Flexibility Improvement on Energy Consumption of Punching Machine Based on Green Manufacturing Method at PT Buana Intan Gemilang

These days, Green Manufacturing has established become a new technology for professional engineers and manufacturing workers to be an important part in the business world. Green Manufacturing was created to reflect the new manufacturing paradigm techniques to make something become more eco-efficient by reducing the energy consumption. PT Buana Intran Gemilang is one of Textile Company that produce curtain and prayer rug. In the production this company use a Jacquard punching machine designed to cut a hole in material such as card stock. The machine works manually with the flexibility less than 90 percent that led to the longest production time in meeting the demand, thus causing the electrical energy released for this machine is also very high. On the basis of these problems required a system to improve the flexibility of the machine in order to reduce energy consumption and make the company become greener environmentally friendly. From this research generated an automation system based on green manufacturing method which will be applied on a jacquard punching machine that can increase flexibility machine to be more than 90 percent. This system has saving the electricity consumption of 2092 KWh every making a complete fabric pattern.


Introduction
The continued development of the industrial revolution causes of result of the greater energy being used, but instead the availability of energy in the world is actually depleting.Statistics value of energy use in Indonesia 2014 shows that industry sector become the biggest user of electricity energy, followed by household in the second place, business in the third place and another general sector in the last place.Besides that, the use of electrical energy in the industrial sector continued to increase from year to year.PT.Buana Intan Gemilang is one of the textile company in Banjaran, Bandung that produce curtain and prayer rug as its product.PT.Buana Intan Gemilang have several production department, and one of the main part of this company is weaving and preparation department.Punching machine is one of machine that used in preparation department, the function of the machine is to make the jacquard card of the curtain and prayer rug to use in the weaving machine.
Reducing the energy consumption of electricity will impact to all other manufacturing competitive edges, such flexibility.The concept flexibility in manufacturing has become a key consideration in the design, operation and management of manufacturing system [1].By increasing the flexibility the same as make a better manufacturing system.Automation technique is use as one way to control and improve the flexibility of jacquard punching machine.Automation is the technology which can perform a series of process or procedure automatically without human assistance.It implemented with execute a list program of instruction which combine by a control system in perform the instruction [2].
The purpose of this research is improving flexibility of jacquard punching machine using automation system to be able to reduce energy consumption and turn the company to be a green manufacturing company.

Jacquard Punching Machine
Jacquard Punching Machine is machine that designed to cut a hole in some material such as paper, metal, or card stock.There are three basic elements of punching device, a punch, a die, and a stripper.The punch is the piece which is driven through the card and cuts the hole.The die serves as a base, supports the card while it is being cut.The stripper serves as a guide for the punch and as a means of stripping the card from the punch after the latter has cut the card.
In PT.Buana Intan Gemilang the purpose of jacquard punching machine is to make the pattern card (jacquard card) that will be represent the pattern of the fabric (curtain or prayer mat).The things that should be noted in this process is the hole making process and the precision location of the hole itself.The good quality of jacquard card is a card that does not have any defect.As increasing demand of textile sector and also supports from the government to develop local textile industries, the company must be able to compete with other local competitor by producing high number of product with high quality, and on the right time.The company usually makes the jacquard card with this punching machine in manual way, so its takes an expensive cost for the energy because the machine running in longer time and also low flexibility because the ability to change jacquard is very slow.

Research Methodology
Green manufacturing is a complicated system engineering problem that needs to be surveyed from the view of system engineering, its kind of sustainable development in the field of modern manufacturing.Making the same product using fewer resources and/or energy is a good strategy to make money.In other words, being efficient through preventing waste is both eco as well as money efficiency.
In designing the concept of green manufacturing, implement a system model as a tool to simplify its application [3].This model system will be applied in case study at PT. Buana Intan Gemilang to be able to assist in applying the concept of green manufacturing so as to improve the flexibility of the punching machine.
Some of benefits of green manufacturing are (1) Controls and reduces material waste in manufacturing cycles.(2) Preserves capital and saves money.(3) Improve productivity and increases cost savings.(4) Helps drive and influence corporate behavior both internal and external to ensure sustainability.(5) Easy adaptability to changing rules in environmental regulations and legislation [3].• Stage 1: Color Identification The process of color identification in PT.Buana Intan Gemilang was doing by questionnaire method that distributed to some operator of jacquard punching machine.This process is done to find out the current state of the company, so it can easily determine what actions can be taking.Questionnaires distributed to 5 operators of punching machine that really know the condition of machine and company.
Base on the result of questionnaire it can be concluded that PT.Buana Intan Gemilang in the brown (medium) position, with the energy of the system have bigger percentage better than the material which means it needs an improvement in part of energy usage.The company has not enough energy-saving in the use of electricity but in terms of waste not too polluting because of all good material of raw materials as well as the rest of the result of production does not damage the environment.• Stage 2: Improvement Object In this part the process of planning on the improvement is about what will the company done on the way to make the company greener without affecting the results and production planning.The development process of this improvement will be focused on the energy consumption section of the punching machine up to the implementation of a new technology on the machine that can support the energy saving process itself.Jacquard punching machine is a machine that is designed to cut a hole in some materials such as paper, metal or card.Aspects to be studied further from the results of this improvement application are the flexibility aspect of the punching machine.• Stage 3: Green Implementation The next process is implementation of all the strategies that have been designed on the punching machine.Automation technology that applied to punching machines will be measured based on changes in production time and energy consumption of punching machines.If the automated punching machine has faster production time and less energy consumption with the amount of production that can meet the targets set by PT.Buana Intan Gemilang, the company has succeeded in increasing the color category from brown to green category.Paint it Green Smooth executing of the green improvement plan at machine, process and system levels.

Identify your color
Greener Manufacturing (Machine level) Performance Metrics: Eco impact (Flexibility)

Energy Improvement Plan Technology Improvement Plan
Greener Manufacturing (System level) Fig. 5. Model for green implementation [4] • Stage 4: Keep it Green The last step is keep it green where green manufacturing realization should have sustainability as in an inherent component in any green planning activity.The expected output at this stage is some green manufacturing policies and guidelines on the operation of the machine.Some trainings conducted to educate operators on how to maintain the achieve improvements and also creation of standard work to sustain improve paint performance.

Keep it Green
Measure G2M and sustain improvement.Look for next improvement opportunities

Maintain new better green manufacturing level
Greener Manufacturing (Machine level)

GSM and G2M
Kaizen groups

Continuous G2M measuremen
Greener Manufacturing (Process level) Greener Manufacturing (System level) Fig. 6.Model for keep it green [4] 3 Results The Energy consumption on AC Motor punching machine: Table 1.Specification of AC Motor [14] The load is calculated use by power analysis tool and power value at 100% loading.For three phase motor, the step is to determine the input power with the following equation: Figure 7 shows the comparison of existing and proposed condition.The comparison is done to see the whether the proposed condition is better or not.Table 4 shows the comparison summary of the production condition.Base on that calculation it can be conclude that automation system can increase the flexibility of machine as well the green manufacturing.The impact has successfully implemented and automation system has running as expected for increasing the flexibility of the jacquard punching machine.This also results in companies to be toward greener manufacturing, where companies can save more energy.The comparison for energy use can see below.
Figure 1 shows a step by step flow diagram of the process.

Fig. 7 .
Fig. 7. Comparison of existing and proposed condition Assessment of the Green level of the manufacturing system

Table 2 .
Comparison production condition

Table 3 .
Comparison of the use of electric energy