You Know Something
Is Wrong.
We'll tell you exactly what, and what it's costing you. Fixed-fee engagements. Remote-first delivery. Results in 90 days or less.
to your loss map
measured in dollars
operational change
zero change orders
Fixed fee · No lock-in · Results in 10 business days
Every engagement begins with Stage 01. Stages 02 to 04 are offered only after it, scoped to what the findings justify, never sold in advance.
Plant Profit Leak Diagnostic
In 10 business days, you'll know exactly where your plant is leaking margin.
Most plants don't have a visibility problem. They have a quantification problem. Leadership knows something is wrong, but without a dollar figure and a ranked list of causes, nothing changes.
The Plant Profit Leak Diagnostic answers both questions. We review your own data, including work orders, downtime logs and production records, and return a ranked loss map with a 90-day recovery roadmap.
- KPI baseline: Reactive work %, schedule compliance, downtime, overtime and backlog measured from your records
- Quantified loss map: Controllable losses in dollars and hours, ranked by impact
- 90-day recovery roadmap: Prioritised actions with expected outcomes and ownership
- Executive readout: Findings presented to your sponsor, PDF and editable source files included
"Before the Diagnostic, we were arguing about where the losses were. Afterwards, we had a ranked list, a dollar figure, and nobody could argue with it."Maintenance Manager, Mining & Processing, Queensland
Extension Pack
Take one high-value finding from the Diagnostic and turn it into a plan, fast.
After the Diagnostic, some sites want depth on a single high-value finding without committing to a full Sprint. The Extension Pack does exactly that: 21 days, one focused outcome, scoped in your Executive Readout once the priority is clear.
- Single leak-zone deep dive: full root-cause analysis, prioritised interventions, and cost-of-inaction modelling
- Plant implementation roadmap: 90-day execution plan with sequencing, owners and KPI baselines
- Leadership workshop series: three facilitated sessions with your operations leaders, plus manager coaching
90-Day Recovery Sprint
Install the operating system and attack the losses across the plant, together.
When the Diagnostic surfaces losses across several zones, the 90-Day Recovery Sprint is the full systemic engagement. It installs the maintenance operating rhythm and attacks the highest-value losses in parallel, with execution support alongside your team, and leaves a daily management system that holds after we are gone.
- Backlog triage rules and cleanse process
- Weekly scheduling cadence with compliance tracking
- Leader standard work and frontline accountability structure
- KPI board and daily management rhythm
- Loss Pareto and constraint attack on the highest-impact zones
- Closeout controls and root-cause discipline
Plant Performance Office Retainer
Sustain the gains, coach the team, and keep an improvement pipeline moving.
Performance systems degrade without governance. The Plant Performance Office Retainer provides ongoing cadence, coaching, and accountability to keep your improvement pipeline moving. Available following a completed Diagnostic or implementation engagement.
- Monthly KPI review pack and performance readout
- Weekly execution call with improvement backlog update
- Dashboard stewardship and data integrity checks
- Quarterly reset and re-prioritisation
Can't we just do this ourselves?
You can, and most plants have tried. The problem isn't knowledge, it's objectivity and method. Internal teams are inside the politics, accustomed to the losses, and rarely have a structured framework to convert raw data into a ranked dollar figure that everyone agrees on.
The Diagnostic's value isn't just the findings. It's that the findings come from an independent view, which means leadership can act on them without relitigating the internal arguments first.
We already use a CMMS (SAP, Maximo, etc.). Why do we need this?
A CMMS records data. The Diagnostic interprets it. Most plants have years of work order history and no ranked loss map to show for it, because the tool captures what happened, not what it cost or what to do about it.
The Diagnostic uses your CMMS exports as its primary data source. We don't replace the system. We make its data actionable.
What data do you actually need from us?
Work order history (12 to 24 months), downtime logs, and production records, all as exported reports. We don't need system access, logins, or read access to your CMMS. Everything is shared via a secure file transfer link we provide at kickoff.
We also have a single structured intake call with your maintenance supervisor at the start to orient to your site context. That's it.
What if our maintenance team resists an external consultant?
Most resistance is about fear of blame. We address this directly: the Diagnostic is a systems audit, not a performance review. We report on losses in the operation, not on people or decisions.
In practice, maintenance teams often become advocates once they see that the findings give them the data to justify what they've been trying to fix internally for years.
What happens after the Diagnostic is delivered?
You receive a ranked loss map, a 90-day roadmap, and an Executive Readout presented to your sponsor. From there, the decision is entirely yours. You can take the roadmap in-house, engage Stages 02 to 04 with us, or do nothing with it.
There is no follow-up sales sequence and no pressure to continue. The Diagnostic is complete as a standalone deliverable.
What if the Diagnostic doesn't find anything significant?
Then the report says so. I would rather give you that answer in writing than invent leverage points to justify a deeper engagement. The Diagnostic is a binary fit-or-not test for the deeper tiers. If the answer is "take the report and execute internally," that is a clean outcome and you keep the report.
In every prior engagement Aaron has delivered, the controllable loss identified has materially exceeded the Diagnostic fee. Specific outcomes vary by site condition and data quality.
What Your Plant is Losing?
The Plant Profit Leak Diagnostic takes 10 business days, delivered remotely. You receive a full KPI baseline, quantified loss map, and a 90-day roadmap, fixed fee $15,000 + GST.
Book Your Free Fit CallFixed fee · No lock-in · Results in 10 business days