Methodology: MRO Process Improvement

Depending on the results of the process assessment, any/all of the following elements may be in-scope for the optimization process: 

• Physical Storeroom Assessment
• Inventory Data Analysis
• Cycle Counting Setup
• Kitting Process
• Aisle, Row, & Bin Labeling Schema
• Digital System Integration
• Training for Storekeepers

We follow a simple and straightforward process to deliver the optimization services.

1. Site Walk-Down
2. Data Audit
3. Gap Analysis & Business Case
4. Strategy Design
5. Implementation Phase
6. Customer Handover

There are a few items that we will need from the customer to make the project successful.

• Data Access - Ready access to MRO purchase history, issue history, work order history, and p-card purchase history are all tantamount to getting an accurate picture of the demand side of the MRO equation
• Staff Availability - Access to stores and purchasing personnel throughout the process is crucial to success as well.  Time for interviews, group sessions, and clarification on data quality and analysis results are very necessary.  Expect stores and purchasing personnel to spend 15-25% of their time with us in various sessions.
• Change Management Participation - Active change management participation ensures customer needs are integrated, fostering alignment, ownership, and smoother transitions during storeroom optimization initiatives—driving sustainable improvements and long-term stakeholder engagement.

There area a few options with regards to how long projects such as these take.

• Assessment and Diagnostics - Take 2-3 weeks of work and another week of presenting results and debriefing site leadership.
• Initial Rollout - Takes 3-12 months depending on the number of elements in-scope and how aggressive the site wants to achieve sustainable results.

Results can vary depending upon the nature of the problem and the scope of the improvement efforts, but examples such as these are quite typical.  We work with the site leadership team to come up with measurements of success for the project.

• Customers typically see a 15–30% reduction in inventory holding costs.
  Example: $200k annual savings for a food manufacturer with 3 sites.
   
• Stock-outs and emergency purchases are reduced by 40–60%, improving equipment uptime and maintenance efficiency.
  Example: One metals processor eliminated over 200 annual emergency orders within 6 months.
   
• Inventory accuracy improves to 95% or higher through structured cycle counting and part standardization.
  Example: A Midwest refinery increased accuracy from 68% to 97% in under 90 days.
   
• Obsolete inventory is reduced by 20–50% through data cleansing and rationalization.
  Example: A pulp and paper plant reclaimed $480k in unused inventory value.
   
• Technician wrench time increases as part retrieval delays are eliminated with redesigned bin layouts and digital lookups.
  Example: One pharmaceutical site cut parts retrieval time by 70%, enabling a 12% increase in maintenance productivity.

Our post-project support ensures long-term success by offering ongoing monitoring, scheduled audits, and personalized coaching to reinforce best practices and drive continuous improvement. 

• We provide clients with access to a user-friendly digital dashboard and KPI tracker that visualizes critical performance indicators, tracks inventory accuracy, identifies stockout risks, and highlights trends in procurement, usage, and cost. This tool empowers maintenance and storeroom teams to make data-driven decisions, respond proactively to issues, and sustain the benefits achieved during the optimization project. 
• Our support model is designed to promote accountability, encourage process ownership, and adapt to evolving operational needs over time.

A key differentiator of MRO Results is our deeper CMMS success—rooted in decades of hands-on field experience across diverse industries. 

• Unlike firms that stop at basic configuration, we ensure your CMMS reflects actual maintenance workflows, supports storeroom integration, and delivers actionable insights. 
• Our approach bridges strategy with execution—enabling clients to leverage their systems for preventive maintenance, asset tracking, failure analysis, and cost control. 
• By aligning technology with operational reality, we help organizations move beyond compliance to achieve true reliability gains, data-driven decision-making, and sustained performance improvements across the entire maintenance and MRO ecosystem.

These outcomes collectively support reliability, reduce costs, and elevate the overall performance of maintenance operations.

1. Reduced Inventory Holding Costs

• Excess inventory ties up capital, increases carrying costs, and often leads to part obsolescence. Optimizing stock levels frees up working capital, improves cash flow, and aligns inventory with actual maintenance demand.

2. Improved Part Availability and Fill Rates

• When critical parts are unavailable, maintenance delays increase downtime and reduce asset reliability. A well-optimized storeroom ensures the right parts are on hand, supporting faster repairs and more effective preventive maintenance.

3. Higher Inventory Accuracy and Visibility

• Accurate data enables better decision-making in procurement, planning, and maintenance execution. Improved visibility minimizes wasted time searching for parts and builds trust between the storeroom and its internal customers.

4. Elimination of Obsolete and Duplicate Stock

• Obsolete and duplicate parts clutter the storeroom, obscure useful inventory, and create confusion. Removing these items improves organization, reduces storage requirements, and ensures that what’s in stock is current, usable, and cataloged correctly.

At the conclusion of a storeroom optimization project, MRO Results provides ongoing support through performance audits, coaching, and digital KPI tracking. Our team ensures sustainability by reinforcing best practices, adjusting strategies as needed, and remaining a trusted partner in driving continuous improvement and long-term value for your organization.