POWER
The International Energy Agency (IEA) highlights energy efficiency as the “first fuel” in the transition to clean energy, offering one of the fastest and most cost-effective ways to lower carbon emissions. However, as global energy costs continue to rise and sustainability pressures intensify, the manufacturing sector faces a critical challenge: how to remain competitive while reducing its environmental impact. Here, Pontus Westlin, product manager at Sandvik Coromant, outlines how machine shops can embrace lean manufacturing, automation and advanced digital technologies to not only reduce costs but also to future-proof their operations in an increasingly demanding market.
WHY ENERGY EFFICIENCY IS
T
he IEA highlights energy efficiency as essential for cutting emissions, reducing energy bills and strengthening energy security. For machine shops, improving energy efficiency is not only a financial necessity but also vital for building a sustainable future. With economic uncertainty, labour shortages and rising material costs, the manufacturing sector must move beyond traditional methods. Let us look at five different ways in which adopting a holistic approach, optimising processes and integrating digital tools enables manufacturers to reduce energy consumption — while maintaining productivity and high-quality output.
1. A HOLISTIC APPROACH: INTEGRATING TECHNOLOGY FOR GREATER EFFICIENCY Energy efficiency requires a connected, system- wide approach and optimising one aspect of production, without considering the full process, can create inefficiencies elsewhere. Instead, a holistic view ensures improvements in one area don’t lead to bottlenecks in another. By using digital tools that
monitor machine performance and energy use, manufacturers can make data-driven decisions to reduce waste and improve equipment effectiveness. Collecting and analysing real-time data allows machine shops to quickly identify where energy is being wasted and take immediate corrective action. This approach helps manufacturers improve overall performance and energy efficiency while avoiding unnecessary resource use.
2. LEAN MANUFACTURING: MAXIMISING EFFICIENCY BEYOND TOOLS Energy efficiency is not just about investing in high- quality tools — it is about using them effectively. Lean manufacturing principles, which focus on minimising waste and optimising workflows, are critical for improving efficiency. Techniques such as the 5S methodology (Sort, Set in Order, Shine, Standardise, Sustain) create organised workspaces that improve safety, reduce energy waste and enhance workflow. Value Stream Mapping (VSM) is another powerful tool that helps visualise the flow of materials and information throughout production. By identifying
and eliminating bottlenecks, VSM enhances both productivity and energy efficiency. Regular performance analysis, such as tracking Overall Equipment Effectiveness (OEE), allows manufacturers to identify inefficiencies, while strategies like Single- Minute Exchange of Die (SMED) and Total Productive Maintenance (TPM) help reduce setup times and increase equipment reliability.
3. SMARTER TOOL MANAGEMENT: DIGITAL INTEGRATION FOR ENHANCED PRECISION Effective tool management is key to improving energy efficiency. By integrating digital tools with CAD/CAM software, manufacturers can select the most suitable tools for each job, reducing errors and minimising energy consumption. Regular tool maintenance, guided by digital monitoring systems, ensures optimal tool performance, preventing the inefficiencies that arise from poorly maintained equipment. One example of digital integration is Sandvik Coromant’s CoroPlus Tool Library, which works with Mastercam CAD/CAM software. This system provides users with a comprehensive tool library that offers recommendations based on material, operation and machine type. Users can import tool assembly data and optimise machining processes with 3D
32 Autumn2025 UKManufacturing
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