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Kausalyze is a University of Sheffield spinout building causal AI solutions for process manufacturing. We help manufacturers in chemicals, energy, pharmaceuticals, utilities and FMCG prevent unplanned downtime by delivering what predictive maintenance tools cannot: actual root cause analysis.
Predictive maintenance has promised much but delivered little. Today's tools can tell you something is wrong, but they cannot tell you why. They flag anomalies, generate alerts, and leave your engineers to figure out the rest. That model worked when experienced process engineers could interpret the signals. It no longer does.
We take a different approach. Our causal AI platform doesn't just correlate patterns in your process data. It maps the underlying causal relationships in your operations, identifying not just that a failure is coming, but precisely what is driving it and what action will prevent it. This is engineering-led root cause analysis, not statistical correlation dressed up as insight.

Unplanned downtime now costs Fortune 500 manufacturers 11% of their annual turnover, totalling $1.4 trillion globally. This isn't a rounding error. It's the single largest controllable cost in process manufacturing, and it's growing.

The average large manufacturing facility now loses $129 million per year to downtime, up 65% from 2019. Costs per hour have risen faster than inflation across every sector. In chemicals and refining, hourly losses have more than doubled. The problem isn't getting better. It's accelerating.

The engineers who know why your processes fail are retiring. Over a quarter of the engineering workforce plans to retire within five years. Deloitte projects 2.1 million manufacturing roles will remain unfilled by 2033. Your most critical institutional knowledge is walking out the door, and there's no one coming to replace it.
For decades, manufacturers relied on experienced process engineers to diagnose failures. These veterans understood the subtle relationships between upstream conditions and downstream problems. They knew which valve position caused which temperature drift, and which temperature drift preceded which equipment failure.
That knowledge was never captured in your control systems. It lived in the heads of engineers who had spent careers learning it. And when those engineers retire, it leaves with them.
Current predictive maintenance tools were designed for a world with ample engineering expertise to interpret their outputs. They weren't designed to replace that expertise. They generate alerts. They don't generate understanding.
Kausalyze was built to close that gap. Our causal AI captures the engineering understanding of how your processes actually work and delivers root cause insight directly, without requiring decades of tribal knowledge to interpret the results.
Our team combines years of process engineering expertise with cutting-edge AI development skills. We understand complex industrial processes from the inside out, and we've worked alongside operations teams to solve real problems on real plant floors. That hands-on experience means we build solutions that actually get used, not just deployed.
Explore exciting opportunities and be a part of a dynamic and innovative work environment