LineFAME: A Design Method for a Lead-Free Bullet Production Line at the Weapons and Ammunition Factory of Peru

Rosas Espinoza E.A.; Quinto Huamán C.; Ruiz Guevara E.C.; Bobadilla Saavedra W.; Ochoa Castillo P.F. · Proceedings of the LACCEI international Multi-conference for Engineering, Education and Technology (2025) · DOI: 10.18687/leird2025.1.1.212

Resumen

Currently, the global defense industry faces the challenge of modernizing its production processes based on principles of environmental sustainability, operational efficiency, and personnel safety. In this context, many ammunition factories are adopting lead-free manufacturing models, in accordance with the Sustainable Development Goals (SDGs) and the technical requirements of international markets. This study is framed within that trend and presents LineFAME, a design model applied to the reengineering of the lead-free bullet production line at the Army Weapons and Ammunition Factory of Peru (FAMESAC). The project begins with a diagnosis of the current processes, which are characterized by intensive lead usage, a process-based functional layout, high operational times, dependence on imported inputs, and occupational health risks. The proposal is structured into two key phases. The first phase is oriented toward the acquisition of suitable raw material, specifically 90/10 brass bars, through in-house melting, extrusion, drawing, and heat treatment. The second phase focuses on configuring an efficient, continuous, and lead-free production line, installed in a single facility and based on a product-oriented layout. This new configuration made it possible to reduce the total manufacturing time from 29 to 17 hours, while also decreasing the amount of machinery, production waste, and personnel required. The results were validated through hardness testing, metallographic analysis, and field ballistics tests, as well as through a survey conducted with the technical and operational personnel of the Army Weapons and Ammunition Factory of Peru. The survey demonstrated a high level of acceptance regarding the implemented changes. In this way, LineFAME represents a viable and replicable alternative aligned with international standards for the modernization of ammunition production, ensuring efficiency, technological autonomy, and institutional sustainability. © LEIRD 2025.All rights reserved.

Instituciones: Universidad Privada del Norte