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Improving profitability with Dr. John’s Lean toolkit

What is Dr. John’s Lean Toolkit?

Based on techniques deployed, honed and optimised in over 200 companies in at least 15 industries, we have developed a series of tools and techniques to help companies achieve World Class Manufacturing standards.

The ‘Toolkit’ combines the most useful aspects of modern Lean Techniques with ‘enabling’ skills such as Leadership, Communication, K.P.I. development  and Project Management that allow the ‘Lean tools’ to be implemented effectively.

Click on the schematic below to see what is contained in the toolkit :

Summary of courses available from Dr John R. Thomas 2

We also advise you on which will be of greatest benefit to your company.

These tools  have been PROVEN TO DELIVER!

5 S Before and After 2

So what’s in the toolkit?toolbox

Let’s take a look at the ‘Lean’ tools :

‘Enabling’ skills elements of the toolkit:

LEAN projects often fail because people do not have the necessary ‘enabling’ skills to motivate their teams and organise their project.

Often, enthusiastic people are demotivated because they encounter a negative initial response from their team – “we’ve seen it all before!”

This is often because they do not have the necessary skills for motivating and facilitating projects in a way that does not end in conflict.

However, people can be trained to become competent at doing so by developing the appropriate facilitation skills and learning to manage their behaviour.

Dr. John R.Thomas Associates have therefore developed a portfolio of ‘enabling’ skills aimed at giving people the confidence and methodologies for maximising the chances of a successful Lean project.


The ‘Enabling’ skills elements of the toolkit:

(Click on the link for a detailed explanation.)


Although traditionally, these courses have been delivered as face-to-face format presentations, this can be modified to suit client needs.

Increasingly, client requirements are for these courses to delivered  as a series of 1 hour webinars to be delivered at a time and frequency as dictated by the client.

We will structure delivery to suit your requirements!

See our Improving profitability with Dr. John’s  Lean toolkit section in the WHAT WE OFFER bar at the top of the website  and chose one of the sidebar options for  detailed  information on each of these courses.


Client feedback on these courses…

From : Mr. Tom Dean , Managing Director,  Screentech Ltd.,  Rhondda.

November 2016

“I thought the experience was great. John was really enthusiastic and encouraging throughout the entire process. It was really useful getting advice from someone with so much experience in manufacturing industry.

John was extremely helpful, and gave us a lot of short term goals as well as long term goals, which means we have things that we can address straight away to make immediate improvements. The other benefit was that all the recommendations given were cost effective which meant we as a company didn’t need to spend a lot of money to make these improvements.”

Thanks again for all your help.


From : Mr. Adrian Swindells , Managing Director Abbey Group,  Bedford.

November 2015

“I have used Dr.John R.Thomas over a number of years as a catalyst for improved and sustained change across the 3 Abbey manufacturing facilities and in the support office functions. World Class manufacturing techniques and analysis have helped to improve the factory operations with safety and bottom line benefits and the world class techniques applied to the office functions have reduced administration time and improved customer service. The wealth of experience and the hands on approach have always ensured the teams are fully engaged.”

Client quote ..

Mr. Ken Wilson,  Managing Director, Euramax Solutions Limited, Barnsley.

“As I have moved from business to business I have always used John to introduce 5S and other World Class Manufacturing techniques.   John has the ability to explain the concepts in an easy to understand manner, usually aided with photos and real life examples.  John’s approach is very practical and I have always seen immediate results.  On repeat visits John has always kept himself updated and it’s a real advantage having John’s experience to learn from.   My operations managers usually can’t wait for the next tips and ideas.    For anyone at any level looking for the next efficiency improvement, I would have no hesitation to recommend John”

Client quote ..

Mr. Graham Coles, Plant Manager,  D.S. Smith Kettering.

November  2015

“ Dr John’s programmes are a very easily accepted Paradigm within an engaged workforce, his concept can be tailored to bring out the best in individuals and teams, John always uses techniques to suit his audience”

Client quote ..

Mr. Peter White, Managing Director, Ralegh Integrated Solutions.

November 2015

”Over the years Dr John Thomas has helped us at Ralegh Integrated Solutions to achieve a very high level of Work place organisation through encouraging us to look at what we do, ask if we need to do it and if it could be done better? John has the distinct knack of getting people engaged at any level within the organisation through his obvious knowledge and determined personality”.

 The essential philosophy of Lean or World Class Manufacturing.

The essence of Lean Manufacturing is the identification and removal of waste.

Typically, each process associated with the design, manufacture, delivery, sales and after-sales function of a manufacturing company will contain waste or, rather, wasteful activities. Eliminating such activities will significantly improve the overall effectiveness and profitability of a company. Lean Manufacturing is a total system philosophy and a set of techniques has been developed that focus on the inefficiency and waste that is built into many business processes. Major cost benefits can be gained by concerted and systematic efforts to eliminate this waste and change unproductive practices.


In addition to specific training on the tools and techniques, Dr. John R. Thomas Associates offer modular training that helps companies to create their own ‘internal experts’ to champion sustainable continuous improvement projects. Profitable companies and the philosophy of lean manufacturing go hand-in-hand and using the right tools and techniques, increased profitability can be achieved through a series of low to nil cost improvements.

The 6 Big Losses

The Six Big Losses provide an equipment-based perspective on lost production time. Just like OEE, the Six Big Losses have their roots in TPM (Total Productive Maintenance).

One of the most effective paths to improving OEE is through the Six Big Losses (as illustrated in the graphic above).

Click on the link  for a taster.


Our USP in all this : making it relevant to your organisation and your people!

Most importantly, all of the improvement techniques taught in these courses will focus on addressing specific business issues relevant to that particular enterprise (e.g. Poor performance,  , quality complaints, service shortfall issues, unacceptable delays  etc.) so that their relevance can be clearly illustrated.

The focus of what we will address in the course will be agreed with senior management in advance and will be configured into the course content.

In this way not only are people being trained, but they are being prepared to solve real business problems.

This course is structured in such a way that allows for a practical project to be run alongside the actual course.

Each module generally takes half day to deliver, but this can be modified to suit client needs. These module can of course be structured to be delivered as a series of 1 hour webinars to be delivered at a time and frequency as required by the client.

Click one of the links in the list of techniques above  for detailed information on the content of each  these courses.