1.

1 Process Background
1.1.1 History and Background
Early examples of Japanese swords were straight and others with unusual shapes,
their styles and forging techniques probably are derived from ancient China during
1st~8th centuries. Some of them are directly imported from China through trade.
Swords forged between 987 and 1597 are called "old swords"; these are
considered the pinnacle of Japanese sword craft. Early models had uneven curves with
the deepest part of the curve at the hilt. As eras changed the center of the curve tended to
move up the blade.
The Japanese sword known today with its deep, graceful curve has its origin in
single-edged blade with ridgeline which was developed sometime around the middle of
the Heian period to service the need of the growing military class. Its shape reflects the
changing form of warfare in Japan. The curved sword is a far more efficient weapon
when wielded by a warrior on horseback where the curve of the blade adds considerably
to the downward force of a cutting action.
The Mongol invasions of Japan in the 13th century spurred further evolution of
the Japanese sword. Often forced to abandon traditional mounted archery for hand-tohand combat, many samurai found that their swords were too delicate and prone to
damage when used against the thick leather armor of the invaders. In response, Japanese
sword smiths started to adopt thinner and simpler temper lines. Certain Japanese sword
smiths of this period began to make blades with thicker backs and bigger points as a
response to the Mongol threat.
By the 15th century, the Sengoku Jidai civil war erupted, and the vast need for
swords together with the ferocity of the fighting caused the highly artistic techniques of
the Kamakura period (known as the "Golden Age of Sword making") to be abandoned in
favor of more utilitarian and disposable weapons.
The craft decayed as time progressed and firearms were introduced as a decisive
force on the battlefield. At the end of the Muromachi period, the Tokugawa shoguns
issued regulations controlling who could own and carry swords, and effectively
standardized the description of a sword.

1.1.2-1 Chemical Structure and Formulation

Fe

CO2

STEEL

1.1.2-2 Chemical and Physical Properties

The iron ore is chemically heated at temperature up to 2,500F in the clay furnace
and dissolve with carbon to make steel. The physical properties of ore become molten as
the contact with the heat. When tempering, the sword become harder when it is
chemically heated at 400F and let it cool to room temperature.
1.1.3 Potential Raw Material
1-Raw Material.
We use iron ore as the raw material to make the product.
2- Processes.
Heat,
Hammer
and Fold
the steel.

Clay
Furnace

Forging
Painting
and
Tempering

Quenching

Iron-bearing
river sand
and charcoal

Grinding

Carbon
dissolve into
the steel

Further
combine the
iron and
carbon

Swords hilt

Curved blade

Sword's
sharp front
edge only
lightly coated

Polished
blade

Decoration

3- Advantages.
Uses pure steel to make the product.
Raw materials are from renewable resources.
Production processes are wide.
1.2 Application
Use to cut things in daily works.
Easily cut things because of its thin area.
As a historical things that we keep in house.

Sword
shaped

1.3 Market Survey

1.3.1Swords current demand in world

1.3.2 Swords market price in Asia

1.3.3Current competition of Swords production around the world

1.4 Site Selection and Plant Layout

1.4.1 Location and Comparison of Site Selection
Consideration/Place
Law & order

Kuantan, Pahang

Klang, Selangor

Butterworth, Penang

10 km

300 km

150 km

200 km

50 km

250 km

Good

Good

Good

There are good

There are no

There are no

infrastructure

infrastructure

infrastructure

There are available

There are no

There are available

Nearest to raw material

source
Nearest to market
Safety
Infrastructure

Availability of suitable
land

land for factories

available land for

land for factories

factories
Near to local
community
Climate

50 km

100 km

150 km

Safe from climate

Have high climate

Have high climate

change

change

change

From the table, the place that has the most suitable consideration is at Kuantan, Pahang.
This place has no problem with law and order of the state. This area is the nearest to raw material
source and local community. This place is about 200km to the nearest market. This place have
good infrastructure that has good safety. This place are also could adapt with the climate change.

1.4.2

Plant Layout

This plant has area of 8093.72 meter square or equal to 2 football field. This plant has 6
parts of different works. Firstly, there are two tanks for the storage of raw materials. Then, there
6

are blocks that work for forge and furnace. After that, tempering and quenching blocks are placed
beside the polishing blocks. In the middle, there is product storage that will be ready for
transportation. From the back of the plant, there are storage for waste that will be treated and
then discharge to drain.