5S in Maintenance

5S in Maintenance – The First Step Towards a stable and efficient factory

In many companies, 5S is implemented in the production area, but 5S principles must also be implemented in the maintenance department. Maintenance is the engine behind equipment availability, and order, standardization and discipline are essential for fast, risk-free and improvisation-free interventions.

5S isn't just about "cleaning" — it's a way of working that allows maintenance teams to react faster, prevent failures, and reduce downtime.

How we apply 5S in maintenance:

1. SEIRI – Sorting: Removing everything that is useless

The first step of 5S involves separating essential tools, parts, and materials from those that don't add value. In maintenance, sorting means:

• Disposal of broken, worn or unnecessary duplicate tools
• Separation of expired or incomplete consumables
• Clarifying the actual stock of spare parts and eliminating those that are no longer needed
• Identifying rarely used equipment and moving it to secondary areas

Sorting creates a solid foundation for quick interventions and avoids times when we can't find a tool or it doesn't work.

2. SEITON – Ordering: "To every thing has a place, and every thing is in its place"

An effective intervention starts with quick access to the right tools. Seiton focuses on the visual and logical organization of the maintenance area:

• Shadow boards
• Clear labels for tools, drawers and cabinets, opis
• Standardised intervention trolleys
• Spare parts organized according to criticality
• Logical access routes and clearly marked areas

When a technician can find a tool in less than 10 seconds, intervention times are significantly reduced.

3. SEISO – Cleaning and Visual Inspection

For maintenance, Seiso is not just about "cleaning". Cleanliness becomes an inspection tool:

• Identifying leaks, vibrations, wear or damaged cables
• Cleaning of electrical panels and measuring equipment
• Disposal of flammable or hazardous residues
• Keeping the workshop in impeccable condition

Preventive cleaning allows anomalies to be detected before they lead to major shutdowns — which reduces costs and increases reliability.

4. SEIKETSU – Standardization: Clear rules, the same for everyone

A high-performance maintenance department has clear, visual, and easy-to-follow procedures. Standardization involves:

• Short and visual instructions for joint interventions
• Standard checklists for preventive maintenance
• Color coding for tools, utilities and equipment
• Visible preventive maintenance program
• Unique format for labels, messages, and boards

Standardization reduces variation between technicians and ensures uniform executions, no matter who is on duty.

5. SHITSUKE – Maintenance and continuous improvement

Shitsuke in maintenance means:

• Regular 5S audits with clear corrective actions
• Tools put back in place immediately after use
• Areas left clean after interventions
• Compliance with procedures and standards
• Involving technicians in continuous improvement

In conclusion, 5S in maintenance is not just an improvement project, but it is a fundamental strategy for increasing reliability.
When tools are in place, when procedures are clear and followed, the work area is organized and clean, then technicians can focus on what really matters: keeping equipment working and preventing breakdowns.

A maintenance company with a strong 5S culture becomes a strategic partner of production, not just a support department. The 5S can be seen and represents the mirror of management.