Recognise early, improve safety, and increase the operational excellence

Recognise early, improve safety, and increase the operational excellence


The HAZOP method is a systematic method for identifying hazards and evaluating countermeasures. A systematic investigation process is used to look for possible hazard scenarios in a technical system or process and develop targeted countermeasures to increase the safety of systems, improve operability and ultimately also optimize service life and plant availability. Operational Excellence/OPEX focuses on increasing productivity, reducing costs and improving (product) quality. HAZOP+ is the combination of the HAZOP study and the implementation of OPEX 4.0. Increasing Digitalisation and Industry 4.0 allow continuous, data-based, and automated investigation and optimisation using AI-based methods of processes of all kinds which opens up new potentials for HAZOP studies and Operational Excellence (OPEX) together.


  • Leverage the synergies, which starts with AI-based optimisation of the production process
  • The HAZOP study benefits from the systematic operational data analysis of the OPEX 4.0 approach and becomes better focused on the real problems in the plant.
  • Benefit from the systematic operational data analysis of the OPEX 4.0 approach
  • Mitigate the risk of exceeding safety limits in plant and process optimisation
  • Increase the stability of your operations at the optimum operating point, which results in higher profitability
  • Fulfil the legal obligations and get up to date towards process safety
  • The production plant becomes safer and more economical


Our experts work closely with our partner, atlan-tec Systems. We offer a new extended, synergetic approach to process safety that uses data and risk analysis and includes data-based operational excellence. Our approach is based on the Industry 4.0 maturity model of the acatech study, the SIRI maturity index, as well as the VDI guideline VDI3714 “Implementation and operation of Big Data applications in the manufacturing industry; implementation of Big Data projects”. As a result, HAZOP+ shows a legally compliant path to continuous, automated process optimization in your plants with improved economic performance (OPEX 4.0) and simultaneously increased plant safety and integrity.

Our services include:

  • Preparing the HAZOP study and OPEX 4.0 analysis in cooperation with the operations team
  • Compilation of the required documents and data in cooperation with your team
  • Moderation and documentation of the HAZOP study along with the requirements for the OPEX 4.0 project
  • AI-based OPEX 4.0 project Implementation for plant and process optimisation
  • OPEX 4.0 Certification


TÜV SÜD is recognised as a Notified Body according to PED 2014/68/EU and TPED 2010/35/EU. We are accredited according to DIN EN ISO/IEC 17020, as well as a testing laboratory according to DIN EN ISO/IEC 17025. TÜV SÜD is a recognised Approved Inspection Body (ZÜS), recognised expert organisation according to the German Ordinance on Installations for the Handling of Substances Hazardous to Water (AwSV). Our management system is certified according to ISO 9001, ISO 14001, and Safety Certificate Contractors (SCCP certificate) and ISO 45001 (management system for occupational health and safety).

We have many years of expertise in safety assessments and plant inspection. We are partnering with atlan-tec Systems, a leading company for Advanced Big Data Analytics, Automated Machine Learning to implement all Industry 4.0 maturity levels starting from visibility, transparency, predictability, and autonomous self-optimisation.


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