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Submission: On September 20 via api from US — Scanned from AU
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</form>Text Content
Skip to content Menu * Work Design™ Benefits * Work Design™ Process * Case Studies * Our Team * Contact Us BECAUSE DETAIL MATTERS INCREASE AVAILABILITY BY CUTTING MAINTENANCE TIME BY UP TO 50% BOOSTING OPERATING HOURS, REDUCING RISK PROFILE AND INCREASING QUALITY WITH DIGITAL STANDARDISED WORK We reduce Maintenance task durations by an average of 50%, delivering more operating hours, improving safety and driving quality by implementing digital standardised work. Vexillum’s proprietary Work Design™ Methodology and supporting digital tools work remove waste and optimise value added activities in your maintenance activities WORK DESIGN™ Our desktop software, Work Design™, improve Safety, Quality & Reliability Performance and empowers the frontline. BUILD YOUR IMPROVED PROCESS LIBRARY WORKING WITH YOU Our team works with your Maintenance department to embed the principles of the Work Design™ methodology including identifying and eliminating waste, sequencing and integrating work, and holistic process improvements. EMBED AN IMPROVEMENT CULTURE WORK D™ Our mobile application puts the improved process in the hands of the frontline workers. Ensuring sequence, knowledge and safety requirements are available and durations and feedback are captured. EMPOWER THE FRONTLINE INCREASING PRODUCTIVITY BY REDUCING VARIABILITY IN TASKS. ACHIEVES RAPID, LASTING PERFORMANCE IMPROVEMENT USING WORK DESIGN™ WORK DESIGN™ BENEFITS WORK DESIGN™ ELIMINATES WASTE, REDUCES VARIATION, AND ENHANCES QUALITY. WORK DESIGN™ BENEFITS INCREASED OPERATING HOURS Reduced average duration of recurring maintenance activities returns operating hours to production via increased availability. WORK DESIGN™ BENEFITS REDUCED BACKLOG Reduced average duration and variation in duration frees up crews to reduce backlog, improving equipment reliability and increasing Mean-Time-To-Failure. WORK DESIGN™ BENEFITS IMPROVED SAFETY Inclusion of critical risks & critical control verifications, required PPE, instructional pictures and videos for each activity, reduces risk of operational errors, improving safety. WORK DESIGN™ BENEFITS CONTROLLED COSTS Feed-back captured during the Work Design™ process helps Supply Chain update Part Lists to reduce returns and increase number of kits ready when Work Orders are planned and scheduled. WORK DESIGN™ BENEFITS ENABLED DIVERSITY Processes improved with Work Design™ include upgraded tooling and other solutions that allow a more diverse workforce to perform tasks. Video and photo images support written instructions support additional learning styles, improving understanding. WORK DESIGN™ BENEFITS OPTIMISED LABOUR As Backlog is reduced and zero-based labour calculations are improved, panel make-up and size, along with contracted 3rd party labour, are optimised to meet demand. WORK DESIGN™ BENEFITS STRUCTURED FEEDBACK Time Durations captured in the WorkD™ app along with delay and variation information are automated into feedback loops with planning, scheduling, maintenance and reliability engineering. WORK DESIGN™ PROCESS THE WORK DESIGN™ METHODOLOGY SYSTEMATICALLY ENHANCES JOB PERFORMANCE BY IMPROVING HOW TASKS ARE EXECUTED. WORK DESIGN™ Establishing a Productivity Team and implementing the process and tools. WORK DESIGN™ EXPANSION Client Productivity Team expands rolls out to additional Tasks and services PRODUCTION SYSTEM With a solid foundation of well-designed work, the Vexillum team helps building out Production and Operating System tools that further accelerate productivity improvements. OUR BOTTOM-UP APPROACH LEVERAGES DETAILED INSIGHTS FROM THE FRONTLINE TO DRIVE CONTINUOUS IMPROVEMENT. Capture Analyse Create Execute Iterate ITERATE: PROCESS CONTINUES TO BE IMPROVED USING INFORMATION CAPTURED DURING EXECUTE. KEY CAUSES OF DELAYS ARE ADDRESSED INCLUDING INTERACTIONS AMONG DEPARTMENTS. CASE STUDIES 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 the availability of their 50-truck Caterpillar 793F haul truck fleet by reducing both the duration of preventative maintenance services and the total labour hours consumed in each service. Fact This project delivered over 8000 Truck Hours back to production, generating a marginal value of $70M in additional ore moved, and reduced maintenance labour spend by over $1M annually. Solution The team applied production system thinking and lean tools to re-design how each of the eight services (250-hour to 2000-hour) were performed. Location: Western Australia Industry: Mining FIXED PLANT CRUSHER SIZER SHUTDOWN Overview Vexillum team members were challenged to help a major miner reduce the duration of Fixed Plant Crusher Sizer Shutdowns, at both the 14 and 28 week shut intervals for a total of four annual shuts. Fact The team delivered over 220 additional crusher hours to operations after deploying improvement methodology. Assuming the crusher was the constraint to production, these hours represent an increase in marginal income of over $100M. During this process over $800k in contractor labour spend savings were identified. Solution Tooling and part kits were optimised and repositioned around the job site to reduce number of times a maintainer needed to come off tools to go looking for items. Industry: Mining RAIL ORE CAR FLEET ENGINEERING MODIFICATION Overview A mining company had 5000 rail cars that needed to be modified to carry more ore. The challenge was to complete these 5000 modifications as quickly and safely as possible, without using excessive additional labour. Fact Via the implementation of the improvement toolkit the project was completed 18 months earlier than originally planned. A savings of $27M in labour costs was realised. The project duration reduction translates to 45-million tonnes being moved at an estimated market value of over $3.5B. Solution Prior to engaging with Vexillum resources, the plan was to modify 7 railcars, across a 2-shift day. When Work Design™ was deployed, the process was improved by both eliminating waste and optimizing how the value-added steps in the process were performed, the number of railcars per 24-hours increased to 50. Location: Western Australia Industry: Rail REDUCING CAT 793F 500HR SERVICE DURATION BY 41% Overview A major iron ore mine invited Vexillum to complete a proof-of-concept trial of the Work Design™ methodology, including deploying both the Work Design™ software, and the WorkD app to be used on the shop floor. Specifically the goal was to reduce the duration of the Cat 793F service duration by 20% in less than 90 days. This included deploying the improved process across all 4 crews. Fact The integrated Vexillum and client productivity team achieved a 41% reduction in duration, including 30% of trials delivered in approximately half the baseline duration. There were zero safety incidents during any of the services where the improved process was deployed. Solution Both Work Design™ & WorkD were deployed. The improved process being drafted in Work Design™ upon completion of the Value/Waste analysis and a collaborative review of requirements across engineering, safety and maintenance. Improvements included establishing a standard bay layout prior to start of service, working with warehousing to open 30 minutes earlier to ensure parts were available, and working with operations to ensure trucks are delivered on-time and queueing for washing was reduced. Location: Western Australia Industry: Mining VEXILLUM SUPPORTS HEAVY INDUSTRIAL PRODUCERS WHERE PLANT AND FLEET EQUIPMENT IS COMPLICATED, EXPENSIVE AND CRITICAL FOR PRODUCTION. OUR TEAM MICHAEL WHITE CEO Michael is the CEO of Vexillum Consulting, bringing over 40 years of expertise in leading operational improvements and transformation programs across the automotive and resource sectors. His experience spans major organisations including Toyota, Rio Tinto, Newcrest, BHP, Valé, and South32, where he has driven impactful change both in Australia and internationally. Before founding Vexillum Consulting, Michael played a pivotal role at BHP as Head of Development and Deployment. He was the chief architect behind the BHP Operating System and oversaw its successful implementation across three global regions. Additionally, he has hands-on experience in the resource sector, having managed a processing plant for a global gold miner in Papua New Guinea, where he enhanced operational stability through the introduction of a Management Operating System (MOS) and a visual information centre. Michael’s leadership and strategic vision continue to deliver exceptional results, positioning Vexillum Consulting as a leader in operational transformation. With a solid foundation in frontline leadership, Barry held key roles at Vale, BP, and United Technologies, including positions within UTC’s Pratt & Whitney, Chubb Security, and Kidde operating companies. His diverse background and global experience make him a valuable asset in optimizing business performance. READ MORE SIMON KAY CPO Simon is the CPO of Vexillum Consulting, with over 30 years experience in manufacturing, technology and mining industries. With a strong engineering focus, Simon is passionate about driving process improvement through the application of lean methodologies and cutting-edge technologies. Over the past decade, he has successfully delivered improvement projects in mining operations and maintenance, building a proven track record of enhancing efficiency and reducing costs. Simon’s background in process and systems engineering has enabled him to pioneer unique lean tools that have been effectively applied across industries, including mining, construction, healthcare, and automotive manufacturing. His expertise in increasing productivity while minimizing operational expenses makes him a key innovator in process optimisation. With a solid foundation in frontline leadership, Barry held key roles at Vale, BP, and United Technologies, including positions within UTC’s Pratt & Whitney, Chubb Security, and Kidde operating companies. His diverse background and global experience make him a valuable asset in optimizing business performance. READ MORE JOHN JESSOP CTO John is the CTO of Vexillum Consulting, with over 30 years of experience in developing and deploying software systems for the resource sector. He has successfully launched multiple commercial products and is passionate about creating software solutions that are built to last for decades. With a deep understanding of how operational and support processes integrate within the mining industry, John’s extensive experience in product management, deployment, and support makes him a leader in delivering sustainable, high-impact software solutions. His expertise ensures that technology serves as a long-term enabler for efficiency and growth in the resource sector. With a solid foundation in frontline leadership, Barry held key roles at Vale, BP, and United Technologies, including positions within UTC’s Pratt & Whitney, Chubb Security, and Kidde operating companies. His diverse background and global experience make him a valuable asset in optimizing business performance. READ MORE BARRY DANIEL BUSINESS DEVELOPMENT & IMPLEMENTATION Barry specializes in delivering precise, data-driven support to help clients make informed business decisions and drive continuous performance improvement. Before joining Vexillum, he led Operational Excellence teams for dss+, Lodestone Partners, and Partners in Performance, working across Brazil, Australia, the United States, and Canada. With a solid foundation in frontline leadership, Barry held key roles at Vale, BP, and United Technologies, including positions within UTC’s Pratt & Whitney, Chubb Security, and Kidde operating companies. His diverse background and global experience make him a valuable asset in optimizing business performance. READ MORE VEXILLUM SUPPORTS HEAVY INDUSTRIAL PRODUCERS WHERE PLANT AND FLEET EQUIPMENT IS COMPLICATED, EXPENSIVE AND CRITICAL FOR PRODUCTION. CONTACT US GET IN TOUCH WITH VEXILLUM TODAY TO EXPLORE HOW OUR WORK DESIGN™ SOLUTIONS CAN BENEFIT YOUR BUSINESS Fields marked with an * are required First Name * Last Name * Email * Job Role Director Engineer Superintendant Manager Other I require solutions for: Maintenance Safety Standardised Work Continuous Improvement Quality Other I agree to the privacy policy and wish to be contacted. I am interested in scheduling a call. Message If you are a human seeing this field, please leave it empty. BECAUSE DETAIL MATTERS. WE ARE LOCATED IN PERTH, WESTERN AUSTRALIA LAUNCESTON, TASMANIA AND WASHINGTON, DC USA © 2024 Vexillum All Rights Reserved Terms, Conditions and Policies Security & Compliance Cookie Policy Privacy policy Close * Work Design™ Benefits * Work Design™ Process * Case Studies * Our Team * Contact Us