Summary

HealthSafe has been a cornerstone of workplace safety in New Zealand for more than ten years. It began as a simple check-in and check-out system using RF cards and access information. Today, it supports contractors, staff, and visitors across the country through a mix of mobile app check-ins, geo-fencing, QR scanning, and integrated workflows.

Over a decade of continuous use created a platform with more than 60GB of live operational data, deep integrations, and a critical role across major government organisations and large enterprises. HealthSafe worked with us not because the system was broken, but because it had outgrown its early framework and needed a modern foundation for future expansion.

Our job was to modernise a mission-critical safety system without disrupting the thousands of people who rely on it every day.

Client: HealthSafe
Industry: Workplace Safety, Compliance, Enterprise Software
Services: Platform Modernisation, Legacy System Refactoring, Data Migration, Consulting
Platforms: Web, Mobile
Role: Long-term engineering and technical consulting partner

The Challenge

• Modernising a live, mission-critical system without downtime
• Migrating more than 60GB of legacy operational data
• Supporting multiple check-in technologies across diverse clients
• Untangling years of undocumented logic and business rules
• Educating stakeholders on the realities of legacy scalability

HealthSafe’s long history was both a strength and a challenge. Years of enhancements, custom logic, and one-off business rules had created an incredibly capable ecosystem, but also a complex one.

The complexity included:

• More than 60GB of legacy data
• A wide range of contractor check-in methods, from RF cards to geo-fencing and QR scanning
• Heavily customised workflows are used across government and enterprise clients.
• Layers of decisions and exceptions built over ten years
• Infrastructure that no longer matched the platform’s scale

 When we began, the onboarding alone took nearly two months. There were countless pockets of hidden information, undocumented behaviours, and logic that only revealed themselves when certain conditions were met.

This was not a simple upgrade. It required deep investigation, careful planning, and a steady hand.

A major part of the challenge was also helping the client understand how legacy systems scale. We took a proactive consulting approach, walking them through what would be required for modernisation and why certain steps were essential for long-term stability.

The goal was clear. Improve everything without breaking anything.

Our Approach

• User experience design for simulation submission
• Automated cloud infrastructure and job orchestration
• Dockerised, repeatable simulation environments
• Cost-efficient lifecycle management for compute resources

Instead of rushing into development, we immersed ourselves in the platform’s history. We studied the reasons behind past decisions, the unique workflows relied on by contractors and enterprises, and the logic embedded in years of incremental updates.

From there, we modernised the system layer by layer.

Stabilising the Core Legacy Platform

We began by strengthening the core, ensuring the system could safely support modern upgrades without compromising data integrity or disrupting users.

Modernising the System Architecture for Scale and Security

We rebuilt essential components to support scalability, security, and future development, while maintaining compatibility with existing clients and integrations.

Migrating Over 60GB of Legacy Workplace Safety Data

One of the most important achievements was the complete migration of more than 60GB of historical and operational data into a modern, structured environment. This ensured a clean, stable foundation without any loss of history or function.

Performance and Workflow Optimisation

We refined processes such as check-ins, contractor management, and app-based workflows. Heavy datasets now load faster, handle more activity, and support higher concurrency.

Clear Guidance for Future Growth

We provided ongoing consultation to help the client understand how to grow and scale a mature platform. This clarity allowed them to make confident decisions about the next generation of their product.

Throughout the process, our guiding belief stayed constant. Respect the past. Upgrade for the future.

Results and Outcomes

• Improved system reliability under load
• Faster workflows and data access
• Easier maintenance and future development
• Reduced operational risk
• Readiness for new features and integrations

HealthSafe now operates on a modern, scalable platform that delivers greater reliability and performance than before. Throughout the project, we uncovered and resolved a number of long-standing issues that had naturally accumulated over more than 10 years of continuous use. Some of these were buried deep within old workflows and data structures, and addressing them helped restore stability and remove risks that could have affected future growth.

All legacy data was safely migrated to a clean, structured environment. Workflows that previously struggled under heavy load now run more smoothly, and the system behaves more easily to understand, maintain, and build on. The platform is no longer constrained by its early foundations and is now in a much better position to support the next round of improvements.

HealthSafe is ready for the next chapter. The system can handle new features, greater demand, and ongoing evolution with confidence.

Most importantly, this work has laid a solid foundation for the partnership ahead. Now that the core is stable and future-proof, we are well prepared to support HealthSafe as they continue to grow, refine their platform, and introduce new capabilities for the organisations that rely on them. We see this as the beginning of a long-term journey, and we are proud to be part of it.