Introduction

Lean in Process Industries Manufacturing Training Course is designed to equip professionals with operational excellence, and continuous improvement strategies tailored for complex process industries such as oil & gas, chemicals, pharmaceuticals, FMCG, and food processing. This training emphasizes the elimination of waste, optimization of production flow, reduction of variability, and enhancement of overall equipment effectiveness (OEE) using globally recognized Lean tools and methodologies.

In today’s highly competitive industrial landscape, organizations must adopt Lean transformation, digital process optimization, and smart manufacturing principles to remain profitable and sustainable. This course empowers participants with practical skills in Value Stream Mapping (VSM), Kaizen, Six Sigma integration, Just-in-Time (JIT) production, and Total Productive Maintenance (TPM), enabling them to drive measurable improvements in cost, quality, safety, and delivery performance.

Programme Curriculum

Lean in Process Industries Manufacturing Training Course

Introduction

Course Duration

5 days

Course Objectives

Master Lean Manufacturing principles in process industries
Apply Value Stream Mapping for end-to-end process optimization
Eliminate operational waste using Lean tools (7+1 wastes)
Improve OEE (Overall Equipment Effectiveness) in production systems
Implement Kaizen for continuous improvement culture
Integrate Six Sigma for defect reduction and quality control
Optimize inventory using Just-in-Time (JIT) systems
Enhance process flow efficiency and cycle time reduction
Develop Standard Work Procedures for consistency
Apply Total Productive Maintenance (TPM) strategies
Strengthen root cause analysis using Lean tools
Drive cost reduction and productivity improvement initiatives
Lead Lean transformation projects in manufacturing environments

Target Audience

Production Managers & Supervisors
Process Engineers
Industrial Engineers
Plant Managers
Quality Assurance Professionals
Operations Managers
Continuous Improvement Specialists
Supply Chain & Logistics Professionals

Course Modules

Module 1: Introduction to Lean Manufacturing in Process Industries

Lean philosophy and history
Lean vs traditional manufacturing
Process industry challenges
Lean transformation roadmap
Waste identification framework
Case Study: Implementation of Lean basics in a chemical processing plant reducing batch delays by 20%

Module 2: Value Stream Mapping (VSM) & Process Mapping

Current state mapping techniques
Future state design
Bottleneck identification
Material & information flow analysis
Lead time reduction strategies
Case Study: Pharmaceutical plant reduces lead time by 35% using VSM redesign

Module 3: Waste Elimination & Process Optimization

7+1 wastes in process industries
Overproduction and inventory waste control
Energy and resource optimization
Lean waste audit techniques
Workplace efficiency improvement
Case Study: FMCG factory reduces material waste by 18% through Lean audits

Module 4: Kaizen & Continuous Improvement Culture

Kaizen philosophy and tools
PDCA cycle implementation
Employee engagement systems
Suggestion schemes
Daily improvement routines
Case Study: Food processing plant achieves 25% productivity increase via Kaizen events

Module 5: Six Sigma Integration for Quality Improvement

DMAIC methodology
Defect reduction strategies
Process capability improvement
Statistical process control basics
Root cause failure analysis
Case Study: Oil refinery reduces defect rate by 40% using Six Sigma DMAIC

Module 6: Total Productive Maintenance (TPM)

Autonomous maintenance principles
Planned maintenance systems
Equipment reliability improvement
OEE enhancement techniques
Breakdown reduction strategies
Case Study: Manufacturing plant improves OEE from 60% to 82% using TPM

Module 7: Just-in-Time (JIT) & Inventory Optimization

Pull system vs push system
Kanban implementation
Inventory reduction techniques
Supplier integration strategies
Demand-driven production
Case Study: Beverage company reduces inventory holding cost by 30%

Module 8: Lean Leadership & Digital Lean Transformation

Lean leadership mindset
Change management strategies
Industry 4.0 integration
Digital Lean tools & dashboards
Performance measurement systems
Case Study: Smart factory improves efficiency by 28% using digital Lean dashboards

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

Process optimization Waste elimination Continuous improvement Flow efficiency

Programme Fee

Duration: 5 Days

Method: Online or Physical

Online Price: $1,000

Physical Price: $1,500

Certification: Accredited Certificate

View Available Dates 📄 Download Course Outline (PDF)

Available Sessions

Location

Month

Year

Oct 19 2026

19 Oct — 23 Oct 2026

💻 Online / Virtual session

Online $1,000