Format: Live instructor-led online training via Zoom / Microsoft Teams

Lean Manufacturing and Six Sigma Training Course

Course Overview

Lean Manufacturing and Six Sigma are globally recognized business improvement methodologies that help organizations eliminate waste, reduce process variation, improve product quality, increase operational efficiency, and achieve sustainable competitive advantage. This comprehensive training course equips participants with practical knowledge and tools for implementing Lean principles and Six Sigma methodologies to enhance organizational performance, improve customer satisfaction, and maximize business value. The course combines process improvement strategies, quality management techniques, operational excellence frameworks, and data-driven decision-making approaches applicable across manufacturing, service, healthcare, logistics, construction, and public sector environments.

The training focuses on continuous improvement, waste elimination, process optimization, quality assurance, root cause analysis, value stream mapping, statistical process control, and performance measurement. Participants will gain hands-on experience using Lean tools and Six Sigma techniques to identify inefficiencies, streamline workflows, improve productivity, reduce defects, and increase operational effectiveness. Through practical exercises and real-world case studies, learners will understand how to create a culture of continuous improvement and operational excellence.

Organizations worldwide are increasingly adopting Lean Six Sigma methodologies to improve quality management systems, enhance customer experience, optimize resource utilization, and strengthen organizational resilience. This course explores internationally recognized frameworks including DMAIC, Kaizen, 5S, Total Quality Management (TQM), Value Stream Mapping (VSM), Statistical Process Control (SPC), Failure Mode and Effects Analysis (FMEA), and process capability analysis. Participants will learn how to manage improvement projects that deliver measurable business results.

By the end of the training, participants will be able to apply Lean Manufacturing and Six Sigma tools to solve operational challenges, reduce costs, improve quality performance, increase productivity, and support strategic business objectives. The course provides practical skills for leading process improvement initiatives, managing change, and building high-performing organizations focused on continuous improvement and customer value creation.

Course Objectives

Upon successful completion of the course, participants will be able to:

1.     Understand the principles and foundations of Lean Manufacturing and Six Sigma.

2.     Identify and eliminate waste within organizational processes.

3.     Apply Six Sigma methodologies to reduce process variation and defects.

4.     Utilize DMAIC for structured process improvement projects.

5.     Conduct root cause analysis and problem-solving activities.

6.     Implement 5S workplace organization systems.

7.     Perform value stream mapping and process flow analysis.

8.     Apply statistical tools for quality improvement and decision-making.

9.     Develop continuous improvement and operational excellence initiatives.

10.  Lead Lean Six Sigma projects that deliver measurable organizational results.

Organizational Benefits

Organizations whose employees attend this training will benefit through:

1.     Reduced operational costs and process inefficiencies.

2.     Improved product and service quality.

3.     Enhanced customer satisfaction and loyalty.

4.     Increased productivity and operational efficiency.

5.     Reduced waste and non-value-added activities.

6.     Improved process consistency and reliability.

7.     Better utilization of organizational resources.

8.     Strengthened quality management systems.

9.     Enhanced employee engagement in continuous improvement.

10.  Increased competitiveness and profitability.

Target Participants

This course is suitable for:

·       Operations Managers

·       Production Managers

·       Quality Assurance Managers

·       Continuous Improvement Specialists

·       Manufacturing Engineers

·       Industrial Engineers

·       Process Improvement Officers

·       Supply Chain Managers

·       Project Managers

·       Business Analysts

·       Operations Supervisors

·       Plant Managers

·       Logistics Professionals

·       Quality Control Personnel

·       Team Leaders

·       Senior Executives responsible for operational excellence

Course Outline

Module 1: Introduction to Lean Manufacturing and Six Sigma

1.     Evolution of Lean Manufacturing and Six Sigma

2.     Principles of operational excellence

3.     Lean versus Six Sigma methodologies

4.     Customer value and quality concepts

5.     Continuous improvement frameworks

6.     Case Study: Lean Six Sigma transformation in a manufacturing company

Module 2: Lean Thinking and Waste Elimination

1.     Lean philosophy and principles

2.     Understanding customer value

3.     Identification of the eight wastes

4.     Value-added versus non-value-added activities

5.     Waste elimination strategies

6.     Case Study: Reducing operational waste in production processes

Module 3: 5S Workplace Organization System

1.     Introduction to 5S methodology

2.     Sort and workplace organization

3.     Set in order and visual management

4.     Shine and workplace cleanliness

5.     Standardize and sustain practices

6.     Case Study: Implementing 5S for workplace efficiency

Module 4: Value Stream Mapping and Process Analysis

1.     Process mapping fundamentals

2.     Current state value stream mapping

3.     Future state design

4.     Process flow analysis

5.     Bottleneck identification techniques

6.     Case Study: Streamlining workflow using value stream mapping

Module 5: DMAIC Methodology

1.     Define phase tools and techniques

2.     Measure phase and data collection

3.     Analyze phase methodologies

4.     Improve phase implementation

5.     Control phase sustainability measures

6.     Case Study: DMAIC project for quality improvement

Module 6: Root Cause Analysis and Problem Solving

1.     Problem-solving frameworks

2.     Fishbone diagram application

3.     5 Whys technique

4.     Pareto analysis

5.     Corrective and preventive actions

6.     Case Study: Resolving recurring operational issues

Module 7: Statistical Process Control (SPC)

1.     Fundamentals of statistical quality control

2.     Control charts and interpretation

3.     Process variation analysis

4.     Process capability measurement

5.     Performance monitoring systems

6.     Case Study: Improving process stability through SPC

Module 8: Six Sigma Quality Improvement Tools

1.     Defect identification and measurement

2.     Sigma level calculations

3.     Measurement system analysis

4.     Hypothesis testing fundamentals

5.     Data-driven decision-making

6.     Case Study: Reducing product defects using Six Sigma tools

Module 9: Kaizen and Continuous Improvement

1.     Kaizen principles and practices

2.     Continuous improvement culture

3.     Employee engagement strategies

4.     Improvement event planning

5.     Performance monitoring techniques

6.     Case Study: Kaizen implementation for productivity enhancement

Module 10: Failure Mode and Effects Analysis (FMEA)

1.     Risk assessment principles

2.     Failure mode identification

3.     Severity, occurrence, and detection ratings

4.     Risk priority number calculations

5.     Mitigation planning strategies

6.     Case Study: Preventing process failures through FMEA

Module 11: Lean Six Sigma Project Management

1.     Project selection and prioritization

2.     Stakeholder management

3.     Team leadership and collaboration

4.     Change management techniques

5.     Project performance evaluation

6.     Case Study: Managing a Lean Six Sigma improvement project

Module 12: Operational Excellence and Sustainability

1.     Building a culture of operational excellence

2.     Lean Six Sigma governance structures

3.     Performance measurement systems

4.     Sustainability of improvement initiatives

5.     Strategic deployment of Lean Six Sigma

6.     Case Study: Enterprise-wide operational excellence implementation

General Information

1.     Customized Training: All our courses can be tailored to meet the specific needs of participants.

2.     Language Proficiency: Participants should have a good command of the English language.

3.     Comprehensive Learning: Our training includes well-structured presentations, practical exercises, web-based tutorials, and collaborative group work. Our facilitators are seasoned experts with over a decade of experience.

4.     Certification: Upon successful completion of training, participants will receive a certificate from Foscore Development Center (FDC-K).

5.     Training Locations: Training sessions are conducted at Foscore Development Center (FDC-K) centers. We also offer options for in-house and online training, customized to the client's schedule.

6.     Flexible Duration: Course durations are adaptable, and content can be adjusted to fit the required number of days.

7.     Onsite Training Inclusions: The course fee for onsite training covers facilitation, training materials, two coffee breaks, a buffet lunch, and a Certificate of Successful Completion. Participants are responsible for their travel expenses, airport transfers, visa applications, dinners, health/accident insurance, and personal expenses.

8.     Additional Services: Accommodation, pickup services, freight booking, and visa processing arrangements are available upon request at discounted rates.

9.     Equipment: Tablets and laptops can be provided to participants at an additional cost.

10.  Post-Training Support: We offer one year of free consultation and coaching after the course.

11.  Group Discounts: Register as a group of more than two and enjoy a discount ranging from 10% to 50%.

12.  Payment Terms: Payment should be made before the commencement of the training or as mutually agreed upon, to the Foscore Development Center account. This ensures better preparation for your training.

13.  Contact Us: For any inquiries, please reach out to us at training@fdc-k.org or call us at +254712260031.

14.  Website: Visit our website at www.fdc-k.org for more information.