Seco is revolutionizing manufacturing by harnessing machine data to make processes faster, simpler, and more sustainable. With growing environmental and regulatory challenges, leveraging real-time machine data is key to navigating the future of sustainable production. At Seco, our mission is simple: “Together, we make manufacturing fast, easy, and sustainable.”
As the manufacturing industry transitions to more sustainable practices, one major hurdle remains—effectively collecting, analyzing, and managing relevant data. Future regulations highlight the importance of machine-connected data as a critical tool for driving sustainability in production. To tackle this challenge, Seco has teamed up with the Advanced Manufacturing Research Centre North West (AMRC) in Samlesbury, UK.
AMRC is known for advancing productivity, recovery, and innovation within manufacturing. The partnership aims to leverage Internet of Things (IoT) technology, industrial communication systems, and IoT protocols to create a unified platform for machine and facility data—essential for tracking environmental impacts and fostering continuous improvements.
This initiative divides the manufacturing process into three interconnected areas: the machine itself, its immediate environment, and the broader facility. By monitoring each domain individually and studying their interdependencies, stakeholders gain both in-depth insights and a comprehensive view of sustainability challenges.
The system focuses on monitoring the machine itself, tracking critical factors such as energy consumption, material usage (e.g., cutting fluids), and CO2 emissions. By collecting this data, it enables real-time cost analysis, incorporating variables like grid carbon intensity and energy prices, providing manufacturers with an up-to-the-minute view of both energy efficiency and environmental impact.
In addition to machine-level metrics, the system also monitors the surrounding environment—specifically, temperature and humidity—which directly affect the machine’s energy requirements. Ensuring that these environmental conditions remain stable is crucial for maintaining optimal machine performance, reducing unnecessary energy consumption, and improving overall efficiency.
At the facility level, the approach broadens to include energy usage across the entire manufacturing plant. This comprehensive monitoring helps to identify inefficiencies and pinpoint patterns that may be driving up energy costs or consumption, offering manufacturers actionable insights to optimize their operations and reduce waste.
The system doesn’t just monitor each area in isolation; it explores how these factors influence each other. For instance, does an increase in humidity around the machine lead to higher cooling energy costs? Are open windows increasing energy demand, or are sealed windows causing poor ventilation and raising temperature-related expenses? By optimizing these relationships, the system helps manufacturers reduce both CO2 emissions and operational costs.
This approach allows Seco UK to analyze machining programs in detail, connecting power usage with CO2 emissions and improving process efficiency based on real-time data. By leveraging independent monitoring and real-time data, Seco can now identify hidden inefficiencies and translate energy consumption into real-time carbon footprint and cost metrics. This detailed insight enables manufacturers to compare energy usage and emissions across different products, programs, or machines—allowing data-driven decisions that place sustainability at the core of the manufacturing process.
The test environment—integrating Seco products and guest machines—aligns Life Cycle Assessments with live machine data. This combination provides precise environmental scores at the component level, paving the way for targeted innovations and validation of sustainable machining practices.
Looking to the future, Seco is working towards an AI-powered, automated feedback system that continuously optimizes manufacturing processes in real-time. This system will help balance the need for productivity and cost management with sustainable, environmentally responsible practices. Every adjustment made will be a step closer to achieving net-zero emissions goals. Together with AMRC and our customers, Seco is turning data intelligence into actionable sustainability, making manufacturing faster, easier, and more sustainable.
