OpEx6

We're an AI SaaS company. We build enterprise-grade technology for industrial and manufacturing businesses.

The problem and our Solution

The problem

Industrial & Manufacturing operations are haemorrhaging. Silently. Every single day.

The problems go deeper than ‘data in different systems’. Across every industrial sector — the same crisis plays out.

The problem

OpEx6 solutions

01 — Technical

73%

of industrial leaders make critical decisions on data that is 3+ weeks old

Data Chaos

Data isn’t just fragmented — it has different definitions, different cadences and different owners across every team. The same KPI means three different things in three different departments. There is no single version of truth.

A plant with 12 operational systems produces 12 conflicting OEE numbers. Finance, operations and maintenance all report different figures to the board.

The Exec App

The Exec App governs your data into 130+ defined KPIs — one formula, one source contract, one meaning per metric across every site, system and shift. The conflicting spreadsheets stop. The argument about whose number is right ends. Executives see one trusted view, always current.

02 — Operational

£50Bn+

lost annually to unplanned downtime across industrial operations worldwide

Operational Blindness

Without connected real-time data, leaders manage in the rearview mirror. Equipment degrades, quality signals drift and demand shifts go unseen until they become crises — and crises cost multiples of what prevention would have.

A pump failure that cost £140k could have been predicted three weeks earlier from vibration data already in your SCADA system.

AI-Computer VisionAI-Connected WorkerThe Exec App

AI-Computer Vision turns camera feeds, IoT and sensor data into real-time operational signals — detecting issues on the line that manual checks miss. AI-Connected Worker closes the loop from alert to corrective action with evidence and accountability. The Exec App surfaces the resulting performance KPIs in the executive view in real time.

03 — Financial

15–25%

of revenue consumed by the hidden cost of poor quality — most of it never measured

Financial Haemorrhage

Scrap, rework, warranty claims, excess inventory, overstaffing, energy waste — these costs are real but invisible when data isn’t governed. In construction, 30% of materials are never used. In food processing, up to 30% of product is wasted. If you can’t see it, you can’t manage it.

Each 1% improvement in OEE in an average plant is worth £1–3M in annual recovered value. Most plants don’t know their OEE today.

The Exec AppDemand Planning

The Exec App’s Cost & Margin Leakage dashboard (D04) surfaces financial haemorrhage in pounds, not percentages — cost per unit, scrap cost, labour efficiency, energy £/unit, all in one governed view. Demand Planning then aligns production reality to actual demand, cutting the overproduction and excess inventory that compounds the financial loss.

04 — HSEQ

1:300

unsafe acts precede every serious incident — nearly all unrecorded (Heinrich’s Triangle)

HSEQ Exposure

Safety, health, environmental and quality risk builds invisibly when data is fragmented. Regulatory drift happens gradually. Permit breaches, environmental exceedances and quality escapes are detected at audit time — not in real time. The direct cost of a major industrial accident averages £2.7M before reputational impact.

A water utility operated outside its discharge consent for 11 days before monitoring flagged it — triggering a £1.2M Environment Agency fine.

AI-Computer VisionAI-Connected WorkerThe Exec App

AI-Computer Vision detects safety situations, PPE compliance and hazard conditions from existing camera infrastructure in real time. AI-Connected Worker captures near-misses, enforces safe-work procedures and creates an evidence trail that satisfies regulators. The Exec App tracks HSEQ KPIs — incidents, open NCRs, audit status — giving leaders early warning before a finding becomes a crisis.

05 — Strategic

68%

of industrial executives regularly make major decisions without reliable operational data

Decision-Making Failure

Without a trusted data foundation, decision-making defaults to the HiPPO — the Highest Paid Person’s Opinion. Capital allocation worth millions is decided on monthly board packs that don’t reflect this week’s operational reality.

A construction group approved a £4M capacity expansion based on utilisation data later found to be 18 months out of date.

The Exec AppDigital Twin

The Exec App surfaces role-aligned, trusted KPIs for every senior executive — grounded AI insight tied to governed data, not generated from opinion. For forward-looking decisions, Digital Twin creates a live digital replica of your operation, allowing leaders to test scenarios, stress-test capacity plans and model outcomes before committing capital.

06 — Lean & Efficiency

Lean wastes present in every industrial operation — most entirely unmeasured

Waste Invisibility

Transportation, excess inventory, motion, waiting, overproduction, overprocessing, defects and skills waste (TIMWOODS) typically consume 15–25% of total output value. Without connected data, you cannot see them, quantify them or prioritise which to eliminate. Lean and Six Sigma programmes fail because the data foundation isn’t there.

A pharmaceutical manufacturer ran a Six Sigma programme for two years with no measurable yield improvement — the root cause was unconnected batch data that made DMAIC impossible.

Digital TwinThe Exec AppAI-Connected Worker

Digital Twin creates a live operational model that makes all eight wastes visible, measurable and simulatable — enabling Lean kaizen and Six Sigma DMAIC to work from real data. The Exec App benchmarks performance against WCM standards and Lean targets, surfacing the gap. AI-Connected Worker digitises operator routines, eliminating the skills waste that most systems never capture.

07 — Operational Excellence

Low

adoption and adherence to Lean, Six Sigma, WCM and continuous improvement routines

Operational Excellence Drift

Most industrial businesses have Lean, Six Sigma, World Class Manufacturing or continuous improvement programmes in place, but adherence often breaks down after launch. Standards are written, but not followed. Improvement actions are raised, but not closed. Daily management routines happen inconsistently. Operators, supervisors and leaders work from different versions of the process, so operational excellence becomes a campaign instead of a sustained operating system.

A site may run kaizen events, 5S audits, centreline checks and DMAIC projects, but if the actions sit in spreadsheets, the evidence is not captured and leaders cannot see adoption by shift, line, site or team, the programme slowly loses discipline.

Operational Excellence AI-Connected Worker The Exec App Digital Twin

OpEx6 turns operational excellence from a static methodology into a governed execution system. AI-Connected Worker digitises routines such as 5S, centreline checks, CIL, audits, standard work, kaizen actions and problem-solving workflows, making adherence visible at the frontline. The Exec App gives leaders a trusted view of adoption, overdue actions, recurring losses, improvement impact and site-by-site maturity. Digital Twin supports scenario modelling so improvement teams can test operational changes before rolling them out. The result is a closed loop: define the standard, execute the routine, capture evidence, track adherence, measure impact and escalate drift before performance falls back.

Behind every one of these problems sits the same root cause: Bad data — incomplete, stale, siloed and disconnected from the frontline. This leads to bad business decisions.

The OpEx6 suite addresses all seven — treating data governance, system unification and operator involvement throughout the process as the foundation, not an afterthought. Before you can explain, predict, flag, advise, challenge or continuously improve, the data must be trusted.

Who is OpEx6

Who we are

We love collaborating to solve Industrial and Manufacturing operational challenges

Our mission crystal clear: focus on our client business outcomes that directly impact the bottom line.

You thrive by partnering with us, which is why we're always open to new challenges. Get in touch and let's see what we can do together.

Early access · Upto 40% discount

Our solutions

Exec App Late 2026

An AI-assisted executive intelligence app for manufacturing leaders. One trusted view of waste, risk, cost, performance, quality and HSEQ — supported by 130+ KPIs and governed data trust.

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AI-Connected / Field Service Worker Early 2027

Connects frontline teams to the right actions, procedures and operational context, so work is completed with evidence, accountability and alignment to the same governed data leaders use.

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AI-Computer Vision Early 2027

Turns CCTV camera feeds, IoT, sensory, telemetry and other sources into operational signals, helping detect safety situations, product quality compliance, operator compliance & work issues that manual checks often miss. Feed this data in to insights & action and close the loop.

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Digital Twin Early 2028

Creates a digital representation of your industrial environment with live operational context, helping leaders understand behaviour, test scenarios and support better decisions.

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Demand Planning Early 2028

Links demand, production reality and operational constraints so manufacturers can plan with greater confidence instead of relying on disconnected forecasts and last month’s assumptions.

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Industries we serve

Manufacturing Construction Waste Management Water & Utilities Oil & Gas Food & Beverage Pharmaceuticals Mining Chemical Processing Defence & Aerospace

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