SHOPFLOORDigital
Operational excellence · Digitally deployed

Stop managing
the floor on
yesterday's data.

Lean practice and digital systems, deployed together on the shop floor. Live SQCDP boards, digital checklists and action escalation — across production, maintenance, quality, safety and warehouse.

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Assembly · Line 4Live
92%OEE
4 minMTTR
0Breakdowns
Live SQCDP performance board displayed on a shop-floor smart board
Live SQCDP and performance data on the floor — smart board display mode
The gap

From chaos

  • Whiteboards and spreadsheets out of date the moment they're written
  • Data collection eats supervisor time and produces nothing anyone acts on
  • No process history, so trends stay invisible and problems repeat
  • Actions raised in the morning meeting quietly disappear

To control

  • Live SQCDP and KPI performance visible on the floor, on any device
  • Digital checklists and SOPs opened by QR code at the machine
  • Actions raised, assigned, escalated and closed with full history
  • One version of the truth from operator to plant head
Digital lean vs lean alone

Lean works. Lean with live data works harder.

Cross-industry benchmarks for digitally-enabled lean deployment against traditional standalone lean.

Chart comparing digital lean against traditional standalone lean across six operational measures
+35%Overall equipment effectiveness
−60%Inventory reduction
+40%Plant output improvement
−30%Cost, vs 15% for lean alone
What I do

Three things, in the order they matter

01 · Diagnose

Operational excellence

Value stream mapping, DMAIC problem solving, 5S and TPM deployment, tier board design. Master Black Belt practice applied on your floor, not in a workshop room.

02 · Deploy

Digital shop-floor systems

OPEX Digital rollout — live KPIs, SQCDP display boards, QR-driven checklists and digital SOPs, action tickets with escalation. Configured for your process, not a template.

03 · Extend

AI & automation

Custom apps, workflow automation and AI-assisted analysis layered on top — so data entry disappears and the insight arrives before the morning meeting.

Platform credentials
Cyber Essentials Certified CPD Certified Training Northwest Automotive Alliance Business Awards UK 2024 — Best Use of Technology Deployed across UK · EU · US
About
Prashaanth Udayaprakash
Master Black Belt · Lean Six Sigma M.S. Advanced Manufacturing

Prashaanth Udayaprakash

Operational excellence and digital transformation leader. I build the systems that make lean stick.

I lead operational excellence and factory digitization at a US-based global manufacturer, where I run the digital transformation programme across multiple sites — digital tier board deployment spanning production, maintenance, quality, safety and warehouse, live floor dashboards, and the data integration behind them.

My background is operations before it was software. I've managed large-scale distribution workforces, run improvement programmes in capital-intensive industries, and spent years on the floor doing the unglamorous work of making standards hold. That's why I build digital systems the way I do — around the operator and the supervisor, not around the dashboard.

I now pair that practice with OPEX Digital, a UK-built lean management platform, to bring both halves to manufacturers: the consulting that finds the problem, and the system that keeps it solved.

Practice

Where the experience sits

Lean Six SigmaIASSC Master Black Belt. DMAIC deployment, statistical problem solving, capability studies, control plans.
Value stream & flowVSM current and future state, line balancing, takt analysis, layout and material flow redesign.
Kaizen & daily managementKaizen event facilitation, gemba walks, tier meeting structure, escalation and action governance.
Digital tier boardsSQCDP board deployment across production, maintenance, quality, safety and warehouse — one performance language across the site.
5S, TPM & standard workWorkplace organisation audits, autonomous maintenance, standard work and SOP digitisation.
Live dashboards & integrationShop-floor data capture, MES and ERP integration, machine and SCADA data, real-time floor displays.
AI & automationLow-code app development, workflow automation, API integration, AI-assisted operational analysis.
Platform deploymentAssessment, configuration, training and adoption of digital lean platforms — through to sustained use.
The approach

The infrastructure caught up. The daily management hasn't.

Manufacturing has moved fast on connectivity, cloud and automation. What often hasn't moved with it is the layer where performance is actually managed day to day — the board at the end of the line, the checklist on the clipboard, the action list nobody can find by Thursday.

That's the gap I work in: hands-on lean deployment paired with a proven platform, rather than selling software and leaving.

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The platform · OPEX Digital

A lean management application, not another dashboard

OPEX Digital is an Industry 4.0 cloud platform built by lean practitioners for lean deployment. It runs on desktop, mobile, tablet and smart boards, locally or across sites — and it's already deployed with manufacturers across the UK, Europe and the United States.

I deliver it as an operational excellence engagement: assessment, configuration, training and adoption — not a licence handover.

SQCDP dashboard with FTT, OEE, safety and cost trends on a desktop display
Display mode

Personalised dashboards, owned locally

Each area builds and owns its own board — SQCDP status rings above, trended KPIs below, target lines visible. Readable from across the bay, updated as the shift runs.

Desktop & mobile

The same system in your hand

Assessment scoring, category progress, KPI entry and action tickets — all accessible on a phone at the machine. Supervisors update the board where the work is, not back at a desk.

OPEX Digital running on a mobile phone showing assessment scores and KPI list
Digital 5S and ISO 14001 compliance checklist opened on a tablet via QR code
OPEX Scan

Checklists and SOPs behind a QR code

Audits, safety patrols, 5S and ISO compliance checks, TPM task instructions with video — scanned at the point of use. Governance that happens because it's easier than not doing it.

Capabilities

Display mode

Live performance data on floor screens and smart boards, readable at a glance.

Lean KPIs

Area and project-level KPIs — OEE, MTTR, near misses, overtime cost, breakdowns — trended against target.

Action tickets

Problems raised, categorised by SQCDP, assigned and escalated, delivered in-app and by email with full history.

Digital checklists & SOPs

Forms, audits and standard operating procedures opened by QR code at the machine.

Lean Academy

CPD-certified lean training built into the platform, so capability grows alongside the system.

Project plan

Customisable improvement project tracking, visible to the team and editable as work progresses.

Power BI interface displays IoT & machine data Multi-site & multi-device Cloud hosted
Provenance

Built by lean consultants, not by a software house

OPEX Digital is developed by Meta Smart Systems Ltd in the United Kingdom, with parent consultancy MAS Optimal behind it — specialists in combined lean and business improvement system implementation, with over twenty years of client work across manufacturing.

That heritage is why the platform is shaped around lean practice rather than around reporting. It was designed by people who had already run the deployments.

opex-digital.com ↗
Contact

Let's talk about your floor

If you run production, operations or improvement at a manufacturing site, I'd value 30 minutes to understand how your daily management works today. No pitch — I'm mapping how plants run shop-floor management, and I'll share what I'm learning.

Direct

prashaanth@shopfloordigital.in

Focus

Manufacturing and automotive — tier 1 suppliers, precision manufacturing and multi-site operations

Platform partner

OPEX Digital — Meta Smart Systems Ltd, United Kingdom