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Green to Black Belt in Lean – Upgrade Program
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Description
This Green Belt to Black Belt in Lean Upgrade Program is designed for professionals who passed our Green Belt in Lean theory exam and want to progress to Black Belt in Lean level of the broadest and most in-depth Lean training and certification program in Europe, with content staying as close as possible to the Toyota Production System (TPS) and the Toyota Way.
It focuses exclusively on the (advanced) Black Belt in Lean modules 2 to 4. Participants deepen their expertise in advanced Lean techniques, Lean organizational design and Six Sigma tools supporting Lean.
The program assumes a solid understandig of our Green Belt In Lean knowledge and immediately starts with more in depth knowledge for complex and realistic value stream design in manufacturing/supply chain/office/service.
Objective: develop Green Belts into Lean leaders capable of designing, leading and sustaining complex improvement initiatives.
Prerequistes
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It is Mandatory having a solid foundation in Lean at the Green Belt in Lean level.
Participants from our Lean Academy Green Belt in Lean program must have passed the GB in Lean theory exam.
Participants from other Green Belt in Lean programs must first pass the Lean Academy Green Belt in Lean theory exam (cost 250€ including one retry) before they get access to the Lean Academy Black Belt in Lean modules -
Basic statistical knowledge is recommended for the supporting Six Sigma module
Benefits
After completing this upgrade program, participants are able to support the implementation of Lean as a business strategy at all levels and in all environments. Not just as a set of tools, but also implementing essential buidling blocks to support the transformation towards a Lean organisation.
You will:
✓ Upgrade your Green Belt in Lean knowlegde expertise to Black Belt in Lean level
✓ Analyze and redesign complex value streams in all environments
✓ Lead cross-functional Lean transformations at all levels for delivering more value to the customer (external but also internal), with higher quality, in a shorter lead time and at a lower cost.
✓ Understand what is needed to support the transformation towards a true continuous improvement (Kaizen) culture
✓ Work with real-life cases, seasoned trainers with lots of practical experience (some even as Master trainer within Toyota) and peer learning
✓ Obtain an official Black Belt in Lean certification (ISO 9001:2015)
Agenda
Module 2 – Advanced Lean Techniques
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Days 1-3 — Mixed Model Value Stream Design
- Mixed Model Value Stream Design: product families typically consist of a wide range of products with different work content, setup times, and processing requirements
- How to improve flow in complex value streams with high product variety
- Managing shared resources (people, workstations, lines) that are used across multiple value streams
- Designing improved flow despite complexity, resulting in:
- shorter lead times
- lower operational cost
- more predictable performance
Day 4 — Internal Logistics & Lean Material Handling
- Why well-designed value streams fail when internal logistics are not aligned
- Typical internal logistics “flow stoppers” and how to eliminate them
- Designing internal logistics to support and protect the main value stream
- Guest lecture by a practitioner from TE Connectivity, where these principles are deeply implemented in practice
Day 4 — Lean Supply Chain Design
- Understanding the value stream beyond a single organization: from suppliers to end customers
- Connecting suppliers, producers, customers, and consumers into one integrated value stream
- Applying Lean principles at supply chain level to achieve flow breakthroughs
- Using Macro / Extended Value Stream Mapping to design improved material and information flows across the supply chain
Day 5 — Lean Tools for Office & Service Environments
- Expanding the Lean toolbox for more effective implementation in office and service environments
- Techniques covered include:
- Overhead Value Analysis
- Contactograms
- Written communication analysis
- Meeting structure analysis
- Variable Factor Programming (VFP) for value streams with high variability
- Multi Moment Observations (MMO / Work Sampling)
- Quantifying waste and improvement potential in environments with variable tasks and work content
Day 6 — Service & Office Lean Simulation
- Hands-on simulation game illustrating Lean principles in a service and office environment
- Multiple value streams and shared resources within one system
- Applying Business Process Value Stream Mapping and Lean Design for Flow principles
- Achieving breakthrough improvement in an office/service context based on previously learned techniques
Day 7 (Part 1) — Lean Design for Flow
- Lean traditionally focuses on improving existing processes by eliminating waste
- Critical reflection: how much waste is actually created during poor initial process design?
- Designing processes right the first time using Lean principles
- The role of Engineering and process design in sustainable Lean implementations
Module 3 – Six Sigma Tools to Support Lean
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This module introduces Six Sigma as a complementary approach to Lean.
The focus is on understanding and reducing variation so that waste is reduced and value streams
perform more reliably and predictably.Days 7 (Part 2), 8 & 9
Six Sigma Fundamentals & DMAIC
- What is Six Sigma and how can it strengthen Lean implementations
- History, philosophy, and positioning of Six Sigma within operational excellence
- Understanding variation and why it creates waste in processes
- Key performance and quality metrics, including:
- Critical to Quality (CTQ)
- Cost of Non-Quality
- Defects per Unit (DPU)
- Defects per Million Opportunities (DPMO)
- First Time Yield
- Throughput Yield
- Rolled Throughput Yield
Basic Statistical Concepts
- Introduction to basic statistics for process improvement
- Normal distribution and data transformations
- Process distributions and parameters:
- mean
- median
- mode
- Confidence intervals and their interpretation in improvement projects
DMAIC Methodology
- The DMAIC improvement cycle:
- Define
- Measure
- Analyse
- Improve
- Control
- Tools and techniques per DMAIC phase, including:
- Voice of the Customer (VoC)
- SIPOC
- Pareto analysis
- Boxplots and Histograms
- Process Mapping (M-PMAP)
- Gage R&R
- FMEA
- Ishikawa (Fishbone) diagrams
- BOB vs. WOW analysis
- 5W2H analysis
- Multi-Vari analysis
- Hypothesis testing (step-by-step)
- One-sample and two-sample tests
- ANOVA (one-factor)
- Control charts
- Out of Control Action Plans
Practical Application
- Hands-on exercises to apply statistical concepts
- Interpreting data correctly to support fact-based decision making
- Linking Six Sigma analysis directly to Lean improvement initiatives
Module 4 – Building a Lean Organisation
Day 10 — Lean & Change, HRD
- Human Resources Development (HRD) at Toyota:
how HR actively steers and supports Lean implementation - Role of leadership development, capability building, and coaching in sustaining Lean
- Lecture by a former Toyota Motor Europe master trainer and Kaizen manager
- Lean and Change Management:
how to design, launch, and guide change in complex organizations - Practical insights
Days 11-12 — Accounting for Lean & Value Stream Costing
- Why traditional cost accounting and financial reporting fail to show improvements in flow
- How conventional accounting systems can unintentionally stimulate overproduction
— the worst form of waste - Understanding why short-term financial results may appear negative after Lean improvements
- Introduction to Value Stream Costing and Throughput Accounting as alternative management accounting approaches
- Making the financial impact of flow improvements visible and measurable
- Using value stream–driven cost models to support:
- investment decisions
- portfolio management
- engineering and product development choices
- Case Study 1:
Value stream cost model at plant level, including:- comparison of current vs. future state
- financial impact of an investment decision
- introduction of a new product
- Case Study 2:
End-to-end supply chain cost model, analyzing different future-state scenarios related to:- transport modes
- supplier locations
- conversion costs and value stream compression
Day 14 — Lean Operating Systems & Culture
- Lean Operating Systems & Daily Management,
illustrated with a real-life case at Mars Food Europe - Guest lecture by the Lean Manager of Mars Olen (Belgium)
- Lean Culture at Johnson & Johnson:
how to achieve a sustainable cultural shift through a structured and thoughtful approach - Practical insights into communication, leadership behavior,
and consistency as drivers of cultural change - Guest lecture by the former GM Manufacturing of
Johnson & Johnson Pharma (Janssen) in Belgium
- Human Resources Development (HRD) at Toyota:
Target Audience
This program is intended for:
- Participants with solid Green Belt Lean knowledge aiming to progress further
- Lean practitioners with responsibility at value stream or organizational level
- Managers, engineers and Lean coaches seeking greater impact
- Professionals in manufacturing, services, offices and healthcare
Not suitable for beginners. Designed for committed practitioners.
Trainers
Dirk Van Goubergen
Program director and owner of Lean-Academy
Prof. dr. ir Dirk van Goubergen has more than 30 years of practical and academic experience in the field of industrial engineering, operations management, lean/operational excellence and value stream design. He worked in all continents with leaders at all levels and employees for companies such as Toyota, Volvo, Mars, Philips, Amazon, Daikin, TE Connectivity, Johnson&Johnson, Delphi Technologies and many others.
Luc Semeese
Vice President Manufacturing Engineering @Volvo Cars
Luc has an extensive career at Volvo Cars, with a background in Logistics, Engineering, global Supplier Quality, and as Plant Manager in Chengdu (China). He speaks about improving flow in internal support processes and material delivery.
Dirk Inghels
Senior Expert in Sustainability & Quality – Associate Professor @Vrije Universiteit Amsterdam
Prof.dr.ir. Dirk Inghels is a passionate leader and entrepreneur with a unique mix of scientific depth and practical business experience. With a strong background in engineering, quality, EHS, and sustainable operations, he helps companies turn complex challenges into concrete, long-term solutions. His expertise bridges academic research and real-world practice, combining strategic insight with hands-on impact.
Raf Mues
Former Manager and Master Trainer Toyota Motor Europe N.V.
Raf is a certified master trainer in Toyota Global Content and TPS courses, including TBP (Toyota Business Practices), Hoshin Kanri, A3/PDCA Thinking. Before joining the Lean Academy, he lived and breathed TPS and the Toyota Way for almost 30 years at Toyota Motor Europe where he held several operational management roles, including leading and supporting Kaizen initiatives across warehouse operations.
Bart Van Waeyenberge – Johnson & Johnson
Head of EMEA CAR T Operations Johnson & Johnson
Bart is a member of the Beerse Campus Management Committee, the Board of Directors of Janssen Pharmaceutica NV, and the Board of Directors of ETiON, the Belgian entrepreneurs’ organization. He has held various local and international positions in Europe and the U.S. in fields such as process industry, automation, operations, supply chain, and business excellence. He shares the story of how the Lean journey began within Janssen Pharmaceutica.
Patrick Wilms
Lean Manager @Mars Food Europe
Patrick has nearly thirty years of experience working on Lean at Mars, formerly Masterfoods. He brings practical expertise in improving standards and developing leadership through Daily Management.
Certification
Theory Exam
✓ Black Belt in Lean – 50 multiple choice questions (90 minutes)
✓ Includes 1 re-examination
Practical Exam
✓ Implementation and defense of a Lean improvement initiative at value stream level
✓ Defense before a jury of Lean leaders and experts
✓ Includes 1 re-examination
Administrative fee for additional exams: €250 per exam.
Cost - Subsidies
Discounts
Organisations registering multiple participants for the same trainings sessions on the same dates benefit from the following reductions:
Second participant: 5%
Third participant: 10%
Fourth and subsequent participants: 15%
Subsidies
For participants from Flanders (Belgium):
This training is recognized by the Flemish government for KMO Portefeuille and VOV (Vlaams Opleidingsverlof)
KMO Portefeuille Registration Number Van Goubergen P&M : DV.O100454 (‘Personeelsmanagement’)
Number of Training Hours : 84 Hours – Maximum subsidy amount : 5.695 euro
Registration Number of this training for Vlaamse opleidingsincentives (VOV): ODB-0003205
Click here for more information
For participants from food industry (Belgium):
This training is also supported by Alimento/IPV for organisations in food industry in Belgium.
Please indicate on the registration form which subsidies you apply for.
Drinks and Meal
Cold and hot drinks are included in the training fee.
A light meal is served around 16:45.
Sessions typically run from 13:30 to 20:30, unless otherwise stated.
Location
The training takes place at Roosenberg, Patotterijstraat 1, 9250 Waasmunster, where free parking is available, unless otherwise stated.
Optional
Individual Coaching (optional)
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€400 excl. VAT for 4 sessions of 30 minutes
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On-site or online
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During or after the training
Upcoming Sessions
Upgrade Green Belt to Black Belt in Lean
Language: NL
Price: €5975,00 – ex VAT
All sessions at Roosenberg Waasmunster (BE) from 13.30 – 20.30, except if mentioned otherwise.
Module 2
• Mon. 9 Nov 2026
• Tue. 10 Nov 2026
• Mon. 23 Nov 2026
• Tue. 24 Nov 2026
• Wed. 25 Nov 2026
• Mon. 7 Dec 2026
• Tue. 8 Dec 2026 (13.30–16.45)
• Wed. 9 Dec 2026
Module 3
• Tue. 8 Dec 2026 (17.15–20.30)
• Mon. 4 Jan 2027
• Tue. 5 Jan 2027
Module 4
• Wed. 6 Jan 2027
• Mon. 18 Jan 2027
• Tue. 19 Jan 2027
• Wed. 20 Jan 2027 (09.30–17.30)
• Mon. 1 Feb 2027 (Exam)
Waiting List
Contact
Feel free to contact us for questions related to our training. You can also check out our FAQ. Are you looking for in-company training?
Drop us a message on academy@vangoubergen.com and we will get back to you.