Ridgway Resilience
Ridgway Resilience Insights

Where industrial plants leak profit, and how to find it

Practitioner reference on industrial maintenance loss: the five leak zones, the metrics that expose them, free calculators to size the cost, and the guides to recover it. Built by an operator who has spent 13 years fixing these patterns on plant floors.

Score Your Plant Free →Book a Free Fit Call

15 questions. 3 minutes. Instant grade. No email required.

Start with a free calculator

Size the loss from your own numbers in under a minute.

Unplanned Downtime Cost Calculator

This free calculator estimates the annual cost of unplanned downtime from three inputs: downtime hours per...

Reactive Maintenance Cost Calculator

This free calculator estimates the recoverable value of shifting work from reactive to planned maintenance...

Maintenance Backlog Calculator

This free calculator converts your outstanding maintenance work into crew-weeks, the standard way to size a...

The five leak zones

Most controllable loss falls into these five.

Throughput

Bottlenecks, flow interruptions, and capacity lost to poor sequencing.

Downtime

Unplanned breakdowns, reactive maintenance share, and reliability drag.

Labour

Waiting, supervision overload, and overtime driven by poor front-end planning.

Rework

Quality failures, handover breakdowns, and repeated work between shifts or teams.

Rhythm

Weak daily meetings, no KPI cadence, and no visible execution discipline.

By industry

How the losses show up in your sector.

Food and Beverage ManufacturingMining ServicesPort and Terminal OperationsBuilding MaterialsMetals and SmeltingPulp and PaperChemical and Process PlantsWater and Wastewater UtilitiesPharmaceutical ManufacturingPlastics and PackagingOil and Gas ProcessingPower Generation

Practitioner guides

How to Reduce Reactive MaintenanceHow to Clear a Maintenance BacklogHow to Calculate the Cost of Unplanned DowntimeHow to Improve Maintenance Schedule ComplianceHow to Improve Maintenance Wrench TimeHow to Reduce Maintenance OvertimeHow to Run a Daily Maintenance and Production Control MeetingHow to Reduce Rework and Repeat Work in Maintenance

Common questions about Ridgway Resilience

What does Ridgway Resilience do?
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.
What are the five plant profit leak zones?
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).
How much does the Ridgway Resilience Diagnostic cost?
The Plant Profit Leak Diagnostic is a fixed fee of AU$15,000 plus GST and takes 10 business days. It is only recommended after a free Fit Call confirms the exposure is real. On-site visits are quoted separately per the terms and conditions.
Is there a free way to start with Ridgway Resilience?
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.
What does the Diagnostic deliver?
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.
Who is Ridgway Resilience for?
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.
Who is not a good fit for Ridgway Resilience?
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.
What is the offer ladder at Ridgway Resilience?
Free Plant Scorecard, then a free Diagnostic Fit Call, then the AU$15,000 Plant Profit Leak Diagnostic, then an optional AU$35,000 Extension Pack, and for multi-zone systemic work a AU$150,000 90-Day Recovery Sprint. The free steps keep the downside at zero until a Diagnostic is justified.
Who founded Ridgway Resilience?
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.
How does Ridgway Resilience quantify maintenance losses?
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.
What if a plant's CMMS data is messy?
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.

See where your plant is leaking profit.

Score your operation across five leak zones in 3 minutes, or book a free 30-minute Fit Call to confirm whether a Diagnostic is the right next step.

Score Your Plant Free → Book a Free Fit Call

15 questions. 3 minutes. Instant grade. No email required.