This study focuses on optimizing the performance of the Statapult®, a device widely used for teaching statistical concepts and process control, by applying Lean Six Sigma's DMAIC framework. The project was motivated by the critical need to address the device's performance inconsistencies, which disrupted training accuracy and negatively impacted learning outcomes. Over the past six months, the Statapult® exhibited variability in launch distances, averaging 6.45 feet ± 0.88 feet, far from the desired target of 8 feet ± 1 foot. A systematic approach was adopted to identify and address key variables, such as launch angle, ball type, operator technique, and equipment stability. Through structured problem-solving and the implementation of targeted solutions, including optimal angle settings, standardized processes, and stable base enhancements, the study achieved consistent performance improvements. This research highlights the efficacy of Lean Six Sigma in resolving variability, enhancing reliability, and ensuring the long-term sustainability of educational tools.