Operational Excellence (OPEX 4.0) Services in India


Optimise the end to end process using AI & Data

Optimise the end to end process using AI & Data


Before we elaborate on OpEx 4.0, let’s quickly understand what operational excellence is.

Operational excellence is an approach to business management that emphasises continuous improvement across all aspects of the business. It is a methodology of striving for efficacy throughout an organisation's processes. OpEx 4.0 is a term that refers to the application of Industry 4.0 technologies to the field of operational excellence. It is the integration of digital technologies such as artificial intelligence, machine learning, and the Internet of Things (IoT) into the operational excellence methodology.

Operational Excellence (OPEX 4.0) aims to increase productivity, reduce costs and risks, and improve product quality by optimization of a plants’ process parameters with advanced data analytics and AI based methodology.

While achieving safety, integrity, and economic efficiency is the core of the industry, we require a comprehensive understanding of the procedural process and the enhancement in current and future operations. OPEX 4.0 becomes a gate to create learning as well as improving operations continuously.


Implementing operational excellence involves:

  • Defining the vision and strategy
  • Establishing a culture of continuous improvement
  • Identifying and prioritising improvement opportunities
  • Implementing improvement initiatives,
  • Monitoring and measuring progress
  • Sustaining improvements

OPEX 4.0 helps organisations perform an in-depth analysis of processes using modern big data analysis methods and automated machine learning for data-based plant and process optimisation. With OPEX 4.0, organisations can increase stability and safety at the optimum operating point.


Together with our partner atlan-tec Systems, TÜV SÜD offers a modular, cost-efficient OPEX 4.0 programme that allows an individual to focus on all relevant topics of operational excellence using state-of-the-art data analysis and AI methods. TÜV SÜD’s qualified and experienced inspectors certify the process of the AI-based optimisation project according to the specifications of the VDI* guidelines.
*(VDI = German Engineering Association)

Our operational excellence services include:

  • Readiness Assessment: to assess if your business meets the requirements for Big Data analytics and Automated Machine Learning
  • In depth analysis: Preparing the OPEX 4.0 analysis through a combined team of TÜV SÜD and our partner atlan-tec in cooperation with the operations team of the customer’s organization
  • Document and data management: Compilation of the required documents and data; updating
  • Implementation: Implementation of the AI-based OPEX 4.0 project for plant and process optimization in manufacturing and process industry
  • Certification of the OPEX 4.0 project through TÜV SÜD following VDI guideline VDI3714


The key features of operational excellence certification can vary depending on the organisation providing the certification. However, there are some common features that are typically included in OpEx certification programs. Here are some key features of operational excellence certification:

  • Assessment: Operational excellence certification programs typically involve assessing an organisation's processes and systems to identify areas for improvement.
  • Training: Certification programs often include training in operational excellence methodologies and tools, such as Lean, Six Sigma, and Kaizen.
  • Implementation support: Certification programs may provide support and guidance to help organisations implement improvement initiatives.
  • Performance measurement: Certification programs typically involve the establishment of key performance indicators (KPIs) to measure progress and track the impact of improvement initiatives.
  • Continuous improvement: OpEx certification programs emphasise the importance of continuous improvement, with a focus on sustaining the improvements made over time.
  • Independent verification: Certification programs provide independent verification of an organisation's operational excellence efforts, giving stakeholders confidence in the organisation's ability to deliver high-quality products and services.


We have longstanding expertise in design reviews, plan audits, and safety assessments. We partner 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.

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).

TÜV SÜD is a leading provider of operational excellence services, offering a range of assessment, certification, and training services to help organisations achieve their operational excellence goals. Here are some reasons why companies choose TÜV SÜD for operational excellence services:

  • Expertise: TÜV SÜD has extensive experience in operational excellence, with a team of experts who are knowledgeable in the latest methodologies and tools.
  • Comprehensive services: TÜV SÜD offers a range of services to support operational excellence, including assessment, certification, and training services.
  • Global presence: TÜV SÜD has a global presence, with offices and experts around the world. This allows them to provide local support and expertise to organisations in different regions.
  • Independent verification: TÜV SÜD's assessment and certification services provide independent verification of competence and qualifications, giving organisations confidence in their operational excellence efforts.
  • Focus on safety: TÜV SÜD's services are designed to help organisations improve safety, reduce risks, and ensure compliance with regulations.

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