Design of Frangible Composite Production Process and Plant Layout with Powder Metallurgy Method and Capacity of 50.000.000 Rounds/Year

Abstract

Frangible composite material is one of the types of advanced material utilized by defense technology application which has been certified. In fact, this material is in development for mass production. In order to realize the mass production stage, it is necessary to have a comprehensive design on process production, specification, machine capacity and the blueprint of plant’s layout. Production process planning would be conducted by the target up to 50 million rounds per year. This process uses powder metallurgy method which consists of mixing, compaction, sintering, finishing, quality control, and packaging. This research would result various variable and constants in each processes, plant design, specification, and number of machines needed by using data from literature review and previous research. Then, the number of machines is going to be calculated in order to find the certain number of machines that are needed. The calculation implies the needed of production machines which are 1 unit of mixer, 3 units of automatic mechanical compaction machine, 1 unit of continuous sintering furnace, 1 unit of finishing machine, and 3 units of quality control machines. For the production process simulation, we use Tecnomatix Plant Simulation in order to simulate the processes to get the data. The simulation process would be started by inputting the total number of machines that are used by and the variables and constants in each process which had been determined before. By calibrating the running time for 365 days 3 hours 15 minutes, the result stated that the simulated production process produced the number of outputs of 50,037,120 rounds/year and 45,696 rounds per shift.