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.

Western Australia · Mining

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.

Mining

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.

Western Australia · Rail

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 Our approach lifted output from 7 railcars per two-shift day to 50 railcars per 24 hours by eliminating waste and refining value-added work.

Western Australia · Mining

Reducing Hitachi EH5000 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.