Introduction

Advanced Lean Manufacturing Practitioner Training Course is designed to equip professionals with skills in Lean Six Sigma, Operational Excellence, Continuous Improvement, and Smart Manufacturing Systems. This course integrates globally recognized methodologies such as Kaizen, 5S, Value Stream Mapping (VSM), Just-In-Time (JIT), Total Productive Maintenance (TPM), and Digital Lean Transformation to help organizations eliminate waste, optimize productivity, and enhance end-to-end supply chain efficiency. Participants will gain hands-on expertise in implementing lean tools, process automation, and data-driven manufacturing strategies aligned with Industry 4.0 standards.

In today’s highly competitive industrial environment, organizations demand professionals who can drive cost reduction, process optimization, defect elimination, and productivity acceleration. This training focuses on developing advanced-level practitioners capable of leading lean transformation projects, smart factory implementation, and operational excellence initiatives across manufacturing sectors such as automotive, FMCG, pharmaceuticals, oil & gas, and heavy engineering. By combining practical simulations, case-based learning, and real-world applications, this program ensures mastery in lean leadership, performance optimization, and digital manufacturing excellence.

Programme Curriculum

Advanced Lean Manufacturing Practitioner Training Course

Introduction

Course Duration

10 days

Course Objectives

Master Lean Manufacturing Principles & Operational Excellence Frameworks
Implement Lean Six Sigma DMAIC Methodology for Process Improvement
Develop expertise in Value Stream Mapping (VSM) & Waste Elimination Strategies
Apply Kaizen Continuous Improvement Culture in Manufacturing Systems
Optimize production using Just-In-Time (JIT) & Pull System Techniques
Enhance efficiency through Total Productive Maintenance (TPM) Implementation
Integrate Industry 4.0 Smart Manufacturing Technologies
Reduce defects using Root Cause Analysis (RCA) & 5 Whys Technique
Improve workflow with 5S Workplace Organization System
Build capability in Lean Supply Chain & Inventory Optimization
Strengthen decision-making using Data-Driven Manufacturing Analytics
Lead Lean Transformation & Change Management Initiatives
Achieve excellence in Cost Reduction & Productivity Enhancement Strategies

Target Audience

Manufacturing Engineers & Production Supervisors
Industrial & Mechanical Engineers
Quality Assurance & Quality Control Professionals
Operations & Plant Managers
Supply Chain & Logistics Managers
Lean Six Sigma Green/Black Belt Aspirants
Process Improvement & Continuous Improvement Teams
Engineering Graduates seeking Lean Manufacturing Careers

Course Modules

Module 1: Fundamentals of Lean Manufacturing

Lean philosophy and evolution
Types of manufacturing waste (Muda, Mura, Muri)
Lean vs Traditional systems
Customer value identification
Process efficiency basics
Case Study: Toyota Production System transformation reducing waste by 40%

Module 2: Value Stream Mapping (VSM)

Current state mapping techniques
Future state design
Bottleneck identification
Lead time reduction strategies
Process flow optimization
Case Study: FMCG plant reduced cycle time by 30% using VSM

Module 3: 5S Workplace Organization

Sort, Set in Order, Shine
Standardize and Sustain principles
Workplace efficiency improvement
Visual management systems
Safety integration
Case Study: Automotive plant improved productivity by 25% after 5S

Module 4: Kaizen Continuous Improvement

Kaizen philosophy and culture
Small incremental improvements
Employee involvement systems
Kaizen event execution
Performance tracking tools
Case Study: Electronics factory achieved 20% defect reduction

Module 5: Lean Six Sigma DMAIC

Define, Measure, Analyze
Improve and Control phases
Statistical process control basics
Data-driven decision-making
Quality improvement projects
Case Study: Pharma company reduced rejection rate by 35%

Module 6: Just-In-Time (JIT) Systems

Demand-driven production
Inventory minimization
Supplier synchronization
Kanban systems
Production scheduling optimization
Case Study: Retail supply chain reduced inventory costs by 28%

Module 7: Total Productive Maintenance (TPM)

Autonomous maintenance
Planned maintenance systems
Equipment efficiency (OEE)
Breakdown reduction techniques
Operator involvement
Case Study: Steel plant improved machine uptime by 22%

Module 8: Root Cause Analysis (RCA)

5 Whys methodology
Fishbone diagram analysis
Defect tracking systems
Corrective action planning
Problem-solving frameworks
Case Study: Automotive defect elimination improved quality by 30%

Module 9: Lean Supply Chain Management

Demand forecasting techniques
Supplier integration models
Logistics optimization
Inventory control systems
Lean procurement strategies
Case Study: FMCG supply chain reduced delays by 25%

Module 10: Process Mapping & Standard Work

Workflow documentation
Standard operating procedures
Cycle time reduction
Process standardization
Work instruction design
Case Study: Assembly line improved throughput by 18%

Module 11: Continuous Flow Manufacturing

Flow balancing techniques
Batch size reduction
Cellular manufacturing
Bottleneck elimination
Production line balancing
Case Study: Electronics firm improved flow efficiency by 27%

Module 12: Lean Leadership & Change Management

Leadership in lean culture
Employee engagement strategies
Resistance management
Communication frameworks
Transformation leadership
Case Study: Manufacturing plant achieved full lean adoption in 1 year

Module 13: Industry 4.0 Integration

Smart factory systems
IoT in manufacturing
Automation & robotics
Digital twin technology
Predictive analytics
Case Study: Automotive industry reduced downtime by 35%

Module 14: Cost Reduction & Productivity Optimization

Cost analysis techniques
Waste elimination models
Resource optimization
Efficiency benchmarking
Profitability improvement
Case Study: Chemical plant reduced operating costs by 20%

Module 15: Advanced Lean Project Implementation

Lean project planning
KPI development
Performance measurement
Implementation roadmap
Sustainability strategies
Case Study: Multi-site manufacturer achieved enterprise-wide lean transformation

Training Methodology

This course employs a participatory and hands-on approach to ensure practical learning, including:

Interactive lectures and presentations.
Group discussions and brainstorming sessions.
Hands-on exercises using real-world datasets.
Role-playing and scenario-based simulations.
Analysis of case studies to bridge theory and practice.
Peer-to-peer learning and networking.
Expert-led Q&A sessions.
Continuous feedback and personalized guidance.

Register as a group from 3 participants for a Discount

Send us an email: info@fineskilltrainingcenter.org or call +254769199797

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to Fineskill Training Center account, as indicated in the invoice so as to enable us prepare better for you.

Skills & Software Covered

Lean principles Waste elimination Value stream optimization Continuous improvement

Programme Fee

Duration: 10 Days

Method: Online or Physical

Online Price: $2,000

Physical Price: $3,000

Certification: Accredited Certificate

View Available Dates 📄 Download Course Outline (PDF)

Available Sessions

Location

Month

Year

Sep 21 2026

21 Sep — 02 Oct 2026

💻 Online / Virtual session

Online $2,000