Essentials of Manufacturing Processes

COURSE DURATION 5 DAYS

Dates:10^th to 14^th August 2026

 

Course Introduction

This Essentials of Manufacturing Processes training course integrates multiple disciplines, including manufacturing engineering, operations management, maintenance, and reliability. It explores various manufacturing management functions and processes. It examines how to effectively manage them using Enterprise Resource Planning (ERP) systems.

 

This Essentials of Manufacturing Processes training course will help you develop effective practices and techniques for managing manufacturing processes and critical assets proactively. By mastering these skills, you’ll be better equipped to meet deadlines, achieve your objectives, and ensure the integrity of your plant. Additionally, you’ll enhance your decision-making abilities to drive operational excellence and reliability.

 

This ALARDI Africa training course will feature:

• Classifications of manufacturing processes
• Manufacturing capacity scheduling
• Just-in-time and lean manufacturing systems
• Quality management systems and Six Sigma
• Learning from failures

 

Objectives

By the end of this ALARDI Africa training course, participants will be able to:

• Have a solid understanding of manufacturing processes and best practice techniques
• Have an understanding of a range of planning, management, and controlling different manufacturing processes
• Have the ability to design a process for managing equipment failures and their implications to the operational organisation
• Know the practical approach to developing an action plan to utilise these technologies in their own areas of responsibility, fitting them into the overall manufacturing strategy, and measuring benefits
• Know the Integration of quality, maintenance, reliability, and information systems concepts

 

Personal Benefits

Operational and Efficiency Improvements 

• Process Improvement Expertise: Participants learn methodologies such as Lean Manufacturing, Six Sigma, and Kaizen to identify and reduce waste and inefficiencies within production systems.
• Production Planning and Control: Participants gain skills in managing schedules, workflows, resource allocation, and capacity, which are critical for meeting customer demands and minimizing operational costs.
• Optimal Resource Usage: Participants understand how to optimize the use of materials, energy, and equipment through methods like automation and predictive maintenance, leading to a more sustainable production model.
• Enhanced Decision Making: Participants get to utilize key performance indicators (KPIs) and data analysis methods to make informed, data-driven decisions and drive continuous improvement.

 

Organization Benefits

The Organization will benefit from:

 

Better Quality and Compliance

• Quality Control and Assurance: The Organization will be able to establish systems that deliver consistent, compliant, and high-quality outcomes, minimizing defects and related hidden costs like rework.
• Workplace Safety and Regulatory Compliance: There will be higher adherence to international safety and regulatory standards, creating a safer work environment and reducing risk.

Reduced Wastes, Efficiency, and lower Costs

 

Training Methodology

This course will utilise a variety of proven adult learning techniques to ensure maximum understanding, comprehension, and retention of the information presented. This is designed to be a hands-on, stimulating experience. This training course is highly interactive with many discussions and facilitated practice sessions led by speakers who are at the forefront of their field. There are plenty of case studies and illustrations of both worst and best practices in the field of maintenance and asset management. The trainer has conducted many research and development projects in aspects of manufacturing, maintenance, quality, and operations management, and will share publications about projects in these fields.

 

Who should Attend?

This comprehensive 5-day training course has been designed to benefit both qualified new professionals as well as experienced professionals who might need to refresh their skills It is highly recommended that all Maintenance, Reliability, Engineering and technical support staff, including leadership and management, attend this workshop. If you and your company are interested in greatly increasing productivity, this will be a very valuable course.

 

This ALARDI AFRICA course is suitable for:

Manufacturing supervisors, superintendents, and anybody involved in setting manufacturing strategy

• Anyone working in materials and procurement management
• Safety and integrity professionals and anyone working in areas related to risk management
• Audit and quality assurance professionals
• Operational professionals who are interested in maintenance reliability and asset management

 

Course Outline

 

Day One: Classifications of Manufacturing Processes

• Introduction to processing and assembly operations
• Production systems
• Volume versus variety in manufacturing processes
• Manufacturing layout configurations
• Fundamentals of metal forming and sheet processes
• Classification of material removal processes

 

Day Two: Capacity Scheduling

• What is Enterprise Resource Planning (ERP)?
• Introduction to Material Requirement Planning (MRP)
• The evolution of Manufacturing Resource Planning (MRPII)
• Introduction to SAP
• Layout and capacity planning
• Master Production Schedule (MPS)

 

Day Three: Just in Time (JIT) and Lean Manufacturing

• The concept of lean thinking
• Push versus pull in manufacturing
• Different types of waste (Muda in the Japanese language)
• Fail-safe systems in manufacturing (Poka Yoke)
• Continuous Improvements (The 5 Ss)
• Case studies

 

Day Four: Quality Management and Six Sigma

• The meaning of quality
• The gap model of quality
• Total quality management
• Deming wheel of Plan-Do-Check-Act (PDSA)
• Quality management maturing grid
• Quality awards

 

Day Five: Learning from Failures

• Why do systems fail?
• The concept of learning from failures
• Case studies from the oil and gas industry
• Case studies from the space and aviation industry
• Case studies from the nuclear power generation industry
• The Decision-Making Grid model for the selection of an appropriate strategy
• Field Visit

 

Certificate

• On successful completion of this training course, the ALARDI Africa Certificate will be issued to the participants.

Venue:

 

Kenya-Nairobi                               Cost USD 1800

Spain-Madrid                                Cost USD 2200

Dates:10^th to 14^th August 2026