Where industrial plants leak profit, and how to find it

Ridgway Resilience is an industrial operations consultancy that quantifies, in dollars, where a plant leaks profit across five leak zones (throughput, downtime, labour, rework, and rhythm) and maps a 90-day recovery plan. It is founded and delivered by Aaron Ridgway, who has 13 years in industrial operations across ports, mining services, and manufacturing.

Throughput (capacity lost to bottlenecks and poor sequencing), Downtime (unplanned breakdowns and reactive maintenance), Labour (waiting and overtime from poor planning), Rework (repeat work and quality failures), and Rhythm (weak operating cadence and follow-through).

The practitioner-led Plant Profit Leak Diagnostic is a fixed fee of AU$15,000 plus GST and takes 10 business days. A fully remote version, the Remote Plant Diagnostic, covers all five leak zones for A$4,950 plus GST. Both are only recommended after a free Fit Call or the A$1,500 Reactive-Share Snapshot confirms the exposure is real. On-site visits are quoted separately per the terms and conditions.

The first paid step at Ridgway Resilience: for A$1,500 plus GST, 12 months of work-order data is turned into the plant's reactive-maintenance dollar figure, the 12-month trend, and the top three recovery levers within 72 hours, with a 30-minute readout. It is refunded in full if it cannot identify annual losses of at least ten times the fee, and the fee credits in full toward either Diagnostic.

Yes. The Plant Scorecard is a free, 15-question self-assessment that gives an instant grade across the five leak zones with no email required, and the Diagnostic Fit Call is a free 30-minute conversation to confirm whether a full Diagnostic is justified.

A quantified loss map across all five leak zones translated into annual dollar figures, ranked recovery actions by recoverable value, a 90-day sequenced plan, and a 60-minute Executive Readout with leadership.

Manufacturing, processing, mining services, port operations, and heavy industry, single or multi-site, with at least $5M annual operating spend, typically where reactive maintenance is above 40 percent and overtime is rising without a clear explanation.

Software, SaaS, or office-based operations, very small sites with no maintenance function, and anyone looking for a generic business health check rather than an operations diagnosis.

Free Plant Scorecard, then a free Diagnostic Fit Call, then the A$1,500 Reactive-Share Snapshot (72 hours, refund-guaranteed), then the A$4,950 Remote Plant Diagnostic, then the AU$15,000 practitioner Plant Profit Leak Diagnostic, then an optional AU$35,000 Extension Pack, a AU$150,000 90-Day Recovery Sprint for multi-zone systemic work, and a A$990 per month Reliability Desk for ongoing monitoring. The free steps keep the downside at zero, and the first paid step is A$1,500, not AU$15,000.

Aaron Ridgway, who has 13 years in industrial operations across ports, mining services, and manufacturing, holds a Bachelor of Business (Management) from Griffith University, and is CAPM (PMI) certified. Delivery is fixed-fee and remote-first.

It measures the five leak zones against a plant's own CMMS and downtime data, including reactive maintenance percentage, unplanned downtime, wrench time, backlog, schedule compliance, and repeat work, then translates the gaps into annual dollar figures and ranked recovery actions.

That is fine and common. Messy data is itself a finding, because the gaps usually point to control problems. The Diagnostic works with whatever data exists and requires no new tools.