Contents

Abstract: .................................................................................................................................................. 2
Plant Introduction: .................................................................................................................................. 2
What is 5S ............................................................................................................................................... 3
Section 1: Sort - Eliminating Unnecessary Items .................................................................................... 3
1.1. Identification of Unnecessary Items: ........................................................................................... 3
1.2. Benefits of Sorting: ...................................................................................................................... 3
1.3. Challenges Faced:......................................................................................................................... 3
Section 2: Straighten - Organizing for Efficiency..................................................................................... 4
2.1. Shelving and Number Tags:.......................................................................................................... 4
2.2. Software Integration - Excel and Maximo: .................................................................................. 4
2.2. Benefits of Software Integration: ................................................................................................ 5
2.4. Visual Management: .................................................................................................................... 5
2.5. Benefits of Straighten: ................................................................................................................. 5
Section 3: Shine - Maintaining Cleanliness and Order ............................................................................ 6
3.1. Routine Cleaning and Maintenance:............................................................................................ 6
3.2. Equipment and Facility Inspection: .............................................................................................. 6
3.3. Employee Engagement: ............................................................................................................... 7
3.3. Benefits of Shine: ......................................................................................................................... 7
Section 4: Standardize - Establishing Consistent Procedures ................................................................. 7
4.1. Emphasis on Standardization: ...................................................................................................... 7
4.2. In-House Teams and Third-Party Involvement: ........................................................................... 7
4.3. Benefits of Standardization:......................................................................................................... 7
Section 5: Sustain - Ensuring Continual Improvement ........................................................................... 8
5.1. Role of the HSE Team: .................................................................................................................. 8
5.2. Health and Safety Environment (HSE) at Plant Site ..................................................................... 9
5.3. Hazards at Haveli Bahadur Shah 1230 MW CCPP ...................................................................... 10
5.4. Safety Measures Plant Site ........................................................................................................ 11
5.5. Portable Facilities ....................................................................................................................... 11
5.6. HSE Team's Authority for Salary Reduction Due to Safety Violations ....................................... 12
5.7. Safety Drills and Seminars:......................................................................................................... 12
5.8. Benefits of Sustain: .................................................................................................................... 12
References ............................................................................................................................................ 12
 Significance of 5S in My Internship at 1230MW CCPP Haveli Bahadur
Shah Power Plant

Abstract:
This assignment explores the profound significance of the 5S methodology in the context of an
internship conducted at the 1230MW Haveli Bahadur Shah Power Plant. The 5S methodology,
encompassing Sort, Set in order, Shine, Standardize, and Sustain, stands as a cornerstone of
workplace organization and efficiency improvement. This document delves into the principles
and applications of 5S within the power plant, shedding light on how it transformed workspaces
and operational processes. Furthermore, it elucidates the far-reaching impacts of 5S, from
enhancing safety protocols to bolstering efficiency metrics. The assignment also emphasizes
personal growth and learning through the internship, providing recommendations for future
implementations of 5S. Ultimately, it underscores the enduring importance of the 5S
methodology in industrial environments, particularly within the dynamic and energy-intensive
realm of power generation.

Plant Introduction:
The plant is located 23 Kilometer away from Jhang on Multan-Jhang Road named after the
small city near the site as Haveli Bahadur Shah. Plant is constructed by SEPCOIII which well-
known Chinese leading power production company under the NPPMCL in (National Power
Perks Management Company Limited) Pakistan in 2017. The Maximum rated Capacity of
Plant is 1230 MW it is Combined Cycle Power Plant (CCPP) and majorly consists of three
turbines to produce above power.
There are two newly advanced GE 9HA.01 having each rated power production of 408 MW at
25-degree Celsius ambient temperature Gas Turbines and one Steam Turbine of capacity 414
MW working under the Combined Cycle Power Plant Mechanism. The plant uses fuels of both
types R-LNG (Regassified Liquified Natural Gas) and HSD (High Speed Diesel). Plant is kept
the name as SEPCOIII 1230 MW Haveli Bahadur Shah power plant CCPP.
The main power house of the plant consists of two Gas Turbines called as GT1 and GT2 and
one Steam Turbine.

SEPCOIII
1230MW
HBS CCPP

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What is 5S
The 5S Method is a standardized process that when properly implemented creates and
maintains an organized, safe, clean and efficient workplace. Improved visual controls are
implemented as part of 5S to make any process non-conformance’s obvious and easily
detectable. The acronym 5S is made up of the following five Japanese words that represent the
method of organising the workplace (English translations are provided in parenthesis) [1]:
1. Seiri (Sort): Separating of the essential from the nonessential items
2. Seiton (Straighten): Organizing the essential materials where everything has its place
3. Seiso (Shine): Cleaning the work area
4. Seiketsu (Standardize): Establishing a system to maintain and make 5S a habit
5. Shitsuke (Sustain): Establishing a safe and sanitary work environment (Safety)

Section 1: Sort - Eliminating Unnecessary Items

The first step in the 5S methodology is "Sort." It involves the systematic identification and
removal of unnecessary items, equipment, or materials from the workplace. During my
internship at the Haveli Bahadur Shah Power Plant, the application of Sort was a fundamental
practice that had a profound impact on the efficiency and organization of various operational
areas.
1.1. Identification of Unnecessary Items:
In the power plant environment, equipment and materials are constantly in use, and over time,
it's easy for unused or redundant items to accumulate. The Sort phase necessitated a meticulous
examination of work areas, storage spaces, and equipment to identify items that were no longer
essential for ongoing operations. This process was not limited to physical items; it also included
digital records, documentation, and files.
1.2. Benefits of Sorting:
The implementation of Sort yielded several significant benefits:
• Space Optimization: By removing unnecessary items, valuable floor space was
reclaimed, allowing for better organization and improved workflow. This was
particularly crucial in areas with limited space, such as control rooms and storage
facilities.
• Reduced Clutter: The elimination of unused items reduced clutter and enhanced visual
management. This made it easier for operators and technicians to quickly locate tools,
equipment, and materials, contributing to time savings and reduced downtime.
• Enhanced Safety: A clutter-free workspace is inherently safer. Removing obstacles
and unnecessary items reduced the risk of accidents and improved overall safety
records.
• Improved Asset Management: The Sort phase also involved the identification of
obsolete or outdated equipment. This allowed for more efficient asset management,
including equipment maintenance and replacement planning.

1.3. Challenges Faced:

During my internship, a significant challenge arose when tasked with identifying and
separating special equipment for the Major Inspection of the 9HA.01 Gas turbine. The absence

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of a systematic sorting and proper placement system made it difficult to locate these vital tools,
occasionally causing delays in inspection processes. This highlighted the need for improved
organization through the 5S methodology, emphasizing the importance of efficient storage
systems for critical maintenance tasks.
The Sort phase at Haveli Bahadur Shah Power Plant represented the initial step in the journey
towards a more organized and efficient workplace. It laid the foundation for subsequent phases,
ensuring that the workplace was free from unnecessary clutter and distractions. As a result, it
facilitated smoother and more streamlined operations, ultimately contributing to the power
plant's overall success.

Section 2: Straighten - Organizing for Efficiency

The "Straighten" phase of the 5S methodology focuses on organizing items and workspaces to
maximize efficiency and productivity. During my internship at the 1220MW Haveli Bahadur
Shah Power Plant, I observed that this phase was already a fundamental practice in various
areas of the power plant.
2.1. Shelving and Number Tags:
One of the most noticeable aspects of Set in Order in the inventory store was the use of shelves
and number tags. Each item had its designated location on the shelves, and these locations were
clearly labelled with number tags. This system allowed for quick and precise identification of
tools and equipment.
Benefits of Shelving and Number Tags:
• Efficient Retrieval: With a designated location for each item and clear
labelling, employees could easily locate and retrieve tools and equipment. This
resulted in significant time savings, especially during maintenance and repair
tasks.
• Reduced Errors: The use of number tags reduced the chances of misplacing
items or confusion regarding their locations. This contributed to higher accuracy
in inventory management.
• Visual Management: The organized shelves and number tags created a visually
appealing and intuitive system. It allowed employees to visually verify that all
items were in their designated locations, simplifying inventory checks and
audits.

2.2. Software Integration - Excel and Maximo:

In addition to physical organization, the power plant leveraged software solutions like Excel
and Maximo for more efficient equipment management.
• Excel: Excel spreadsheets were used to maintain digital records of inventory. Each
item's details, including its name, quantity, location (shelf number), and maintenance
history, were meticulously recorded. This digital record-keeping ensured that inventory
data was up-to-date and easily accessible.
• Maximo Software: Maximo, a robust enterprise asset management software, played a
crucial role in tracking the lifecycle of tools and equipment. It allowed for
comprehensive asset tracking, maintenance scheduling, and performance analysis.

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 Maximo's integration with barcode scanning further expedited the check-in and check-
out process, reducing the likelihood of errors.

2.2. Benefits of Software Integration:

The integration of Excel and Maximo software brought about several advantages:
• Real-time Tracking: Maximo provided real-time visibility into the status and location
of equipment. This was invaluable for maintenance planning, ensuring that tools were
available when needed.
• Historical Data: The software maintained a historical record of maintenance activities,
which proved valuable for predictive maintenance planning and performance analysis.
• Streamlined Procurement: Accurate inventory data allowed for better procurement
planning. The power plant could order replacements or new tools precisely when
needed, reducing excess inventory.

The Set in Order phase, as implemented in the inventory store, exemplified how the
combination of physical organization and digital tools could significantly enhance operational
efficiency. It ensured that tools and equipment were readily available, reducing downtime and
contributing to the overall reliability of the power plant's operations. This approach also
emphasized the importance of integrating technology to streamline inventory management and
asset tracking.

2.4. Visual Management:

As part of the Straighten phase, the power plant had implemented various visual management
techniques. Color-coding, labelling, and clear signage were already in place to make it easier
for employees to identify and locate items. For example, tools and equipment were color-coded
based on their function, allowing for easy differentiation at a glance.
2.5. Benefits of Straighten:
The proactive implementation of the Straighten phase had already provided numerous benefits:
• Improved Efficiency: The well-optimized layout and organization minimized wasted
time and effort, resulting in increased operational efficiency.
• Enhanced Productivity: Employees could focus on their tasks instead of searching for
tools or materials, leading to higher productivity levels.
• Reduced Errors: Standardized procedures and visual cues had already reduced the
likelihood of errors and mistakes in equipment selection or placement.
• Safety: The power plant's commitment to a well-organized workspace had enhanced
safety by reducing the risk of accidents and injuries.

The Haveli Bahadur Shah Power Plant's dedication to efficient organization and workspace
optimization reflected a proactive approach that aligned perfectly with the principles of the 5S
methodology. It showcased the transformative impact of already well-implemented 5S
practices, emphasizing the significance of maintaining a structured and efficient work
environment.

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Section 3: Shine - Maintaining Cleanliness and Order
The "Shine" phase of the 5S methodology emphasizes the importance of cleanliness and
ongoing maintenance in the workplace. At the Haveli Bahadur Shah Power Plant, this phase
played a crucial role in ensuring a safe, efficient, and reliable operation. Notably, the
commitment to cleanliness, particularly observed among the Chinese personnel, exemplified
the power plant's dedication to this phase.

Figure 1: HBS Power plant

3.1. Routine Cleaning and Maintenance:

Throughout my internship, I observed the diligent implementation of the Shine phase in various
areas of the power plant. Regular cleaning schedules were established, and teams were
responsible for ensuring that all equipment, workspaces, and common areas were kept clean
and well-maintained. This rigorous maintenance not only enhanced the visual appeal of the
facility but also had several critical benefits:
• Safety: A clean and well-maintained workplace is inherently safer. It reduces the risk
of accidents, slips, and falls, which can be particularly hazardous in an industrial setting.
• Preventative Maintenance: Routine cleaning and inspections helped identify wear
and tear on equipment or infrastructure early, enabling timely maintenance and
preventing costly breakdowns.
• Improved Efficiency: Clean and organized workspaces contributed to improved
operational efficiency. Workers could move more freely, access tools easily, and
perform tasks without unnecessary hindrances.

3.2. Equipment and Facility Inspection:

As part of the Shine phase, regular equipment and facility inspections were carried out. This
involved not only cleaning but also checking for any signs of wear, corrosion, or damage. Any
issues discovered during these inspections were promptly addressed to ensure the continued
reliability of the power plant's operations.

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3.3. Employee Engagement:
One noteworthy aspect of the Shine phase at the power plant was the emphasis on employee
engagement. Workers, including the Chinese personnel, were highly committed to maintaining
a clean and orderly workplace. This commitment set a positive example for all team members
and fostered a culture of cleanliness and responsibility.
3.3. Benefits of Shine:
The Shine phase, as practiced at the Haveli Bahadur Shah Power Plant, delivered several
notable advantages:
• Enhanced Safety: By eliminating hazards and maintaining equipment, the power plant
significantly reduced the risk of accidents and injuries.
• Cost Savings: Timely maintenance and the prevention of breakdowns led to cost
savings by reducing the need for expensive emergency repairs.
• Operational Efficiency: Clean and organized workspaces promoted efficiency,
reducing downtime and enhancing overall productivity.
• Positive Work Environment: The commitment to cleanliness, especially among the
Chinese personnel, contributed to a positive work environment, boosting employee
morale and productivity.

The strict adherence to cleanliness standards, particularly among the Chinese personnel,
demonstrated the universal importance of a clean and well-organized work environment in the
power generation industry. It underscored that cleanliness is not just a matter of aesthetics but
a fundamental practice that contributes to safety, efficiency, and overall operational success.
This observation reinforced the significance of the Shine phase of the 5S methodology and its
enduring impact on the power plant's operations and culture.

Section 4: Standardize - Establishing Consistent Procedures

The "Standardize" phase of the 4S methodology revolves around creating and implementing
standardized procedures and processes in the workplace. At the Haveli Bahadur Shah Power
Plant, the importance of standardization was underscored by the O&M contract ownership of
globally reputable companies like GE and Siemens.
4.1. Emphasis on Standardization:
Throughout my internship, it was evident that GE and Siemens, renowned companies with a
global presence, never compromised on standardization. This commitment to consistent
procedures and practices was particularly pronounced during inspections and maintenance
activities.
4.2. In-House Teams and Third-Party Involvement:
One noteworthy aspect of the Standardize phase was the clear distinction between in-house
teams and third-party involvement. While the power plant had its dedicated teams for
inspections and maintenance, there was also a strong reliance on third-party specialists to
ensure impartial assessments and compliance with international standards.
4.3. Benefits of Standardization:
The adherence to standardized procedures and the involvement of reputable companies had
several significant benefits:

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 • Reliability: Standardized procedures ensured that inspections and maintenance
activities were conducted with a high level of reliability and consistency, reducing the
margin for error.
• Compliance: The involvement of globally recognized companies like GE and Siemens
ensured compliance with international standards and best practices, instilling
confidence in the reliability and safety of power plant operations.
• Efficiency: Standardization led to streamlined processes, enabling more efficient
inspections and maintenance activities, ultimately reducing downtime and operational
disruptions.
• Accountability: The clear distinction between in-house teams and third-party
specialists provided accountability and transparency in the inspection and maintenance
processes.

The commitment to standardization by companies like GE and Siemens, as witnessed at the

Haveli Bahadur Shah Power Plant, exemplified the importance of consistent procedures and
practices in the power generation industry. It demonstrated that standardization is not only a
matter of efficiency but also a fundamental aspect of safety, compliance, and operational
excellence. This commitment further emphasized the significance of the Standardize phase of
the 4S methodology, highlighting its enduring impact on ensuring the reliable and safe
operation of the power plant.

Section 5: Sustain - Ensuring Continual Improvement

The "Sustain" phase of the 5S methodology focuses on maintaining the improvements achieved
through the previous four phases—Sort, Set in Order, Shine, and Standardize. In the context of
your internship at the Haveli Bahadur Shah Power Plant, the contributions of the HSE team
were instrumental in fostering a culture of safety and continuous improvement.
5.1. Role of the HSE Team:
During my internship, I observed that the HSE team at the power plant played a pivotal role in
ensuring the sustainability of the 5S principles and promoting a culture of safety and safe
procedures. Their contributions were evident in several key areas:
• Safety Training: The HSE team conducted regular safety training sessions for all
employees, emphasizing the importance of adhering to 5S principles and safe work
practices. These sessions were particularly impactful during the first two days of my
internship when they provided a comprehensive briefing on plant safety and
precautions. During this period, they also issued Personal Protective Equipment (PPE)
to ensure that all employees were equipped for safe operations.
• Audits and Inspections: The HSE team conducted routine audits and inspections to
assess the implementation of 5S principles and identify areas that required
improvement. These audits served as a feedback mechanism, driving continuous
improvement efforts.
• Incident Reporting: The HSE team managed incident reporting and investigation
processes. They ensured that any safety concerns or incidents were promptly addressed,
and corrective actions were taken to prevent recurrences.

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5.2. Health and Safety Environment (HSE) at Plant Site
In P the HSE is kept at the top priorities and certified with ISO 45001. Health and safety of
every person is very important not only for himself but also a whole family is attached with
him. Let’s Discuss how the health and safety is assured at Haveli Bahadur Shah 1230 MW
CCPP.
HSE team is a compliance team of Plant having responsibility of health of and safety of
everyone at Haveli Bahadur Shah 1230 MW CCPP. Here are the responsibilities of HSE
officers at plant site
• No Violation
• Compliance of Management Responsibilities
• Ensures Human Safety

Here at Haveli Bahadur Shah 1230 MW CCPP the proper response team and different methods
are in use to ensure safety. Some of observed are listed here
✓ Placed importance of health quotes on ✓ Placed methods of using Fire
walls extinguishers.

✓ Placed boards of safety theories like 4C’s method

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 ✓ Placed small boards to remind the workers to wear Hamlet, Safety shoes etc.

✓ Placed boards of possible hazards in each section or station of the plant so that
employs to take possible measures for health and safety accordingly.

5.3. Hazards at Haveli Bahadur Shah 1230 MW CCPP

In all over the world every industry or plant has different types of hazards which varies based
on the mechanisms or machines which are in use in each industry. Here is the list of possible
hazards at Haveli Bahadur Shah 1230 MW CCPP.
• Fire
• Electric Short (Possibly at Switch Yard of 500 KV)
• Oil and Chemical Spillage (at HSD Station and in Turbines)
• Steam Spillage (In Gas Turbine and Boilers)
• Gas Hazards (In RLNG Station and Steam Turbine)
• Equipment Handling
• Fall from Hight
• House Keeping
• Noise

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5.4. Safety Measures Plant Site
In this plant the both portable and fixed measures are in use.
Fixed systems
✓ Fire Fighting sprinkler system ✓ Indore Boxes

5.5. Portable Facilities

Fire Fighting Truck
Fire Fighting Truck Contains Fallowing Firefighting chemicals
• DCP
• AFFF
• 𝐶𝑂2

✓ Fire Fighting truck ✓ Ambulance

Also, at plant site a Ambulance is available for 24 hours/ day in case any injury to take patients
into nearest Hospital.

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5.6. HSE Team's Authority for Salary Reduction Due to Safety Violations
At the Haveli Bahadur Shah Power Plant, the HSE (Health, Safety, and Environment) team
held the authority to enforce safety rules and precautions rigorously. In cases where individuals
were found neglecting safety guidelines, the HSE team could impose salary reductions,
typically as a percentage cut. This policy emphasized the power plant's unwavering
commitment to safety and served as a strong incentive for compliance while acting as a
deterrent against unsafe practices. It highlighted safety as a fundamental core value, ensuring
a culture of safety and well-being throughout the power plant's operations.
5.7. Safety Drills and Seminars:
During my internship, I also had the privilege of participating in several safety drills and
seminars conducted by the HSE team. These events provided valuable hands-on experience in
responding to emergency situations and further reinforced the importance of health and safety
in power plant operations. The seminars covered a wide range of topics, including fire safety,
first aid, and hazard recognition.
5.8. Benefits of Sustain:
The Sustain phase, with the active involvement of the HSE team and comprehensive safety
training, yielded several significant benefits:
• Long-Term Safety: By continually reinforcing safety practices and the 5S principles,
the power plant maintained a long-term commitment to the safety and well-being of its
workforce.
• Operational Excellence: The culture of continual improvement led to enhanced
operational excellence, resulting in increased reliability, efficiency, and productivity.
• Adaptation to Change: The power plant remained adaptable to changes in technology,
regulations, and industry best practices, ensuring that it stayed at the forefront of the
power generation field.
• Employee Engagement: Employees, including interns, were actively engaged in the
process of improvement, fostering a sense of ownership and responsibility for their
work environment and safety.

The contributions of the HSE team, including safety training, drills, and seminars, at the Haveli
Bahadur Shah Power Plant showcased the significance of the Sustain phase of the 5S
methodology. They demonstrated that the journey toward excellence and safety is an ongoing
one, requiring dedication, vigilance, and a commitment to continual improvement. This phase
emphasized the enduring importance of the 5S principles in maintaining a safe, efficient, and
reliable power generation facility.

References

[1] B. Chandrayan, A. K. Solanki, and R. Sharma, “Study of 5S lean technique: A review paper,”
International Journal of Productivity and Quality Management, vol. 26, no. 4, pp. 469–491,
2019, doi: 10.1504/IJPQM.2019.099625.

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