AML Sheffield

Advanced Manufacturing Ltd in Sheffield set out to reduce electricity spend and carbon impact on its CNC assets. Pairing SensPro Industrial IoT with SensIt Energy Monitoring delivered real-time visibility, pinpointed idle waste, and guided simple policy changes that improved efficiency and lowered operating costs.

We were amazed to see how much energy we were burning just from leaving the machines running over the weekend.

Alex Cotton

Research & Development Manager

Seeing the CNC controller data overlaid with power data was essential to seeing how consistent the power usage was from cycle to cycle.

Roger Singleton, PhD CEng

Research Development Advisor

ROI and Performance Metrics

Factory wide impact

Yearly avoided electricity cost at 30 machines: ~£15,000

Idle energy savings

Annual savings potential/machine: ~£507 based on 0.726 kW idle draw at £0.28 per kWh.

Quick deployment

Elapsed deployment time: 1 shift

Time to receive data: Same day

Client Profile

Facility Location
Sheffield, United Kingdom
Website
https://www.amlsheffield.co.uk/
Industry
Aerospace
Defense
Energy
Nuclear
Equipment Types
CNC Machining

Challenges

AML needed a practical way to see where power was being used on the shop floor. The team suspected machines sat energized during breaks and weekends. Without high resolution data they could not quantify the cost or coach behaviors that drive better use of assets.

AML Sheffield

Strategy & Implementation

SensFlo instrumented priority machines with the SensPro IoT Box and SensIt Energy Monitoring. Sampling frequency was tuned per asset from milliseconds to minutes. GCODE monitoring via API correlated electrical load to specific program steps. Data streamed to the cloud for multi-week review by AML, Riscon Solutions, and SensFlo. The team identified idle periods, ESTOP release spikes, and operator habits that were easy to address.