Current and Completed Projects

Current/Recent Projects

  • Dr. J.R.Thomas Associates are co-ordinating a 5S and Value-stream mapping project for Smurfit Kappa  at their Mold, North Wales, Corrugated packaging plant.
  • Dr. J. R.Thomas Associates undertook a Value-stream mapping project for Tȳ Mawr Lime of Brecon, during which significant cost-reduction opportunities were identified.
  • Dr. J. R.Thomas Associates co-ordinated a 5S project for Chivas Bros. of Dunbarton – a leading player in the  Scotch Whisky Industry.
  • Dr. John R. Thomas ran a workshop on Value-Stream Mapping for the Engineering faculty  at University of Wales Trinity St. Davids.
  • Dr. J. R.Thomas Associates delivered  Time Management courses for key leaders at market-leading Cruise specialists  Cruise Nation Ltd.
  • Dr. J. R.Thomas Associates led a Lean programme for leading chimney manufacturers Brickfab at their facility in Pontypool.
  • Throughout 2018-2020 Dr. John R. Thomas Associates undertook regular business diagnostic studies on behalf of Enterprise Professional Services Ltd.
  • In 2017/2019 Dr. J. R.Thomas Associates led a 5S programme for  Roberts of Port Dinorwic who develop and produce quality, award-winning prepared dishes at their facility on the banks of the Menai Strait in North Wales.

Client quote …

Mr. Martin Topps, HR Manager, Roberts of Port Dinorwic.

We were introduced to 5S methodology  by Dr John Thomas of Dr. John R, Thomas Associates consultancy. The project is in its early stages and is now starting to gather momentum. The results are evident and are having a positive impact across the factory.

We are regularly audited by our customers and we hope that as well as improving safety and efficiency, we hope that we have a positive impact on our customers.


Completed Projects

Client quote …

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

“  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”


  • A Lean programme  run  for leading instrument manufacturers British Rototherm and Caerbont Automotive under the auspices of the Engineering Employers Federation (EEF)  has delivered significant gains in Productivity and Quality.


Client quote ..

Mr. Mike Grimwood, Managing Director, Peters Food Services.

“Firstly and most importantly I should like to thank you (belatedly) for the second project management segment. Without exaggerating I am already convinced that it has been the single most beneficial series of training workshops I have seen in my years in business. The guys have caught the concept and have been practicing application from day 1.. interestingly in Food Service where additional sales contracts requiring additional routes has been a key agenda item; or ranging is being reviewed we’re off to a flying start.
So again many thanks. Mike.”


  • Dr. John R. Thomas Associates  co-ordinated a strategy development programme for electronics manufacturer DBK Technitherm.
  • Total Productive Maintenance and Quick changeover programme run for Texturing Technologies Ltd. at the Tata Steel Site at Margam.
  • In response to major changes to the market requirements that the company have experienced, Dr. John R. Thomas Associates ran a major 5S/SMED Changeover time reduction programme for the UK’s leading plastic container manufacturers RPC : This has resulted in a significant capacity increases, service level improvements  and profit generation to the client due to the considerable time and cost savings generated by the project.
  • Lean  programme run for  high quality printers and bookbinders Cambrian printers.
  • Lean manufacturing improvement programme  run for Optical lens specialist manufacturers Lenstec Optical in Caerphilly.
  • Lean manufacturing improvement programme run for Altron Communications Equipment Ltd.
  • Co-ordinated  2 Lean projects in the supply chain of the Scotch Whisky Industry.
  • A Process analysis project to develop better control systems for the key process variables of the Jaffa cake manufacturing line at Burtons foods has resulted in significant quality and performance improvements through use of techniques such as Failure Modes and Effects Analysis (F.M.E.A.) and POKA YOKE (Fool-proofing).
  • Other Lean projects  completed for Safety Letterbox, Excel Engineering, Carlisle Brake products, Labelgraphics,  De La Rue and Northern Automotive Systems

Train the Trainer Programmes.

Following the launch of the successful  'Train the Trainer' programmes launched in 2006, several organisations have contracted Dr. John R. Thomas Associates to run trainer development programmes during 2007 to 2011. (Details of this programme are outlined in the...

Public Courses

An exciting and timely new course is scheduled to be launched :   LEAN APPROACHES FOR LEAN TIMES : ENSURING THE PUBLIC SECTOR DELIVERS VALUE FOR MONEY SUMMARY OF COURSE CONTENTS. Day 1 : Leadership skills for Lean Times ! In this session we get current and...

Leadership development courses

Current Management development programmes :   1.  A six month management development programme was run in 2010, 2011, 2012 and 2014 across 3 sites  for Abbey Board : the U.K.’s largest sheetfeeder.  This initiative involved training and mentoring a team of people...

International projects

Dr John R. Thomas Associates undertook a major Lean Manufacturing Project for a leading Insulation panel manufacturer in Nijmegen in the Netherlands . This programme focused on maximising throughput and minimising waste from the process. This has now been extended to...

Public Courses

An exciting and timely new course is scheduled to be launched in conjunction with Training Services Wales in the 2nd half of 2012 : LEAN APPROACHES FOR LEAN TIMES : ENSURING THE PUBLIC SECTOR DELIVERS VALUE FOR MONEY SUMMARY OF COURSE CONTENTS. Day 1 : Leadership...

The Lean Leader : The L² Initiative.

bjective of the Lean Leader initiative. We have constructed a programme that combines... Developing a range of hard skills based on key Lean Manufacturing methodologies that the Leaders would need in their roles, with…. Developing the soft skills of Leadership that...

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