Work Design™
Desktop software that builds safety, quality, and reliability into the process while giving the frontline clear, durable standards.
Build your improved process library
Digital Standardised Work
Increase availability by cutting maintenance time by up to 50%
Vexillum reduces recurring maintenance task duration by an average of 50 percent, returning operating hours to production while improving safety, quality, and workforce capability.
Because detail matters.
Operational improvement for complex plant and fleet maintenance environments.
Core platform
Increasing productivity by reducing task variability.
Vexillum combines software, field execution support, and embedded improvement work to achieve rapid and lasting gains.
Working with you
Client teams learn the Work Design™ methodology through direct collaboration, waste removal, better sequencing, and integrated process improvement.
Embed an improvement culture
WorkD™
The mobile application puts the improved process in the hands of frontline workers and captures duration, delay, and feedback data in the field.
Empower the frontline
Work Design™ Benefits
Work Design™ eliminates waste, reduces variation, and enhances quality.
Increased Equipment Operating Hours
Reduced average duration of recurring maintenance activities returns operating hours to production via increased availability.
Reduced Backlog
Reduced average duration and variation frees up crews to reduce backlog, improve reliability, and increase mean-time-to-failure.
Improved Safety
Critical risks and corresponding controls are embedded into the work sequence so frontline workers execute them at the right place and time.
Controlled Costs
Captured feedback sharpens planning, kits, and supply chain readiness, reducing returns and improving schedule confidence.
Enabled Diversity
Improved tooling, richer work instructions, and visual guidance help a broader range of workers perform tasks effectively.
Optimised Labour
As backlog falls and labour calculations improve, crews and third-party labour can be aligned more precisely to demand.
Structured Feedback
WorkD™ duration and delay capture feeds maintenance, planning, scheduling, and reliability engineering with usable operating data.
Work Design™ Process
The methodology systematically improves how work gets executed.
Vexillum’s bottom-up approach uses frontline evidence to redesign task execution, then closes the loop with field data.
Capture
Film the current task with multiple cameras, including hard-hat mounted viewpoints, to expose the real operating sequence.
Analyse
Use VALUE-WASTE analysis to quantify value, enabling work, and waste while establishing baseline timings step by step.
Create
Rebuild the job using captured timings, requirements, engineering constraints, safety controls, and eliminated waste.
Execute
Deploy the improved process with WorkD™ and capture delays, conflicts, and further improvements directly from crews.
Iterate
Keep improving using execution data and remove recurring causes of delay, including interactions between departments.
Case Studies
Selected examples from heavy industrial maintenance environments.
These engagements show the scale of gains available when detailed work design is applied to constrained production systems.
Mobile Maintenance of CAT793F routine servicing reduced total hours by over 57%
Overview Members of the Vexillum team worked with a major miner in Australia to increase haul truck availability by reducing service duration and labour hours across the Caterpillar 793F fleet.
Impact The project delivered over 8,000 truck hours back to production, generated an estimated $70M in marginal value, and reduced maintenance labour spend by more than $1M annually.
Solution Production system thinking and lean tools were used to redesign how each of the eight services was performed.
Fixed Plant Crusher Sizer Shutdown
Overview Vexillum team members helped a major miner reduce the duration of crusher sizer shutdowns across four annual shutdown windows.
Impact The work returned more than 220 crusher hours to operations and identified over $800k in contractor labour savings.
Solution Tooling and part kits were optimised and repositioned to reduce time lost searching for items and stepping away from the work.
Rail Ore Car Fleet Engineering Modification
Overview A mining company needed to modify 5,000 rail cars to carry more ore without excessive additional labour.
Impact The project finished 18 months earlier than planned, saved $27M in labour cost, and accelerated the movement of 45 million tonnes.
Solution Work Design™ lifted output from 7 railcars per two-shift day to 50 railcars per 24 hours by eliminating waste and refining value-added work.
Reducing CAT 793F 500hr Service Duration by 41%
Overview A proof-of-concept deployment of Work Design™ and WorkD™ targeted a 20 percent duration reduction in less than 90 days across all four crews.
Impact The combined Vexillum and client team achieved a 41 percent reduction with zero safety incidents during improved services.
Solution The team redesigned service flow, improved parts availability, and tightened truck delivery and wash queue timing.
Our Team
Experienced operators, engineers, and software builders.
Vexillum supports heavy industrial producers where plant and fleet equipment is complicated, expensive, and critical for production.
Michael White
CEO
Michael brings more than 45 years of experience leading operational improvement and transformation across automotive and resource businesses including Toyota, Rio Tinto, Newcrest, BHP, Vale, and South32.
Simon Kay
CPO
Simon has over 30 years of experience across manufacturing, technology, and mining, combining engineering discipline with practical lean implementation.
John Jessop
CTO
John has spent more than 30 years developing and deploying software systems for the resource sector, with a focus on durable products that support operating performance.
Contact us
Get in touch with Vexillum today to explore how Work Design™ can benefit your business
- Perth, WA, Australia
- Melbourne, VIC, Australia