 10sec +
(two 13cm parts)
20 Paste the 13cm parts to model 22sec +
21 Paste two 12cm part to the corresponding marks 21sec +
th
22 Paste the parts 6 step’s outputs to model 54sec +
23 Stick 11th step’s output to the mark point of the 40sec +
model with silicon
24 Stretch the band to the corresponding places 26sec +
2.2 Catapult Design

Catapults consist of 5 parts. These are:

1- Payload: object that will be launched by catapult.
2- Bucket and arm: it holds payload in stable state until payload’s release.
3- Base
4- Frame
5- Restraining material: it creates tension and acts like catapult’s trigger (mostly rubber
band or spring is used).
6- Wheels (not essential but we used in our design)

The base design is essential for the catapult to stay firmly on the ground during the release
of the payload. Also, since the other parts are in the connection with the base, an action-
reaction force occurs between them. For these reasons, it is crucial to make a solid and
proper base. Our first idea to make a strong and stable base was to use wooden sticks.
Therefore, we decided to use wooden sticks which have 1 cm thickness. Even though it was
our first idea, we realized that this design meets the requirements for the base. We built
base and frame simultaneously since they are connected to each other. For the base part we
used two 17 cm sticks and two 11 cm sticks. Yet, we saw that in order for catapult to be
stable during the discharging of the payload, shorter wooden sticks should not be placed
parallel to the ground. Instead, we rotated them and placed them in a way that they are
perpendicular to the ground. For the frame, we determined the length of sticks with the
help of mathematical calculations. In order to make a proper triangle, we decided to use
wooden sticks which have 12 cm and 11 cm lengths.
 Figure 1: Our first design Figure 2: Our final design
This was the first design that we made, and since it met the requirements we did not
make profound changes in the base and frame design. Also, we saw that using wooden
sticks helps us to create a strong catapult so; we decided to use wooden sticks in other parts
as well. However, we made some dimensional regulations in other parts of the catapult,
which will be explained in the tolerances and specifications part.
For the bucket part we used bottle cap since our payload was ping pong ball. For the
arm, we used 17 cm wooden stick. The essential part was creating an arm that rotates
freely. After making some research, in order for arm to rotate freely we decided to use
bearing. Owing to the fact that bearing decreases the friction and provides easier rotation, it
reduced the wasted energy. However, since bearing has a round shape, using prismatic
wooden stick is not feasible. Therefore, we used a cylindrical 13 cm wooden stick and
passed the wooden stick through to the bearing so that we were able to connect the bearing
to the arm and to the frame.
For the restraining material we used a rubber band, since it stores potential energy and
we can arrange this energy by changing the number of rubber bands. We passed the rubber
band under the base and placed it into the notch on the arm that we scraped. Since we
could change the range of the catapult without changing its design, using rubber bands was
beneficial.
2.3 Tolerances and Specifications
The six primer elements of our catapult are base (lower body), frame, arm, wheels, and
the parts that adjust the height of the arm and the location of the rubber band. As it is
mentioned in the previous part, the base and frame consist of two 17 cm, four 11 cm and two
12 cm wooden sticks. These wooden sticks attached each other with super glue. Also, at the top
of the frame, we decided to put a 13 cm wooden stick to hold the arm after the release of the
payload. Since, the tension on the rubber band may be excessive for the wooden stick; we
agreed to put two 13 cm wooden sticks, which are attached with the super glue, at the top of
the frame.
Additionally, throughout the design we mostly used super glue. However, when we
attach bearing to the arm with super glue, it caused redundant waiting time and waste of super
glue since metal and wood has different surface quality. Therefore, we used caulking gun to
attach the arm to the bearing.
After lower body and frame is glued, we decided where to attach other sticks which are
13 cm cylindrical stick with bearing, two 12 cm sticks to adjust the height of the arm and the
location of the rubber band. The most challenging part is to calculate the height of the arm since
we want our catapult to throw the material into a certain range. In order to decide where to
attach, we made some experiments with different conditions. After numerous different trials,
we found the optimal position for each wooden stick. We placed the cylindrical stick 7 cm above
of the 12 cm frame stick, and placed the 12 cm sticks that arranges the height of the arm and
arranges the location of the rubber band 6 and 3.8 cm above of the 11 cm wooden stick
respectively.
Lastly, we calculated the optimal place for rubber band and scraped a notch in order for
rubber band to stay still. The optimal position for rubber band is 0.8 cm above of the 17 cm arm
stick, and since we passed the rubber band under the catapult we created notches under the 17
cm base sticks as well. In base sticks we scraped 3.8 cm from the right side. As a result, with
these measurements we obtained the most favorable results from the catapult.
2.4 Materials
While our meetings, we evaluated older designs and selected the best design and argued
how this best design can be better. Hence, even though it was our first design we obtained a
catapult that is durable and meets most of the expectations.
Lower Body Part:
So as to build the lower body we used wooden sticks with different lengths as it is
explained in the previous parts. Using wooden sticks was convenient since it is straightforward
to attach them with super glue. Using super glue made a solid catapult with less time compared
to the caulking gun. Additionally, in order for rubber band to fit, we created a notch that is at
the bottom and 3.8 cm distant from the right side of the 17 cm stick.

17 cm and 11 cm sticks that are used in the lower body design

Upper Body Part:
For the upper body parts we used triangular shape in the sides. Also, we used 13 cm
cylindrical wooden stick with bearing to rotate the arm, 12 cm wooden stick to arrange the
height of the arm, 12 cm wooden stick to arrange the location of the rubber band and at the top
we used two 13 cm wooden sticks to hold the arm after the release.
At the top part we used wooden sticks to hold the arm since, we want to release the
payload at the maximum height so that it can make horizontal projectile motion and we get
maximum shooting distance.
 12 cm and 11 cm wooden sticks that are used in frame.

13 cm cylindrical stick that passes through the bearing. Bearing

 Two 13 cm sticks which act like a barrier for the arm.

12 cm sticks that adjust the height of the arm and the location of the rubber band.
Arm and Wheels:
For the arm we used a 17 cm wooden stick and scraped a notch in order for rubber band
to be fixed. For the bucket and wheels, we used bottle caps.
 Wooden stick for arm. Bottle cap that is used for bucket and wheels.

2.5. Manufacturing Sequences and Process

Initially we decided our processes and then made the process chart of our catapult
production. Based on the process chart, we determined which tasks are predecessor for which
tasks so that we were able to make an AON diagram. After that, we made the operation chart
and finally made Gantt chart according to work stations that we found using largest candidate
heuristic.
Table 2) AON Diagram
Table 3) Operation Chart

Table 4) Gantt Chart

Progress visualized in SolidWorks software;

Main body of the catapult made from 13,12,11cm parts.

Thrower made as another part from the 16cm stick, 13cm cylinder, bearing and
bottle cap.
 Wheels and 17cm parts used for making sides of the catapult. This process was
made two times.

Thrower and main parts of the catapult joined at marked points. (Wheels have been
remoted in this figure to show sides.)
From the side view of the catapult parts that are placed behind is used for place for
band and second part used as an aim point for 2 meters.

Final look of the catapult is shown above.

Final look of the catapult is shown above.

2.6 Setup and Tools

We used different materials for different parts of the catapult. We thought that the
wood would be the best material because of the surface of the wood, it would paste each other
more quickly, therefore we used wooden sticks for the body parts and the handle of the spoon.
The wooden sticks are in different shapes and sizes. We decided to use plastic bottle cap for the
head of the spoon.

Firstly, we agreed to use silicon as our glue for pasting all of the parts to each other,
however it turned out that the time that we spend on waiting for the silicon is more than we
estimated so we tried super glue and for fixating the body parts, the super glue was the right
choice but for pasting bearing to the wooden stick, it did not work well. Finally, we decided to
use super glue for pasting wooden sticks and bottle cap, and silicon for pasting bearing to the
wooden sticks.

In order to give the right shape to woods, we used fret saw for cutting the wood into
wooden sticks, utility knife for notching specific sticks for stabling the rubber band.

Silicon gun utility knife super glue fret saw

2.7 Material Handling

Due to the compact size of our workplace, there is no need for a complicated system to
handle materials during manufacturing. Instead, we can easily transfer materials between
workers by handing them over directly. The parts we cut and marked are kept ready and
separated by their size, type, and station they will be used. By marking them, we do not have to
measure the sticks every time we manufacture a catapult and quickly make the right placement.
Also, by separating the materials into groups according to their stations, we decrease the time
we spend finding the right material for the correct process.

2.8. Plant Layout

Since we were 4 people in our project group, we had to have 4 work stations. Using the
heuristic of largest candidate for line balancing, we finally had some tasks in different work
stations for different parts of the catapult. For instance; tasks 14, 13 and 10 are carried out for
different parts. Because of this aspect of the work stations in our layout, the plant layout for
catapult manufacturing became a cellular layout.

WS2
WS1
5,13,8,10,11,
1,6,2,3,9
4,14,19,7,12

WS3 WS4
22,23,15,24,16 17,18,20,21
2.9. Work Design
Catapult in our design can easily fit into an a5 paper which makes it a product that can be
done in a small area. Considering that, we thought that 4 people sitting next to each other
around a table can make the production of the catapult. Since people will be next to each other
mistakes can be noticed from other before the next step is handled. Also, the assembly of some
parts can be performed together if needed.
3. Time Study and Line Balancing:
Table 5) Time table
TASK NUMBER DURATION (second) PREDECESSOR

17 71 16

6 65 1

22 54 7

1 50 -

10 40 9,8

23 40 22,12

15 35 14

24 26 23

14 24 2,4

20 22 19,18

21 21 20

2 20 -

3 20 -

5 20 -

11 20 10

13 19 -

8 16 5

9 15 3

4 12 -

18 10 17

19 10 13

16 5 15

7 2 6

12 2 11
 Using the time table of tasks and predecessors of them, we made 4 work stations using the
largest candidate rule.

WS1 WS2 WS3

WS3 WS4
1, 6,WS1
2, 3, 9 5, 13,WS2
8, 10, 11, 22, 23,
22, 23, 15,
15, WS4
17, 18, 20, 21
1, 6, 2, 3, 9 5,
4, 14,8,
13, 19,10,
7,11,
12 24, 16
16 17, 18, 20, 21
24,
4, 14, 19, 7, 12

Takt time=170 sec

𝑇𝑊𝑆1 = 170 𝑠𝑒𝑐 𝑇𝑊𝑆2 = 165 𝑠𝑒𝑐
𝑇𝑊𝑆3 = 160 𝑠𝑒𝑐 𝑇𝑊𝑆4 = 124 𝑠𝑒𝑐
𝑇𝑊𝐶 = 619 𝑠𝑒𝑐
Using the efficiency formula for our work stations, the efficiency of the system founded as:
170 + 160 + 165 + 124
= 0,9102
4 × 170

𝐸𝑓𝑓𝑖𝑐𝑒𝑛𝑦 𝑖𝑛 𝑠𝑦𝑠𝑡𝑒𝑚: %91,02

4. Performance Evaluation Studies

When we made an initial design, all that remained was to determine where to aim the
catapult. Together, we decided to put the 11 cm stick in a way that it would be 5 cm according
to the part below, and we shot the ball and record the range in centimeters.
 5cm

RANGE(cm)
228

226

224

222
RANGE(cm)
220

218

216
0 2 4 6 8 10 12

When these shots were far from what we wanted, this time we made measurements by

increasing 2 cm and placing a wooden stick on the 7 cm.

 7cm

RANGE(cm)
188

186

184

182

180

178 RANGE(cm)
176

174

172

170
0 2 4 6 8 10 12

As can be seen in the graphic above, being 7 cm also shortened the distance of the shot.
Thereupon, we placed the board at a distance of 6 cm, as in the final catapult, and made our
shots.
 6cm

RANGE(cm)
208
206
204
202
200
198
196
RANGE(cm)
194
192
190
188
186
0 2 4 6 8 10 12

After placing wooden stick at 6 cm, we were finally able to record 10 shots closer to 200
cm. However, our graph was fluctuating higher than we expected. We examined the structure
of catapult and observe that rubber band was sliding over wooden sticks as we make throwings.
We observed the location of the rubber band during the shots we made and we decided to
place the same bars to prevent the rubber band from slipping. When we put this stick we used
the information of where the rubber band was while making the 200 cm shot above, which was
at 3,8 cm.
With those arrangements our final catapult became this:

6cm
3,8cm

RANGE(cm)
204

203

202

201

200 RANGE(cm)

199

198

197

196
0 2 4 6 8 10 12
5. Conclusion

In conclusion, we successfully completed the manufacturing of the catapult. The aim of

this project was to manufacture a catapult and design an assembly line for its mass production.
We applied our knowledge that we learnt in class and used lean principles during the project.
We changed the materials during the trials according to catapults that we manufactured and we
tried the find the best way to manufacture it. Our priority was to increase efficiency. We
considered two properties for the efficiency; these were the time we spent on every process
and stability of the catapult. Therefore, while making this project, we made our changes and
improvements with respect to these priorities.

We tried to stick to the following Gantt chart throughout the project;

27.04 04.05 09.05 20.05 24.05 28.05

RESEARCHING
FOR INITIAL
DESIGN

MANUFACTURING
OF THE FIRST
CATAPULT

TEST, STUDIES
AND MAKING
IMPROVEMENTS

WRITING THE
REPORT

(COLLECTING THE
DATA AND THE
WRITING PROCESS)

MANUFACTURING
THE SECOND
CATAPULT

PRODUCTION
PLANNING AND
DESIGNING THE
ASSEMBLY LINE

MANUFACTURING
OF THE FINAL
CATAPULT
 In the first stage of this project, we decided the design of the catapult, in the second
stage we made our first catapult which had deficiency such as the time that is spent on waiting
for glue to dry and the catapult broke up after a certain shot. We searched how to eliminate
these deficiencies and applied the solutions that we found in the third stage of the project. In
the third stage, we manufactured another catapult with considering the mistakes that we did in
the last catapult, however there were still deficiencies and we needed to make one more
catapult. The defect of the second catapult was the stability of the bearing and spoon. The
bearing did not paste well to the handle of spoon, so we changed the glue for this specific part
of the catapult. In the fourth stage, we manufactured our final catapult.

As a result, we experienced how to work as a team and found a space that we can apply
what we learnt in the class during this semester. We faced so many difficulties, especially,
finding the suitable time to gather. However, we believed that we managed the period very
smoothly because every member of the team was very hard working and they were willing to
participate. In conclusion, we successfully finished our project.