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✓Management Systems
✓Risk Assessments
✓Audits
✓Training
✗ Actual Compliance, Risk & Competency — verified in the workplace

Why is so much still going wrong?

Across high-hazard and high-performance industries, incidents, injuries, errors, rework and avoidable loss continue at enormous scale — despite decades of investment in training, management systems and risk assessment. Progress has stalled. In several sectors it is worsening.* The reason is not a lack of process. It is the illusion of operational compliance, competency and controlled risk.

  • An audited corporate management system is not a safe or efficient operation.
  • Risk assessments do not control risk.
  • Training completion is not competency.
Annual Cost of Preventable Loss — Published Figures
Human factors, compliance failures & procedure non-adherence. Log scale. Geographic scope shown per bar.
Manufacturing
Global · downtime
$1.4T
Workplace Injuries
USA · all sectors
$181B
Pharmaceutical
Global · quality failures
~$50B
Workplace Injuries
UK · all sectors
£22.9B
Healthcare
USA · workplace injuries
~$15B
Aviation MRO
Global · maintenance errors
~$11B
Geographic scope shown per bar. Manufacturing: Siemens True Cost of Downtime 2024 (global top 500). Workplace injury USA: NSC Work Injury Costs 2024. Workplace injury UK: HSE Annual Statistics 2023/24. Pharmaceutical quality failures: CAI/PwC 2024 (global estimate). Aviation maintenance errors: derived from FAA/industry data — estimated unscheduled engine removals × $500K per event (Rankin et al., FAA). Healthcare USA: OSHA 2024 injury count × NSC cost per injury.
  • Verified Execution — Can you prove that critical procedures are being executed correctly NOW?
  • Controlled Risk — Can you demonstrate that critical risks are actively being controlled NOW?
  • Competent People — Can you prove the right people are competent to perform the work NOW?

The three pillars of operational assurance, continuously evidenced in the workplace by Sysmax.

Trusted by global leaders in high-hazard and high-performance industries since 1996

Shell
Neptune Energy
BP Wind USA
CNOOC
Sasol
TotalEnergies
Tullow Oil
Apache
NeoNext
Ithaca
Defence Programme Confidential client
Global Food & Beverage Group Confidential client
⚡
Risked impact alerts
Know immediately when critical controls, competencies or mandatory procedures are not being followed. Benchmax automatically notifies workers, supervisors and leaders based on the operational risk created, enabling intervention before incidents occur.
🎯
Reduce risk through 24/7 protocol implementation
Risk is not controlled by writing it down. They are controlled when the protocols that manage risks are actually being followed — every shift, verified in real time, not sampled occasionally.
👥
Prove workforce competency
Ensure the right people, with the right skills, do the right work — verified at the point of action, not just at the time of training. Validate where it matters. In the workplace.
🛡️
Reduce incidents and rework
Address the causes of operational failure — not just the symptoms. Competency verified, risk controlled, procedures validated as done correctly. Make valuable protocols role-based and active 24/7.

The Bridge Between HR and Operations

Capability is built in HR.
Performance is proven in Operations.

HR builds capability. Operations delivers performance by applying the right controls, validating active procedures and competencies to reduce risk in the workplace. With evidence to prove it when a customer, regulator, insurer or law enforcement asks.

What HR measures as success
What Operations is accountable for

Training

100% of mandatory training completed on time. Certificates current. Green dashboard. Compliance officer satisfied.

Performance

Production targets met. Quality standards met. Work done correctly first time, every time.

Efficiency

Headcount on target. Absence within KPI. Attrition within benchmark. Time-to-hire met.

Efficiency

No rework. No repeated jobs. No equipment damage. Costs under control. Margins protected. Plant running. Product leaving the door to the right standard, at the right time.

Compliance

Training records up to date. Certificates current. Audit trail. Policies signed off.

Operational Compliance

Zero incidents. Zero injuries. Zero near misses becoming incidents. Risk controls verified as working. No regulatory enforcement action. No prohibition notices. No loss of licence to operate. Verified evidence of what is happening in the workplace continuously.

Reputation

No employment tribunal. No grievance upheld. Good employer brand scores. Low staff turnover.

Reputation

No product recall. No failed customer audit. No environmental incident. No front page news. Stakeholder confidence, investor trust and licence to operate maintained — because the operation performs, not because the paperwork is tidy.

When it goes wrong

“The training record shows the course was completed on time. HR has achieved its objective. For the Operations Director, that's where the real challenge begins..

WHEN IT GOES wrong

The question isn't "Was the training completed?" The question is "Can you prove the work was done correctly?"

Regulators, customers, insurers and courts don't ask whether someone attended training. They ask whether the correct controls, procedures and competencies were actually applied by the right people, at the right time. Training records are the starting point. Sysmax provides the evidence that critical work was performed correctly.. The training record is the start of the evidence. Sysmax provides the rest.

The Operational Assurance Gap

What your HR platform records.
What your operation depends on.

HR platforms record that training happened. Sysmax verifies it is being applied. The greatest risks don't come from missing training records. They come from critical controls, risk management and competencies not being executed correctly in the workplace.

Phase / Activity HR Platform Sysmax Accountable?
Train & Certify — Where typical HR platforms stop providing value
Managing the forgetting curve ✘ Training is recorded as complete. No mechanism exists to detect knowledge or skill decay after training ends. ✔ Continuous validation detects performance drift. Refresher triggered before gaps cause loss, rework or incident. OPS ⚠
Access to procedures in the workplace ✘ Procedures sit on a separate intranet — not accessible at the point of work, not verified as current ✔ Version-controlled, role-based SOPs (Standard Operating Procedures) on any device, any language, online and offline — at the point of work OPS ⚠
Deploy & Operate — The gap HR platforms cannot close
Competency verified at deployment ✘ A training record confirms learning occurred. It does not confirm the person is performing safely and correctly. ✔ Competency verified before and during deployment — the right person, doing it right, every time OPS ⚠
Procedure adherence in the workplace ✘ Zero visibility. HR platforms do not monitor what happens in the workplace after training. ✔ Real-time procedure adherence across every site and every shift. Rework, deviation and risk detected before they cause loss. OPS ⚠
PSM (Process Safety Management) & risk control verification ✘ Entirely outside scope for any HR platform ✔ MAH (Major Accident Hazard) controls and safety-critical competency continuously verified in real time — not sampled at audit HSE ⚠
Risk-weighted gap intelligence ✘ Training completion is not risk intelligence. HR systems cannot tell you which gaps represent live exposure today. ✔ Gaps scored and prioritised by operational consequence — leaders act on what matters most, before it becomes an incident EHS ⚠
Workplace-verified audit evidence ✘ HR records training inputs. Regulators ask for evidence of operational outputs — what was actually done, by who, where and when. ✔ Timestamped, workplace-verified evidence — ready for HSE (Health, Safety and Environment), OSHA (Occupational Safety and Health Administration), COMAH (Control of Major Accident Hazards Regulations) or GMP (Good Manufacturing Practice) audit at any time EHS ⚠
⚖️
When something goes wrong, it is not the HR Director in the witness box. It is the Operations Director, the Process Safety Manager, the Plant Manager and the Board. Their evidence requirement is not a training record. It is continuous, workplace-verified proof that work was done right. That is what Sysmax provides.

✔ Covered  ◑ Partial  ✘ Not in scope  ⚠ Operational accountability — not HR

HR technology partners: Sysmax verifies what your platform records — actual compliance, risk controls and competency in the workplace, continuously. A complementary partnership that takes your clients from training completion to verified performance.

Explore Partnership →
👥
14,500+
Workers verified on the front line
And growing every day
📅
34
Years of experience
In high-hazard & high-performance industries
🌐
100+
Sites across multiple nations
Trusted by leading organisations worldwide
One Company. Three connected capabilities.
Built for how work actually happens.
🏛️
Benchmax
Operational Compliance, Risk & Competency
Manage policies, controls and risk assessments. Ensure actual compliance is embedded in daily work — not just documented in a system. Continuous monitoring of whether best practices are being followed across every site and shift. Supports PSM (Process Safety Management), MAH (Major Accident Hazard), COMAH (Control of Major Accident Hazards Regulations) and GMP (Good Manufacturing Practice) frameworks.
🔔
Risk Impact Alerts — Prioritise what matters. Workers, supervisors and leaders are alerted to focused controls in real time. Where failures to adhere to controls create risk, the right person is notified immediately — before loss occurs.
Explore Benchmax →
👤
Casmax
4D Competence Assurance
Build competence assurance around what roles must actually do. Identify gaps, verify readiness and connect training to actual performance — across all four dimensions of competency: knowledge, skills, behaviours and experience. Not just what the LMS (Learning Management System) records, but what the role genuinely demands in operation. From junior supervisors to board members.
Explore Casmax →
📈
Sawmax
Testing, Simulation & eLearning
Turn tested findings into corrective actions, and measurable performance uplift across the workforce. Deliver knowledge testing, scenario simulation and eLearning directly within the platform — connecting every learning activity to verified competency improvement and measurable operational outcomes.
Explore Sawmax →
🔗
Benchmax, Casmax and Sawmax build organisational resilience — the verified capability to perform safely, efficiently and effectively under any operating condition. Built on 34 years of running high-hazard operations: Sysmax understands what actual compliance looks like because we have lived it.

What's at Stake

When things aren't done right,
the losses go far beyond safety.

Sysmax is deployed across energy, manufacturing, chemicals and utilities — to protect every dimension of operational and financial performance. These are the published industry figures.

⚙️  Energy & Oil and Gas
80%
of well-control incidents are attributed to human error
IOGP Well Control Programme; IOGP Report 810 – Human Performance Framework
$500K+
per hour cost of unplanned downtime at large industrial operations
ABB Global Maintenance Survey, 2023
Human performance is recognised by IOGP as a critical contributor to well control and process safety performance. IOGP's Well Control Programme highlights procedure execution, competency and supervision as key areas for reducing well control incidents. Unplanned downtime at large industrial facilities can exceed $500,000 per hour.

Around 80% of well-control incidents are attributed to human error, including non-adherence to procedures, competency gaps and supervisory failures.
🏭  Manufacturing
$1.4T
annual downtime cost to the world's 500 largest companies — 11% of total revenues
Siemens True Cost of Downtime, 2024
$125K
average cost per hour of unplanned downtime — two thirds of manufacturers report this monthly
ABB Global Maintenance Survey, 3,215 respondents, 2023
Unplanned downtime costs the world's 500 largest companies $1.4 trillion annually, which is 11% of their total revenues. Two-thirds of manufacturers report average downtime costs of $125,000 per hour.
🧪  Chemical & Pharmaceutical
80%
of GMP (Good Manufacturing Practice) process deviations traced to human error and procedure non-adherence
MasterControl Human Error Solutions; FDA Report on the State of Pharmaceutical Quality FY2024
According to industry analyses, around 80% of GMP process deviations are attributed to human error and procedural non-compliance. Pharmaceutical quality failures continue to impose multi-billion-dollar costs globally through deviations, recalls and batch losses.

The number of FDA warning letters issued to pharmaceutical manufacturers increased in FY2024 compared with FY2023, reflecting ongoing deficiencies in quality systems, procedures and manufacturing controls.
🏥  Healthcare
~$15B
Estimated annual cost of workplace injuries in US healthcare, based on approximately 308,000 recorded injuries and the National Safety Council's average cost per medically consulted injury.
OSHA / BLS Survey of Occupational Injuries and Illnesses, 2024; NSC Work Injury Costs, 2024
60%
of healthcare leaders said they would automate workforce credentialing and compliance management if budget were no constraint. Their primary motivation was increasing visibility, not avoiding fines.
Propelus / Becker's Hospital Review Workforce Compliance Survey, 2025
US healthcare workplaces reported 308,000 injuries in 2024, more than any other sector. At an average cost of $48,000 per medically consulted injury, this represents approximately $15 billion in annual preventable loss. 60% of healthcare leaders say that automating workforce credentialing and compliance verification would be their first unconstrained budget investment, with visibility, not avoiding fines, as a primary motivation.
⚡  Utilities & Infrastructure
High severity
Utilities operate critical infrastructure where failures involving electrical systems, pressure systems and energy isolation can have serious consequences for workers, the public and essential services.
OSHA Bureau of Labor Statistics injury severity data by industry sector, 2024
ISO 45001
& HSE
Utilities operate critical infrastructure where failures have serious consequences. Training records alone do not prove competent execution of safety-critical work. Sysmax provides the operational assurance that critical controls and procedures are being applied..
ISO 45001:2018 Occupational Health & Safety Management; UK RIDDOR 2013
Utilities experience fewer incidents, but when failures occur, they are significantly more severe. Pressure systems, electrical hazards and ageing infrastructure mean that human error in a safety-critical role can have catastrophic consequences.

ISO 45001 requires organisations to ensure worker competency and maintain effective occupational health and safety management systems. RIDDOR requires the reporting of serious workplace incidents. Both standards expect evidence of sustained compliance, which periodic audits alone cannot provide. .
✈️  Aviation & Aerospace MRO
$136B
global MRO (Maintenance, Repair and Overhaul) market in 2025 — with 80% of current technicians expected to retire within 5–6 years, creating an acute verified-competency crisis
IATA Annual Safety Report 2024; Oliver Wyman Global Fleet and MRO Market Forecast, 2026.
Human factors remain a leading contributor to aviation accidents and incidents. Global MRO demand reached $136 billion in 2025. This coincides with around 41% of current technicians being over 60 years of age, creating an acute, verified-competency crisis at scale.

Trusted Across Industries

For every industry where
performance standards are non-negotiable.

All sectors →
⚙️
Oil, Gas & Energy
PSM · COMAH · MAH · HSE
Our founding sector. Process safety management, duty-holder compliance, major accident hazard control and actual performance — continuously verified.
🏭
Manufacturing
OSHA · ISO 45001 · ISO 9001
Rework and unplanned downtime are the primary business risk. Sysmax ensures every standard is applied correctly by every person on every shift — protecting margins and safety records.
🥤
Food & Beverage
FSMA · HACCP · BRC · GFSI
Deployed by the second largest food and beverage company in the world across more than 100 sites in multiple nations. In FMCG (Fast-Moving Consumer Goods), every deviation and every rework event is a direct P&L hit.
🧪
Chemical & Pharmaceutical
COSHH · FDA · GMP · REACH · COMAH
Where a procedure not followed is a GMP deviation, a batch loss or a warning letter. 80% of process deviations trace to human factors. Verified competency and actual compliance are the first line of defence.
⚡
Utilities & Infrastructure
ISO 45001 · HSE · OFGEM
Critical operations where failures in safety-critical work can have catastrophic consequences. Regulators expect organisations to demonstrate competence and effective operational control—not simply rely on periodic audits or training records.
✈️
Aviation & Aerospace MRO
EASA Part 66 · FAA Part 145 · CAMO
Human factors remain a leading contributor to aviation accidents and incidents. With global MRO demand reaching approximately $136 billion in 2025 and qualified technician shortages intensifying, structured competency management and progressive authorisation are now both commercial and regulatory imperatives.

Who We Serve

Built for the leaders accountable for operational outcomes.

Sysmax is built for the leaders who carry operational accountability—bridging the gap between workforce capability and operational performance.

Operations & Risk Leaders

You run a complex operation. We verify it's being executed correctly.

Your systems show training was completed. Your audits passed. Your dashboard is green. But if you cannot verify that best practices are being followed in the workplace right now — on this shift, at this site — Sysmax closes that gap. Continuously, at scale, with evidence that stands up when it matters.

  • Continuous verification of operational compliance across all sites and shifts
  • Real-time alerts when failures to follow critical controls create operational risk
  • Rework, deviation and procedure non-adherence detected before they cause loss
  • Workplace-verified evidence for HSE, OSHA, COMAH, GMP and customer Assurance
  • Integrates alongside your existing HR and LMS platforms — not a replacement
See Sysmax in action
Process Safety & HSE Directors

Your safety case needs more than a training record. We provide the evidence.

For MAH (Major Accident Hazard) environments, COMAH duty holders, PSM operators and organisations working under ALARP (As Low As Reasonably Practicable) principles, a training record is only the beginning of the evidence. Sysmax provides continuous, workplace-verified evidence that competent people are applying critical controls and procedures, strengthening confidence that operational barriers are being executed as intended.

  • PContinuous verification of process safety and safety-critical competency—not periodic audit sampling
  • Barrier management and Safety Critical Element (SCE) competency assurance
  • Bow-tie barrier ownership linked to verified individual competency profiles
  • Reduce Loss of Primary Containment (LOPC) risk through verified execution of critical procedures
  • Regulator-ready evidence that stands up to HSE, OSHA and COMAH inspection
  • Aligned with IChemE competency frameworks and recognised process safety good practice
See Process Safety capability

Work With Us

Two partnership channels.
One shared purpose.

HR Technology Platforms

Your platform initiates. Sysmax verifies 24/7.

Major HR platforms manage the employee lifecycle brilliantly. None of them verify that trained behaviours are actually being applied in the workplace, every shift. Sysmax provides that layer — as your partner, not your competitor. Together the combined offer covers hire to verified performance.

  • Complementary positioning—your platform manages the workforce lifecycle; Sysmax verifies operational execution.
  • API (Application Programming Interface) integration with employee, role and learning data
  • Referral commission or co-branded integration partnership models available
  • Joint GTM (Go-to-Market) collateral and sales enablement
Explore HR Platform Partnership
Risk, Safety & Assurance Consultancies

You identify the gap. Sysmax closes it.

Process safety consultancies, assurance providers and risk management specialists work every day with the leaders Sysmax serves. When you identify gaps in operational assurance, competency, procedure execution or audit readiness, Sysmax provides the continuous workplace evidence that helps clients close those gaps—strengthening both your recommendations and your long-term client relationships.

  • Supports PSM, COMAH, Seveso III and OSHA process safety frameworks
  • Provides a continuous operational assurance and competency evidence layer
  • Aligned with IChemE, OEUK, Step Change in Safety and IoD process safety leadership competency guidelines
  • Referral, integration and managed service partnership models available
Discuss a Consultancy Partnership

What Our Clients Say

Trusted by operational leaders across the world.

"

Sysmax achieves what five of our existing tools do — and does it better than all of them.

Head of Safety
Major Renewable Energy Company
"

Training time reduced by 80%. New starts could rapidly get up to speed and demonstrate they could execute their role safely and efficiently.

Director
Global Food & Drink Company
"

We are required to prove compliance and competency to regulatory and internal auditors regularly. Sysmax has ensured we passed multiple audits with ease.

Engineering Manager
Major Oil & Gas Company

Get Started

Move from compliance on paper
to performance in practice.

Book a demo to see how Sysmax closes the gap — every day, on every site.

* Supporting Evidence — Published Sources

The claim that operational loss continues at enormous scale — and that progress has stalled or reversed in key sectors — is supported by the following published data:

Energy & Oil and Gas Human performance is recognised by IOGP as a critical contributor to well control and process safety performance. IOGP's Well Control Programme highlights procedure execution, competency and supervision as key areas for reducing well control incidents. Unplanned downtime at large industrial facilities can exceed $500,000 per hour. Around 80% of well-control incidents are attributed to human error, including non-adherence to procedures, competency gaps and supervisory failures. IOGP Well Control Programme; IOGP Report 810 – Human Performance Framework, IOGP Well Control Programme, ABB Global Maintenance Survey 2023
Manufacturing Unplanned downtime costs the world's 500 largest companies $1.4 trillion annually, which is 11% of their total revenues. Two-thirds of manufacturers report average downtime costs of $125,000 per hour. Siemens True Cost of Downtime, 2024; ABB Global Maintenance Survey, 3,215 respondents, 2023.
Chemical & Pharmaceutical According to industry analyses, around 80% of GMP process deviations are attributed to human error and procedural non-compliance. Pharmaceutical quality failures continue to impose multi-billion-dollar costs globally through deviations, recalls and batch losses. The number of FDA warning letters issued to pharmaceutical manufacturers increased in FY2024 compared with FY2023, reflecting ongoing deficiencies in quality systems, procedures and manufacturing controls. Master Control Human Error Solutions; FDA Report on the State of Pharmaceutical Quality FY2024.
Healthcare US healthcare workplaces reported 308,000 injuries in 2024, more than any other sector. At an average cost of $48,000 per medically consulted injury, this represents approximately $15 billion in annual preventable loss. 60% of healthcare leaders say that automating workforce credentialing and compliance verification would be their first unconstrained budget investment, with visibility, not avoiding fines, as a primary motivation. OSHA / BLS Survey of Occupational Injuries and Illnesses, 2024; NSC Work Injury Costs, 2024; Propelus / Becker's Hospital Review Workforce Compliance Survey, 2025.
Utilities & Infrastructure Utilities experience fewer incidents, but when failures occur, they are significantly more severe. Pressure systems, electrical hazards and ageing infrastructure mean that human error in a safety-critical role can have catastrophic consequences. ISO 45001 requires organisations to ensure worker competency and maintain effective occupational health and safety management systems. RIDDOR requires the reporting of serious workplace incidents. Both standards expect evidence of sustained compliance, which periodic audits alone cannot provide. ISO 45001:2018 Occupational Health & Safety Management; UK RIDDOR 2013; OSHA Bureau of Labor Statistics injury severity data by industry sector, 2024.
Aviation & Aerospace MRO Human factors remain a leading contributor to aviation accidents and incidents. Global MRO demand reached $136 billion in 2025. This coincides with around 41% of current technicians being over 60 years of age, creating an acute, verified-competency crisis at scale. IATA Annual Safety Report 2024; Oliver Wyman Global Fleet and MRO Market Forecast, 2026.

All figures are drawn from publicly available published sources. Sysmax does not make claims on behalf of clients whose operational data is proprietary.

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