Introduction

Advanced Lean Project Management in Manufacturing Training Course is designed to equip professionals with methodologies to eliminate waste, optimize production flow, and accelerate operational excellence. This course integrates Lean Manufacturing Principles, Six Sigma tools, Agile Project Management, Kaizen culture, and Continuous Improvement strategies to deliver measurable improvements in cost reduction, productivity enhancement, and quality optimization across manufacturing environments. Participants will gain hands-on expertise in deploying value stream mapping, Just-in-Time (JIT), 5S systems, Kanban scheduling, and root cause analysis to transform traditional manufacturing systems into agile, data-driven, and lean enterprises.

In today’s highly competitive industrial landscape, organizations demand professionals capable of leading Lean transformation projects, digital manufacturing optimization, smart factory integration, and operational excellence initiatives. This training empowers learners with practical skills in Lean KPI tracking, project lifecycle management, waste elimination (Muda reduction), and performance analytics. By combining strategic project leadership with Lean thinking, this course ensures sustainable productivity gains, improved supply chain efficiency, and world-class manufacturing performance aligned with Industry 4.0 standards.

Programme Curriculum

Advanced Lean Project Management in Manufacturing Training Course

Introduction

Course Duration

10 days

Course Objectives

Master Lean Manufacturing Project Management principles for industrial optimization
Apply Six Sigma DMAIC methodology for defect reduction and process improvement
Implement Value Stream Mapping (VSM) for workflow efficiency
Develop expertise in Kaizen Continuous Improvement Systems
Optimize production using Just-in-Time (JIT) inventory management
Design and execute Lean transformation projects in manufacturing plants
Reduce operational waste using Muda elimination techniques
Enhance productivity through 5S workplace organization systems
Apply Kanban scheduling systems for workflow automation
Strengthen decision-making using Lean KPI dashboards and analytics
Lead Agile manufacturing project execution frameworks
Integrate Smart Manufacturing and Industry 4.0 Lean strategies
Build capability in Root Cause Analysis (RCA) and problem-solving tools

Target Audience

Manufacturing Plant Managers
Production and Operations Engineers
Lean Six Sigma Professionals
Industrial Project Managers
Quality Assurance and Quality Control Managers
Supply Chain and Logistics Managers
Continuous Improvement Specialists
Engineering Graduates and Technical Professionals

Course Modules

Module 1: Introduction to Lean Manufacturing

Lean philosophy and principles
Waste identification (Muda, Mura, Muri)
Lean vs traditional manufacturing
Value creation concepts
Lean transformation roadmap
Case Study: Toyota Production System success model

Module 2: Lean Project Management Fundamentals

Lean project lifecycle
Project charter development
Stakeholder mapping
Lean leadership roles
Project prioritization tools
Case Study: Lean implementation in automotive assembly line

Module 3: Value Stream Mapping (VSM)

Current vs future state mapping
Process flow visualization
Bottleneck identification
Cycle time analysis
Lead time reduction strategies
Case Study: Electronics manufacturing process optimization

Module 4: 5S Workplace Organization

Sort, Set, Shine, Standardize, Sustain
Workplace efficiency design
Safety integration
Visual management systems
Audit systems
Case Study: 5S implementation in FMCG plant

Module 5: Kaizen Continuous Improvement

Kaizen philosophy
Daily improvement systems
Employee engagement models
PDCA cycle application
Improvement tracking tools
Case Study: Kaizen culture in Japanese manufacturing firm

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

Inventory minimization strategies
Demand-driven production
Supplier synchronization
Pull system design
Waste reduction in inventory
Case Study: JIT success in automotive supply chain

Module 7: Kanban Systems

Visual workflow management
Kanban board design
Work-in-progress control
Digital Kanban tools
Flow optimization
Case Study: Kanban in semiconductor production line

Module 8: Six Sigma DMAIC

Define, Measure, Analyze, Improve, Control
Statistical process control
Defect reduction tools
Process capability analysis
Quality improvement methods
Case Study: Defect reduction in textile manufacturing

Module 9: Root Cause Analysis (RCA)

5 Whys technique
Fishbone diagram
Failure mode analysis
Problem prioritization
Corrective action planning
Case Study: Machine breakdown analysis in factory

Module 10: Lean KPI & Performance Metrics

OEE (Overall Equipment Effectiveness)
Cycle time and takt time
Productivity measurement
Real-time dashboards
Performance tracking systems
Case Study: KPI optimization in food processing plant

Module 11: Agile Manufacturing Systems

Agile vs Lean integration
Flexible production systems
Rapid response manufacturing
Digital workflow systems
Customer-driven production
Case Study: Agile transformation in electronics industry

Module 12: Supply Chain Lean Optimization

End-to-end supply chain mapping
Demand forecasting
Logistics waste reduction
Supplier collaboration
Inventory optimization
Case Study: Retail supply chain lean transformation

Module 13: Industry 4.0 & Smart Manufacturing

IoT in manufacturing
Automation integration
AI-driven production systems
Digital twins
Smart factory design
Case Study: Smart factory implementation in Germany

Module 14: Lean Leadership & Change Management

Leadership styles in Lean environments
Change resistance management
Team empowerment
Communication strategies
Lean culture building
Case Study: Organizational Lean transformation in aerospace firm

Module 15: Lean Project Implementation & Simulation

End-to-end project execution
Simulation tools
Risk management
Continuous monitoring
Final project delivery
Case Study: Full Lean transformation simulation in manufacturing plant

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

Project planning Lean execution Resource 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