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

Abstract

The global defense industry is currently challenged to modernize its production processes under principles of environmental sustainability, operational efficiency, and worker safety. In this context, many ammunition factories are shifting to lead-free production models, in line with the Sustainable Development Goals (SDGs) and international standards. This study presents LineFAME, a design method 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 system, marked by heavy lead use, a process-oriented layout, extended production times, dependence on imported materials, and occupational health risks. The proposal consists of two main phases. Phase one focuses on obtaining 90/10 brass bars through internal melting, extrusion, drawing, and heat treatment. Phase two configures a continuous, efficient production line within a single facility, using a product-based layout. This redesign reduced production time from 29 to 17 hours, minimized machinery use and material waste, and lowered personnel requirements. Validation included hardness testing, metallographic analysis, ballistic trials, and a survey of technical staff, which confirmed strong acceptance. LineFAME emerges as a viable and replicable model aligned with international standards, offering a path toward sustainable, efficient, and autonomous ammunition manufacturing.