What Is the Management of Change (MOC) Process?

Management of Change (MOC) is a structured process used to manage technical changes within a company or organization. Its purpose is to ensure that changes are systematically evaluated, documented and implemented so that risks are minimized, operational efficiency is maintained and proper safety measures are in place. 

For example, a chemical manufacturing plant upgrades its reactor to increase production capacity. Not only would the new, larger reactor require more space within the plant, but the staff would need to be trained on how to use the new technology and any new operating procedures involved. To help prepare for this change, the plant management team would need to assess all potential risks and create new processes and safety measures to execute. 

Implementing change is never easy, no matter how big or small the modification. In this Management of Change guide, we address the most common types of change that a business can face as well as the processes involved, ensuring your change initiatives are as successful as can be.

Management of Change (MOC) vs. Change Management 

While Management of Change (MOC) and Change Management both focus on organizational changes, they address very different aspects of the systematic approach. Here’s how the two compare:

Management of Change (MOC)

• Focus: Primarily addresses the technical, such as modifications to equipment, business processes or facility layouts.
• Application: Most commonly used in industrial settings such as manufacturing plants or chemical facilities.
• Objective: To ensure changes are made systematically to reduce safety risks and prevent harm during transitions.
• Tools: Involves risk assessments, technical reviews, safety audits and compliance checks.
• Goal: To maintain operational safety, minimize disruptions and ensure compliance with industry regulations.

Change Management

• Focus: Addresses the people aspect of change, such as how employees adapt to organizational changes, new workflows or restructuring.
• Application: Can be applied across all types of organizations, particularly with shifts in company strategy, leadership or culture.
• Objective: To help employees transition smoothly during the change management process by addressing questions, building support and ensuring buy-in.
• Tools: Involves effective communication (both internally and externally), training programs, stakeholder engagement and emotional support mechanisms.
• Goal: To ensure successful change management, with minimal disruption to workforce morale, productivity and engagement.

At its core, MOC focuses on minimizing risks related to technical and operational changes, while Change Management focuses on helping employees through changes to ensure effective change management implementation and acceptance.

Changes That Typically Require MOC

MOC changes have the potential to impact safety, efficiency or compliance, which is why the process is so critical to ensure that transitions happen smoothly and risks are minimized. Examples of changes that require MOC include:

• Equipment: Changes in design, installation of new equipment or replacement of existing machinery. A good example is upgrading a production line or replacing key pieces of equipment with a different model.
• Operations: Modifications to how work is performed, which could include changes in operating procedures, workflows or safety protocols. A good example is altering production processes or adjusting safety practices for continuous improvement.
• Facilities: Renovations or structural changes to the physical area where equipment is located or operations are conducted. A good example is expanding a facility or rearranging equipment layouts.
• Personnel: Changes to staffing or personnel roles, which could include new hires, staff reassignments or the introduction of new training programs. This ensures that workers are properly trained for any updated processes or equipment.

Agencies Involved With MOC Guidelines

For industries that handle hazardous chemicals or materials and need to ensure safety and regulatory compliance, MOC is essential to their day-to-day operations. As a result, it’s important to know the agencies that provide guidelines and enforce regulations for the MOC processes:

Environmental Protection Agency (EPA)

The EPA oversees regulations related to environmental protection. In industries dealing with hazardous materials, the EPA mandates MOC practices to prevent environmental hazards, such as chemical spills or emissions, that affect air, water or soil quality.

Occupational Safety and Health Administration (OSHA)

OSHA requires MOC under its Process Safety Management (PSM) standards, especially for industries that manage highly hazardous chemicals. OSHA’s MOC guidelines protect workers by ensuring that changes to equipment, procedures and operations are carefully evaluated to minimize risks.

Control of Major Accident Hazards Regulations (COMAH)

Applicable in the U.K., COMAH enforces MOC for industries that handle large quantities of dangerous substances. These regulations require MOC processes to be in place to reduce the risk of major accidents, ensuring safety for workers, the public and the environment.

Overall, these agencies help ensure that MOC practices are systematically applied to manage risks associated with changes in hazardous environments, protecting both workers and the public.

The MOC Process, Defined

What steps are needed to reduce risks and improve safety and efficiency, especially during a transformational change? Here are the basic steps involved in the MOC process:

1. Consider all possible outcomes, hazards and risks: Identify potential risks, hazards and unintended consequences of proposed changes. Assess if these risks can be minimized or avoided through any adjustments or additional safety measures.
2. Ensure the change is possible: Verify that any proposed change efforts are feasible within the current operational, technical and regulatory constraints. You should also ensure that resources, equipment and expertise are available to support the change.
3. Conduct a pre-safety startup review: Before implementing any change, perform a thorough safety review. This includes checking that all safety measures are in place, equipment is ready and procedures are clear to avoid accidents or malfunctions during startup.
4. Implement the change: Execute the approved changes, making sure all necessary steps are being followed according to the established MOC plan. This might include modifying equipment, adjusting procedures or altering the physical workspace.
5. Train all employees: Ensure all employees involved in or affected by the change are trained on new procedures, safety protocols and equipment operations. This training is critical when it comes to preventing confusion and ensuring smooth transitions.
6. Continue to evaluate the change and make adjustments: After the change has been implemented, regularly monitor and evaluate its effectiveness. Make any necessary adjustments to address unforeseen issues or improve the process, ensuring long-term success and safety.

How to Implement MOC Effectively  

Your MOC process will become more efficient, transparent and safer for everyone involved if you address these key factors into the process of change:

Consider All Perspectives of the Change

Engage stakeholders from various departments (engineering, operations, safety and management) to ensure a comprehensive understanding of how the change will impact the organization. This holistic view will help you identify potential impacts, opportunities and best practices.

Prioritize Employee Opinions & Safety

Since employees are often the first to experience the effects of any change, involve employees in the MOC process. Make sure you address their concerns and prioritize their safety throughout the transition. Getting this type of buy-in from the workforce leads to smoother implementation and fewer issues during any changes.

Use Digital Tools & Software

By using tools like a computerized maintenance management system (CMMS), you can help streamline the process. A CMMS will help track changes, assign tasks and ensure that procedures are followed consistently and correctly. Digital maintenance management systems also make it easier to document and review the entire process and any metrics you put in place, which improves accountability and compliance.

MOC Use Case Example

In the early 2000s, BP, the multinational oil and gas company headquartered in London, implemented a Safety and Operational Risk (S&OR) system to address potential risks in its North Sea oil and gas operations. The new system involved creating comprehensive risk assessment processes, safety procedures and real-time monitoring tools to improve safety and operational performance. The system involved these key steps:

• Assessment and planning:
  • Risk assessment: BP identified potential safety and operational risks related to its North Sea operations and developed a detailed risk assessment plan to address them.
  • Stakeholder engagement: BP consulted with key stakeholders, including management, engineers and workers, to ensure that the new system would meet operational needs while maintaining high safety standards.
• Implementation:
  • Pilot testing: The S&OR system was initially tested in a few key operational areas to ensure it functioned as intended. This pilot allowed BP to make necessary adjustments before a full-scale rollout.
  • Training: Employees were trained on the new risk assessment processes, safety procedures and real-time monitoring tools to ensure they understood how to operate under the new system.
• Monitoring and review:
  • Continuous monitoring: BP implemented real-time monitoring tools that continuously tracked operational risks and safety performance, allowing immediate response to potential issues.
  • Feedback loops: Feedback from employees and monitoring data was regularly reviewed to identify areas for improvement in the system.
• Adjustment and optimization:
  • Iterative improvements: Based on feedback and data, BP made iterative adjustments to optimize the S&OR system, continuously refining its processes to further improve safety performance as part of its change management strategy.

The implementation of the S&OR system, supported by a well-structured MOC process, significantly improved BP’s safety performance in the North Sea. The systematic risk management approach helped BP effectively manage the transition to the new system, reducing the risk of safety incidents and minimizing operational disruptions.

Using a CMMS to Implement MOC

A CMMS like Coast can significantly streamline your MOC process by automating and organizing key aspects of asset management and equipment maintenance. Here are just a few ways that a CMMS can assist you with implementation:

Asset Management

A CMMS helps you track and manage all equipment and assets within your business. When changes are proposed, such as equipment upgrades or replacements, a CMMS provides a centralized database to monitor the status and performance of all assets, ensuring that decision-making is based on real-time data.

Preventive Maintenance Scheduling

A CMMS simplifies preventive maintenance by automatically scheduling preventive maintenance tasks for equipment undergoing changes. This ensures that the equipment is properly maintained during the transition period, reducing the likelihood of breakdowns and ensuring compliance with safety standards.

Asset Tracking

A CMMS enables detailed asset tracking, allowing you to document and monitor any changes made to machinery, including upgrades, replacements or relocations. This helps ensure that the new equipment is integrated smoothly into your operations, with a clear record of changes.

Reporting & Analytics

Most CMMS solutions provide robust reporting and analytics features, which allow you to assess the impact of the changes on operational performance. By generating detailed reports, you can track safety improvements, cost savings and equipment efficiency after the MOC process is implemented.

How Does Coast Stand Out From Other CMMS Software?

There are a few ways that Coast sets itself apart from other CMMS software solutions. These include:

• Having a user-friendly interface: Coast offers a highly intuitive and easy-to-use platform, making it accessible for teams with varying technical expertise. This helps ensure that all staff can effectively use the software to manage MOC processes.
• Being highly mobile: Unlike several alternative CMMS platforms, Coast is fully mobile, allowing users to access the system from anywhere through Coast’s app. This feature is particularly useful for real-time updates and tracking during MOC implementation.
• Offering collaborative features: Coast includes collaboration tools that make it easy for cross-functional teams to work together during the MOC process. Engineers, safety managers and maintenance teams can communicate and share updates directly within the platform, streamlining the process.
• Providing completely customizable options: Coast offers customizable workflows and reporting features, allowing organizations to tailor the system to their specific MOC requirements and industry standards.

By using a CMMS like Coast, organizations can more effectively manage the technical aspects of the MOC process, ensuring that changes are systematically planned, implemented and tracked for optimal safety and efficiency.