Implementation of 5S Methodology in an Aircraft Maintenance Training Hangar: A Case Study

Abstract

Aircraft maintenance training requires well-organized and standardized working environments to support safe, efficient, and high-quality practical training operations. The 5S methodology, one of the fundamental tools of lean management, provides a systematic approach for improving workplace organization, eliminating unnecessary materials, supporting standardized storage practices, and maintaining sustainable working standards. This case study presents the planning and implementation of the 5S methodology in an aircraft maintenance training hangar at İskenderun Technical University. The implementation process involved a comprehensive workplace assessment, inventory identification, material classification, workplace organization, cleaning, labeling, standardization, and the establishment of procedures to ensure sustainability. A detailed implementation plan was developed and applied throughout the training hangar to improve the organization of tools, equipment, spare parts, and maintenance areas. The implementation stages and the resulting workplace improvements were systematically documented using inventory records and before-and-after photographs. The implementation resulted in a more organized workplace layout, standardized storage locations, improved inventory documentation, and clearer identification of tools, equipment, and spare parts throughout the training environment. The documented implementation process provides a practical reference for universities and vocational institutions seeking to establish organized, standardized, and sustainable aircraft maintenance training facilities through the practical application of lean management principles.

Keywords

• Aircraft maintenance training
• 5S methodology
• Lean management
• Workplace organization
• Standardization
• Aircraft maintenance

Ethical Statement

Ethics committee approval was not required for this study because it did not involve human participants or animals.

References

1. Blicharska, M., Szmaglik, I., Szulc, O., Murawski, L., Szeleziński, A., & Jasiński, K. (2025). Analysis of the process of implementing the 5S method at ZPS “Lubiana” S.A. Scientific Journal of Gdynia Maritime University, (134), 7-26. https://doi.org/10.26408/134.01
2. Dela Peña, A., Rutao, M., & Ganal, M. A. (2025). Evaluating lean implementation and its operational impact in Philippine aviation MRO: A mixed-methods case study approach. Emerging Technologies and Engineering Journal, 2(2), 35-56. https://doi.org/10.53898/etej2025223
3. Gupta, S., & Chandna, P. (2020). A case study concerning the 5S lean technique in a scientific equipment manufacturing company. Grey Systems: Theory and Application, 10(3), 339-357. https://doi.org/10.1108/GS-01-2020-0004
4. Gupta, S., & Jain, S. K. (2015). An application of 5S concept to organize the workplace at a scientific instruments manufacturing company. International Journal of Lean Six Sigma, 6(1), 73-88. https://doi.org/10.1108/IJLSS-08-2013-0047
5. Ismara, K. I., & Prianto, E. (2020). Safety education management in welding robotic laboratory. Journal of Physics: Conference Series, 1446(1), 012061. https://doi.org/10.1088/1742-6596/1446/1/012061
6. Jiménez, M., Romero, L., Domínguez, M., & Espinosa, M. del M. (2015). 5S methodology implementation in the laboratories of an industrial engineering university school. Safety Science, 78, 163-172. https://doi.org/10.1016/j.ssci.2015.04.022
7. Kania, J., Hulek, D., Danko, P., & Novak, M. (2020). Organization of line maintenance hangar equipment. In 2020 New Trends in Aviation Development (NTAD) (pp. 127-130). IEEE. https://doi.org/10.1109/NTAD51447.2020.9379085
8. Keleş, A. E., Gürsoy, G., & Çelik, G. T. (2016). 5S sistematik aşamaları ve örnek bir uygulama [5S systematic steps and a sample application]. Çukurova Üniversitesi Mühendislik-Mimarlık Fakültesi Dergisi, 28(2), 51-60. https://izlik.org/JA97RE25LP

9. Kotwal, H. H., Pitroda, J. R., Patel, R. L., & Prajapati, J. D. (2025). Lean construction through 5S implementation: A review. International Journal of Scientific Research in Engineering and Management, 9(11), 1-9. https://doi.org/10.55041/IJSREM53843
10. Mazur, M., Korenko, M., Žitňák, M., Shchur, T., Kiełbasa, P., Dostál, P., Dzhidzhora, O., & Idzikowski, A. (2024). Implementation and benefits of the 5S method in improving workplace organisation - A case study. Management Systems in Production Engineering, 32(4), 498-507. https://doi.org/10.2478/mspe-2024-0047
11. Mohan Sharma, K., & Lata, S. (2018). Effectuation of lean tool “5S” on materials and work space efficiency in a copper wire drawing micro-scale industry in India. Materials Today: Proceedings, 5(2), 4678-4683. https://doi.org/10.1016/j.matpr.2017.12.039
12. Monnanyana, O., & Gupta, K. (2021). A case study on implementation of 5S in a manufacturing plant to improve operational effectiveness. MATEC Web of Conferences, 346, Article 03109. https://doi.org/10.1051/matecconf/202134603109
13. Mrugalska, B., Konieczna, M., & Wyrwicka, M. K. (2020). How to improve manufacturing process implementing 5S practices: A case study. In W. Karwowski, R. Goossens, & N. A. Stanton (Eds.), Advances in Human Factors and Systems Review (pp. 1225-1232). Springer. https://doi.org/10.1007/978-3-030-39512-4_187
14. Muotka, S., Togiani, A., & Varis, J. (2023). A design thinking approach: Applying 5S methodology effectively in an industrial work environment. Procedia CIRP, 119, 363-370. https://doi.org/10.1016/j.procir.2023.03.103
15. Oleksiak, B., Żyszczyński, M., & Micor, K. (2025). 5S method usage for the improvement of production process in the manufacturing company. Management Systems in Production Engineering, 33(3), 354-361. https://doi.org/10.2478/mspe-2025-0033
16. Rahman, M. N. A., Khamis, N. K., Zain, R. M., Deros, B. M., & Mahmood, W. H. W. (2010). Implementation of 5S practices in the manufacturing companies: A case study. American Journal of Applied Sciences, 7(8), 1182-1189. https://doi.org/10.3844/ajassp.2010.1182.1189
17. Randhawa, J. S., & Ahuja, I. S. (2017). Evaluating impact of 5S implementation on business performance. International Journal of Productivity and Performance Management, 66(7), 948-978. https://doi.org/10.1108/IJPPM-08-2016-0154
18. Rizkya, I., Syahputri, K., Sari, R. M., & Siregar, I. (2019). 5S implementation in welding workshop - A lean tool in waste minimization. IOP Conference Series: Materials Science and Engineering, 505(1), Article 012018. https://doi.org/10.1088/1757-899X/505/1/012018
19. Singh, J., Rastogi, V., & Sharma, R. (2014). Implementation of 5S practices: A review. Uncertain Supply Chain Management, 2(3), 155-162. https://doi.org/10.5267/j.uscm.2014.5.002
20. Siyaev, A., & Jo, G.-S. (2021). Towards Aircraft Maintenance Metaverse Using Speech Interactions with Virtual Objects in Mixed Reality. Sensors, 21(6), 2066. https://doi.org/10.3390/s21062066
21. Sremcev, N., Lazarevic, M., Krainovic, B., Mandic, J., & Medojevic, M. (2018). Improving teaching and learning process by applying Lean thinking. Procedia Manufacturing, 17, 595-602. https://doi.org/10.1016/J.PROMFG.2018.10.101
22. Suárez-Barraza, M. F., & Ramis-Pujol, J. (2012). An exploratory study of 5S: A multiple case study of multinational organizations in Mexico. Asian Journal on Quality, 13(1), 77-99. https://doi.org/10.1108/15982681211237842
23. Uma Maheshwari, V., Sridhar, G., Seema, V., Sivaraja, G., & Samuel Thavaraj, H. (2025). A study on implementation of 5’s in XYZ oil seal production company Madurai. World Journal of Advanced Research and Reviews, 26(2), 2240-2250. https://doi.org/10.30574/wjarr.2025.26.2.1241