John Bolger
Lean Business Consultant, Mentor & Coach
With over three decades of experience, I’ve held senior management positions in Equipment Maintenance and Continuous Improvement with some of the most respected multinational corporations.
My journey in the manufacturing world has been diverse, covering sectors such as electronics, medical devices, pharmaceuticals, and the motor industry. This wide-ranging experience has given me a profound understanding of the unique operational challenges faced by businesses in these fields.
Before I ventured into consultancy, I had the privilege of serving as the Senior OpEx Engineer at Integer (formerly Lake Region Medical). During my tenure, I played a pivotal role in helping the company achieve the prestigious Shingo Bronze Medallion, an accolade often likened to the ‘Nobel Prize’ for manufacturing excellence.
My leadership and expertise in lean manufacturing principles were instrumental in driving operational excellence and continuous improvement within the engineering and maintenance departments.
In addition to practical experience, I’ve also invested in my academic growth. I hold a City & Guilds Certificate in Maintenance Technology from W.I.T. (1997), a Certificate in Supervisory Management from I.M.I. (2003), and an MSc in Lean Operations from Cardiff University (2009).
My dissertation at Cardiff University focused on the importance of standard work processes in maintenance activities, emphasising their role in ensuring consistency, repeatability, and enhanced equipment performance in modern automated factories. This approach not only upheld equipment efficiency but also laid the foundation for continuous improvement, enabling the identification of opportunities to refine maintenance processes further.
My passion for helping companies achieve growth through the effective application of Lean tools, systems, and principles led me to establish my consultancy, Lean Manufacturing Systems, in 2021. Through this venture, I leverage my extensive practical experience to guide organisations along their Lean implementation journey. I’m not just a practitioner; I’m an active member of various Lean networks across Ireland. I also serve as a steering group member of Cobotics Skillnet, underscoring my commitment to advancing the manufacturing industry in Ireland.
Sharing knowledge is something I hold dear. I’ve had the privilege of being a keynote speaker at national and international conferences, including the University of Buckingham Lean Conference in 2017, Waterford Institute of Technology’s Lean Forum in 2018, and the Reliability Ireland Conference in Cork. These platforms allowed me to share my expertise and insights on lean manufacturing and continuous improvement, with the aim of inspiring others in the industry to strive for excellence.
When I’m not working, I enjoy reading, hillwalking and other outdoor activities.
Areas of Expertise:
- Lean Manufacturing Strategies
- Continuous Improvement Initiatives
- Equipment Maintenance
- Operational Excellence
- Standard Work Process Development
- Lean Tools and Principles Application
- Shingo Bronze Medallion Achievement
- Academic Qualifications in Lean Operations
- Consultant in Lean Manufacturing
- Lean Networks Engagement
- Keynote Speaker in Lean and Improvement Conferences