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John Allen is an internationally-known Sensei and thought leader in lean systems and change management, who spent the last 15 years as founder, CEO and president of Total Systems Development, designing and conducting lean training and certification programs and implementing lean-continuous process improvement (CPI) systems throughout the world for major multinational corporations and the US Air Force and Navy. For over two decades, his work as an author, lecturer and broad-based practitioner has made him an expert in lean systems as applied to manufacturing production, supply chain, logistics, maintenance, and business-administrative operations. Mr. Allen is a recognized author, co-editing and writing much of the 500-page reference work Lean Manufacturing: A Plant Floor Guide (published by the Society of Manufacturing Engineers & available on amazon.com), as well as publishing numerous articles on the origins and operations of a lean system, such as The Realities of Culture Change and How It Worked At Toyota; Making Lean Manufacturing Work For You; Choosing The Right People; New Plant Start-up: A Case Study At Toyota; and Making Lifetime Employment a U.S. Reality: The Toyota Experience.Specialties: Coaching, Mentoring, Lean Systems, Lean Manufacturing, Toyota Production System, Continuous Process Improvement, Lean Production, Lean Enterprise, Industrial Engineering, Supply Chain, Logistics, Materials Management, Inventory Optimization, Business Process Improvement, Change Management, Kanban, Kaizen, Kaizen Events, Rapid Improvement Events.
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ChairmanTotal Systems Development, Inc.Lexington, Ky, Us
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ChairmanTotal Systems Development, Inc. Mar 2017 - PresentLouisville, Kentucky, UsWe credit our success to the highly qualified, dedicated, and talented lean-CPI experts and change management specialists that make up the TSD team. Our team of experts average over 15 years of lean experience and many have first-hand employment experience with Toyota, the very source of lean methodology. So we come to you not only with thorough formal training, but significant experience and the ability to engage your workforce to create a culture of positive change. This is the basis of our characteristic pragmatic, hands on, and personal style of analysis and implementation. -
CeoTotal Systems Development, Inc. Apr 1992 - Mar 2017Louisville, Kentucky, UsResponsible for the growth and development of the employees and business of TSD. Accountable for the results achieved.
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Senior Human Resources ConsultantTerex Corporation Feb 2008 - Apr 2012Norwalk, Ct, UsSupported senior leadership in developing the overall architecture and roadmap of the Terex Business System. In execution, he primarily supported the implementation of human systems to support the company's first mixed model Andon line. This included people development, organizational structure, team-based work structure, selection systems, recognition and reward, retention systems, policy deployment, manpower planning, labor relations, employee relations & compensation systems. -
Advisor, Osd Cpi Transformation (Afso21)United States Air Force Oct 2005 - Sep 2011Randolph Afb, Tx, UsJohn’s reputation prompted his enlistment by the Office of the Secretary of Defense (OSD) to conduct, with several others, a service-wide best practices survey of process improvement activities within the Department of Defense logistics community. This led to his role as one of the principal authors of the OSD CPI Transformation Guidebook. This, in turn, led to his role as a significant contributor in the development of the Continuous Process Improvement methodology set forth in the US Air Force AFSO21 program. In addition, he was principal author of the AFSO21 Playbook (the USAF interpreter of lean) and an original mentor to the Air Combat Command AFSO21 effort. He participated in the evolution of the AFSO21 program as co-designer of the University of Tennessee Master Process Officer Certification Program, where he was mentor to the Special Operations Command and Air University. His work also included dedicated sessions on alignment, leadership and change management for decision-makers at USAF Headquarters. -
Lead Consultant, Mas Operating SystemMas Holdings Aug 2007 - Mar 2011Colombo, Colombo, LkJohn co-developed client-focused proprietary version of lean-based production system to create strategic, multi-year lean implementation plan to move from pilot program to multi-site rollout throughout Sri Lanka. He co-directed plan implementation with TSD team, conducted on-going corporate leadership training, implemented workshops and coaching sessions in Sri Lanka, in change management & alignment, policy deployment and leadership. -
Global Supplier Network Senior Lean ConsultantNike Jan 2002 - Jan 2006Beaverton, Or, Usfter aligning and training executive leadership, John and the client collaborated to create comprehensive strategic multi-year plans and corporate charters to develop a client-focused proprietary version of lean-based production system. John directed the plan with the TSD team and conducted metric-driven monitored training, implementation and mentoring activities at pilot sites in Vietnam, including corporate leadership training, VSA activities, Rapid Improvement Events and coaching sessions. Methods and lessons learned were internalized, and the implementation process was successfully expanded to 12 more sites throughout Asia (China, Vietnam, Thailand, and Taiwan). He also conducted change management & alignment, policy deployment (Hoshin Kanri) and leadership workshops for parent company executives. The results: $440 million in projected savings over four year period, installed lean-based production system in over 12 facilities, established an in-house process for perpetuating improvements, and created a centralized “learning academy” for supporting lean deployment. -
Strategic Advisor & Senior Consultant, HrDaimler Chrysler May 1998 - Jul 2000Auburn Hills, Mi, UsJohn was responsible for strategic and plant-level planning of lean implementation at Greenfield (new) site in Brazil, including HR system development, succession planning, employee selection, policy deployment, management development, including change management and shop floor implementation of the Toyota Production System. -
Senior Consultant To The Executive TeamDelphi May 1997 - Nov 1999Gillingham, United Kingdom, GbJohn provided consultant executive leadership for the implementation of the Delphi production system at facilities in Saginaw, Michigan and Athens, Alabama resulting in a one year savings of over $28 million. He presented implementation strategies to division leaders and coached division and plant executives in the resolution of issues concerning implementation. He coached the plant manager on the resolution of significant issues that were barriers to implementation and created systems to facilitate the implementation in conjunction with the labor union representatives. -
Senior ConsultantFord Motor Company 1992 - 1997Dearborn, Michigan, UsJohn coached external consultants and internal employees assigned to the Vehicle Operations Division on the Ford Production System (FPS) methodology and acted as a consultant to the human resources function as they created the HR systems to support FPS and implemented a Toyota Production type system at all vehicle assembly operations worldwide. Additionally, John provide similar services throughout the supplier network. -
Manager Human ResoucrcsToyota Motor Corporation Dec 1986 - Mar 1992Toyota City, Aichi Prefecture, JpManager of Training and Development (120 direct reports)Designed and developed the all training for 2500 employees at the startup of the Georgetown,KY Toyota facility. Staffed and developed the skill trades course for multi-functional skill tradespersonnel. Created competency-based training programs to develop all members. Set thegoals for training including on-the-job training. Established a learning center for self-directedlearning. Created the Group Leader and Team Leader promotion program. Developed the skilltrades up-grade program for developing team member into multi-skilled trades team membersincluding the machine by machine standard maintenance practice.Manager of Personnel (30 direct reports)Managed the compensation, payroll and benefits program. Developed annual performanceplanning and performance measurement. Managed the competency-based selection system todeliver hundreds of team member, specialists and managers to fill the manpower plan.Developed the manpower planning process. Managed the salaried personnel employeerelations activities.Manager of HR Research and DevelopmentDeveloped the Managerial Job Rotation Program. Created the multi-sourced performanceappraisal system. Worked with Purchasing Department as a consultant to outside suppliers.Created the development program for managers using competency. The “Day In the Life" simulation was the basis. Coached and mentored salaried personnel for personal development. -
Division Hr Manager (Ts/Sci)Trw Apr 1978 - Dec 1986
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Personnel ManagerAaf International (American Air Filter) Jan 1973 - Mar 1978Louisville, Ky, Us -
Artillery SpecialistKentucky Army National Guard Nov 1970 - Feb 1976Franfort, Ky, Us -
Personnel AdministratorState Of Kentucky Jan 1970 - Dec 1972Us
John Allen Skills
John Allen Education Details
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University Of KentuckyBs In Personnel -
The University Of MemphisManagement
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Harvard UniversityStrategic Management
Frequently Asked Questions about John Allen
What company does John Allen work for?
John Allen works for Total Systems Development, Inc.
What is John Allen's role at the current company?
John Allen's current role is Chairman.
What is John Allen's email address?
John Allen's email address is ja****@****ing.com
What is John Allen's direct phone number?
John Allen's direct phone number is +185949*****
What schools did John Allen attend?
John Allen attended University Of Kentucky, The University Of Memphis, Harvard University.
What are some of John Allen's interests?
John Allen has interest in Collecting Antiques, Home Improvement, Lean Manufacturing, Reading, Human Resources, Gourmet Cooking, Sports, The Arts, Home Decoration, Cooking.
What skills is John Allen known for?
John Allen has skills like Six Sigma, Process Improvement, Business Process Improvement, Kaizen, Lean Manufacturing, Change Management, Continuous Improvement, Operational Excellence, Toyota Production System, Data Analysis, Kanban, Manufacturing.
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