Repairing Smarter: 5S System Saves RUB 44 Million at Zhigulevskaya Hydropower Plant
RusHydro is applying modern optimization methods across its operations. By combining the 5S workplace organization system with AI-driven algorithms, the company significantly reduced the duration of a major overhaul of a generating unit at the Zhigulevskaya Hydropower Plant.
In June 2026, at the IN'HUB Innovation and Productivity Week, RusHydro presented a project that optimized the major overhaul of generating unit No. 16 at the Zhigulevskaya Hydropower Plant. The project was implemented using the 5S system, one of the core principles of lean manufacturing, encompassing workplace sorting, organization, cleanliness, standardization and continuous improvement.
Artificial intelligence played a key role in implementing the project. The system analyzed the required operational data and developed both the optimal workplace layout and the workflow sequence for carrying out the overhaul.
As a result, the overhaul schedule was reduced from 406 days to 370 days. AI algorithms eliminated time losses throughout the process. For example, locating the required tool now takes just 30 seconds instead of 300. Work crew authorization has been reduced from 50 minutes to 15 minutes, while the walk to the designated rest area now takes only one minute instead of 15. Deploying AI generated not only time savings but also measurable financial benefits. The optimization delivered an economic impact of RUB 44.3 million (approximately USD 560,000). Shorter overhaul periods also improve the reliability of electricity supply by returning generating equipment to service sooner.
From a Pilot Project to a Systemwide Approach
The experience gained through the pilot project will now be expanded. Deployment will begin at the Zhigulevskaya Hydropower Plant itself, where the overhaul program extends through 2034. The same practices will subsequently be introduced at other RusHydro generating facilities.
The initiative goes well beyond deploying standalone algorithms. Instead, the new capabilities will be integrated with the company's existing digital tools, including maintenance planning software, electronic work instructions, predictive diagnostic systems and digital twins of generating facilities. That integration will make it possible to manage the entire overhaul process, from equipment diagnostics and procurement of required materials through testing and the unit's return to commercial operation.
The Road to Digital Transformation
The project at the Zhigulevskaya Hydropower Plant forms part of RusHydro's digital transformation strategy, originally approved in 2021. The strategy was updated in 2022, with its primary objective defined as improving the company's operational efficiency while maintaining equipment safety and reliability. The document was revised again in 2024 as RusHydro continued developing approaches for deploying digital technologies and optimizing internal business processes.
Efficiency as a Strategic Trend
The Zhigulevskaya Hydropower Plant project demonstrates that significant economic gains come not only from equipment modernization and repair activities. Comparable benefits can also be achieved by optimizing production processes through the extensive use of artificial intelligence.
Over the next several years, projects of this type are expected to become a key element of integrated maintenance optimization across RusHydro's generating fleet. By combining lean manufacturing principles with digital technologies, the company aims to accelerate the development of a more efficient and resilient power infrastructure.
