MCP Consulting Group Ltd. is supporting Sembcorp in 5S Theory. In 2018 they started on The AMIS Journey – this forms part of a bigger Maintenance Improvement Programme, which is still being implemented.

Sembcorp Energy UK generates and supplies energy to major industrial firms at the Wilton International manufacturing site on Teesside.

Focus on maintenance

Sembcorp has a large maintenance function on-site at Castleton Court made up of various workshops and offices, ranging from Electrical / Instrumentation through to Mechanical and Fabrication. 

As a result of this work, Sembcorp wanted to know how they can bring order to the maintenance function and other areas through operational changes and better organisation. The obvious choice was to introduce and follow the 5S process.

The theory of 5S

Originating from Japan, the philosophy of 5S represents a way of focusing and thinking in order to better organise and manage the workspace. The 5S stands for two sets of words: one in Japanese seiri (整理), seiton (整頓), seisō (清掃), seiketsu (清潔), and shitsuke (躾). These translate ‘Sort’, ‘Set In order’, ‘Shine’, ‘Standardise’ and ‘Sustain’.

The initial interest came from a 5S presentation to Steve and his supervisors by Dave Fishwick, Consultant and Trainer. This was so well received that it generated further discussions in what 5S could deliver and offer the Sembcorp team. 

The best way to learn

The best way to help this understanding is to visit a site where 5S is already in place and embedded within a maintenance working environment. Knowing this, Dave organised a visit to Nestlé‘s factory in Dalston Carlisle.

Seeing first hand how a similar organisation benefits from 5S is a more reliable way to learn, it is also a very effective way to transfer practical knowledge from one team to another.

The Sembcorp team – made up of a lead sponsor (Dave), the Manager (Steve) and a team of technicians and supervisors – visited the site came back with lots of ideas.

Many of which they are already implementing. For instance, a weekly meeting is in place. The 5S team report back actions and update the planner with actions and assign these to individuals from the team, including the management!

Dave said, “The visit was so successful – the plan moving forward is for more staff to visit Nestlé”.

Find out more about 5S and The AMIS Journey, please call 0121 506 9032 or email

About Dave Porrill, Principal Consultant

Eleven years in the South African Breweries followed by thirteen years in the pharmaceutical industry, three years in the sugar industry and then one year in the biofuels industry. Dave primary responsibility is to grow the maintenance consulting business in the UK and internationally.

Daves specialist skills are in the field of production equipment maintenance and reliability strategies and systems within the FMCG environment. His international consulting prowess is across multiple geographies, by assisting sites to improve all aspects of maintenance and reliability processes and systems, including CMMS implementation and use. Experienced in TPM programme implementation, World Class Manufacturing systems and processes, and modern training and development techniques.