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Reliability Improvement Methodology

Successful organization change is not just a technical issue. Marshall Institute’s 8-Phase Reliability Improvement Model provides a flexible, though disciplined approach for successfully implementing major change projects in real organizations, with real people. It is a structured process combining the technical side of improvement, the elements of culture change, and the imperatives of business need.

We Build Capabilities, Not Dependencies

Marshall Institute’s reliability improvement methodology emphasizes providing clients with capabilities, not dependencies. We do this by building internal support, building internal competencies, and fully engaging internal resources for sustainable change. We leave our clients stronger, more capable, more knowledgeable, and more aligned—ultimately more self-sufficient. Marshall Institute succeeds if our clients succeed.

8-Phase Reliability Improvement Model

Assess the Current Systems
Marshall Institute uses a variety of assessments based on surveys, data collection, observations, discussions, one-on-one interviews and focus groups. Our assessments provide the framework for examination of your current maintenance and reliability practices and identify areas for improvement. Our goal is to have client involvement in the process and ownership in the result.

Build the Case for Change
Based on the results of the assessment, Marshall Institute will work with your team to develop a clear case for change that outlines the priority recommendations and return that you may realize from implementing identified improvements.

Develop the Strategy
Clarity of vision, relevance of mission and constancy of message are critical to sustainable success for any major change initiative. We work side by side with leadership to clarify major issues, refine ideas, and frame them into strategic direction. Marshall Institute provides tools and processes to guide organizations in developing tactics and practices to achieve optimal results, even in resource-constrained environments.

Enable the Organization
Effectively implementing reliability improvement requires common vision, strong corporate and plant leadership, good planning, high involvement, engagement at all levels of an organization, and a collaborative, working partnership between operations, maintenance, and engineering.

Charter the Leadership
Cross-functional Steering, Implementation, and Focus teams must be chartered to provide leadership, strategy development, strategy deployment and oversight during the change initiative.

Develop Internal Expertise to Drive Change
One key factor in sustained reliability improvement is the development of internal Coordinators— dedicated and capable internal “change agents.” By internalizing the change at the plant level, the dependence on outside resources is reduced, while increasing the probability of success.

Sustain the Improvements
Major change initiatives are sustained through frequent and consistent auditing of progress, process, and results. Marshall Institute will provide assistance with formal auditing and review of the clients’ improvement initiatives. Our review process focuses on the degree to which the planned improvement initiatives are being accomplished, implemented and embedded into current business practices, and the extent to which the organizational culture is absorbing the new practices.

Systems Training and Implementation Support
For long term sustained results, key systems need to be improved, documented, and standardized. In addition, the relevant people tasked with these systems must be trained accordingly. Having assisted numerous clients in the implementation of major reliability improvement initiatives, Marshall Institute has established training programs for improving the reliability related business systems. We specialize in Planning and Scheduling, Preventive and Predictive Maintenance, Maintenance Inventory Control, Maintenance Measures, Root Cause Analysis, PM Optimization, and others.

Sustain the Improvements - Audit & Review
To ensure you are sustaining your improvements Marshall Institute can also provide on-going audit assistance. This would involve auditing your TPM/TPR activities on a quarterly or semi-annual basis to help keep your process “on track.” This usually involves two consulting days on-site per year. At the end of the second day we would provide an oral report outlining the strengths and areas for improvement.

A written report is optional. Our experts have many years of experience in implementing the process at numerous sites, domestically and internationally, and they bring a rich background from which to draw. We can share what has worked and what has not to increase the probability of a successful TPM/TPR process at your location.

Our model has been refined by dozens of reliability improvement implementation efforts in various industries, countries and multi-plant operations. It has proved time and time again to be a uniquely successful roadmap to achieving significant and lasting improvements.

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