Current/Recent Projects

Dr. J.R.Thomas Associates have recently:

• Co-ordinated a 5S and Value-stream mapping project for Smurfit Kappa  at their Mold, North Wales. Corrugated packaging plant.
• Undertaken a Value-stream mapping project for Tȳ Mawr Lime of Brecon, during which significant cost-reduction opportunities were identified.
• Co-ordinated a 5S project for Chivas Bros. of Dunbarton – a leading player in the  Scotch Whisky Industry.
• Ran a workshop on Value-Stream Mapping for the Engineering faculty  at University of Wales Trinity St. Davids.
• Delivered  Time Management courses for key leaders at market-leading Cruise specialists  Cruise Nation Ltd.
• Led a Lean programme for leading chimney manufacturers Brickfab at their facility in Pontypool.
• Throughout 2018-2020, undertook regular business diagnostic studies on behalf of Enterprise Professional Services Ltd.
• In 2017/2019 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.”

Range of courses offered:

Click on the schematic below to reveal the range of courses we are able to offer.

Portfolio

Completed Projects

Over recent years Dr. J.R.Thomas Associates have:

• Designed and led an extensive Lean manufacturing improvement project for the UK’s leading packaging manufacturer D.S.Smith Packaging at 24 locations throughout the UK. These projects make extensive use of World Class manufacturing techniques such as Workplace Organisation (Including  co-ordinating an extensive 5S programme throughout the company), Quick Changeovers (S.M.E.D.) , Total Productive Maintenance and Value-Stream mapping.

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

“ Dr John’s programmes are a very easily accepted Paradigm with 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”

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

• Co-ordinated a strategy development programme for electronics manufacturer DBK Technitherm.

• Ran a Total Productive Maintenance and Quick changeover programme  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 resulted in  significant capacity increases, service level improvements  and profit generation to the client due to the considerable time and cost savings generated by the project.

• Ran a long-term Lean programme for high quality printers and bookbinders Cambrian printers.

• Ran a Lean manufacturing improvement programme for Optical lens specialist manufacturers Lenstec Optical in Caerphilly.

• Ran a Lean manufacturing improvement programme 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 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