Introduction

The Lean Six Sigma Black Belt in Manufacturing Training Course is a highly advanced, industry-focused certification program designed to develop world-class process improvement leaders capable of driving operational excellence, waste reduction, and defect-free manufacturing systems. Lean Six Sigma Black Belt in Manufacturing Training Course integrates the powerful methodologies of Lean Manufacturing, Six Sigma DMAIC, statistical process control (SPC), and continuous improvement strategies to transform professionals into data-driven problem solvers and strategic decision-makers in modern production environments.

In today’s competitive manufacturing landscape, organizations demand professionals who can lead process optimization, cost reduction, quality enhancement, and productivity improvement initiatives. This course equips participants with advanced tools such as Minitab, root cause analysis, value stream mapping, Kaizen, and advanced statistical modeling, enabling them to lead high-impact projects that align with global standards like ISO 9001, World Class Manufacturing (WCM), and Industry 4.0 transformation.

Programme Curriculum

Lean Six Sigma Black Belt in Manufacturing Training Course

Introduction

Course Duration

5 days

Course Objectives

Master Lean Six Sigma DMAIC methodology for manufacturing excellence
Apply advanced statistical analysis and hypothesis testing for process control
Lead end-to-end continuous improvement and operational excellence projects
Implement waste elimination techniques (Muda, Mura, Muri) in production systems
Develop expertise in Root Cause Analysis (RCA) and Failure Mode Effects Analysis (FMEA)
Optimize manufacturing cycle time and throughput efficiency
Improve quality management systems and defect reduction strategies
Design lean production systems using Value Stream Mapping (VSM)
Enhance supply chain and inventory optimization in manufacturing
Drive cost reduction and profit maximization initiatives
Utilize SPC, control charts, and process capability analysis (Cp, Cpk)
Lead cross-functional teams in Six Sigma Black Belt projects
Align manufacturing processes with Industry 4.0, smart factory, and digital transformation trends

Target Audience

Manufacturing Engineers
Quality Assurance & Quality Control Professionals
Production Managers & Supervisors
Industrial Engineers
Process Improvement Specialists
Supply Chain & Operations Managers
Six Sigma Green Belts aspiring for Black Belt certification
Continuous Improvement & Lean Manufacturing Professionals

Course Modules

Module 1: Lean Six Sigma Foundations & DMAIC Mastery

Introduction to Lean & Six Sigma integration
DMAIC framework (Define, Measure, Analyze, Improve, Control)
Project selection and charter development
Voice of Customer (VOC) analysis
KPI alignment with manufacturing goals
Case Study: Reduction of defect rate in an automotive assembly line using DMAIC

Module 2: Advanced Statistical Analysis & Minitab Application

Descriptive & inferential statistics
Hypothesis testing and regression analysis
ANOVA in manufacturing processes
Probability distributions in quality control
Minitab software for data-driven decisions
Case Study: Reducing machine downtime using statistical correlation analysis

Module 3: Lean Manufacturing & Waste Elimination

8 types of waste (DOWNTIME)
Kaizen continuous improvement culture
5S workplace organization system
Just-In-Time (JIT) production system
Value-added vs non-value-added activities
Case Study: Warehouse efficiency improvement through 5S implementation

Module 4: Root Cause Analysis & Problem Solving Tools

5 Whys technique
Fishbone (Ishikawa) diagram
Failure Mode and Effects Analysis (FMEA)
Pareto analysis (80/20 rule)
Corrective and preventive actions (CAPA)
Case Study: Eliminating recurring defects in packaging line using RCA tools

Module 5: Statistical Process Control (SPC)

Control charts (X-bar, R, P charts)
Process capability (Cp, Cpk, Pp, Ppk)
Process stability analysis
Variation reduction strategies
Real-time monitoring systems
Case Study: Improving process stability in injection molding operations

Module 6: Value Stream Mapping & Process Optimization

Current state vs future state mapping
Bottleneck identification techniques
Lead time reduction strategies
Flow optimization in production lines
Lean layout design principles
Case Study: Redesigning production flow in a FMCG bottling plant

Module 7: Advanced Lean Six Sigma Project Execution

Black Belt project lifecycle management
Stakeholder management & communication
Financial impact analysis (Cost-Benefit)
Risk management in improvement projects
Change management strategies
Case Study: Multi-department cost reduction project in a pharmaceutical plant

Module 8: Industry 4.0 & Smart Manufacturing Integration

Digital transformation in manufacturing
IoT-enabled process monitoring
Predictive maintenance analytics
AI & machine learning in quality control
Smart factory implementation strategies
Case Study: Predictive maintenance implementation reducing equipment failure in CNC machining

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

DMAIC methodology Statistical analysis Process improvement Quality optimization

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