Open Letter to a Manufacturing CEO

Subject: Unlocking Manufacturing Excellence through the Toyota Production System, Lean Six Sigma, and Master Black Belt Expertise – An Open Letter:

Adopt the Toyota Production System for Manufacturing Excellence

You have got to be prepared to take those risks or you … are never going to make that leap in life that you need to make to be a great leader” – Retired Admiral William McRaven.

I hope this letter finds you in good health and spirits. I am writing to share an innovative approach that has the potential to revolutionize your manufacturing operations and elevate your company to new heights of efficiency and excellence. By integrating the Toyota Production System, and Lean Six Sigma, and harnessing the expertise of a Master Black Belt in Lean Six Sigma, your organization can pave the way for transformative success.

  1. The Toyota Production System (TPS): TPS is renowned for its philosophy of continuous improvement and waste reduction. Inspired by Toyota’s manufacturing principles, this system focuses on streamlining processes, eliminating non-value-adding activities, and empowering employees to drive change. TPS principles such as “Just-In-Time” production and “Jidoka” (automation with human intelligence) can significantly enhance your manufacturing efficiency.
  2. Lean Six Sigma: Lean Six Sigma provides a powerful set of tools and methodologies for process optimization and problem-solving. It combines the Lean principles of waste reduction with the statistical rigor of Six Sigma to identify root causes of defects and variability in processes. Implementing Lean Six Sigma can lead to improved product quality, reduced lead times, decreased costs, and enhanced customer satisfaction.
  3. Master Black Belt, Lean Six Sigma Expertise: A Master Black Belt is a highly trained and experienced professional in Lean Six Sigma methodologies. With their guidance, your organization can achieve optimal results in process improvement projects, data-driven decision-making, and overall Lean Six Sigma implementation. Their expertise will ensure the success of complex initiatives and create a culture of continuous improvement across the organization.

By integrating TPS, Lean Six Sigma, and leveraging the skills of a Master Black Belt, your company can achieve the following benefits:

  1. Elimination of Waste: Through TPS and Lean Six Sigma, your manufacturing processes will be systematically analyzed, leading to the identification and elimination of wasteful activities, such as overproduction, excess inventory, and waiting times.
  2. Data-Driven Decision Making: The application of Lean Six Sigma tools, under the guidance of a Master Black Belt, will enable your organization to make informed decisions based on data analysis and statistical evidence.
  3. Build your Lean Production System: Lean Production builds a product responding to a customer order. It also eliminates the waste of excess inventory. There is a 6 step process to accomplish this.
  4. Streamlined Operations: TPS principles will ensure a smooth flow of materials and information, reducing cycle times and improving overall operational efficiency. This will position your company to respond rapidly to changing market demands.
  5. Enhanced Product Quality: Lean Six Sigma’s focus on defect reduction and process standardization will lead to higher product quality, fewer customer complaints, and increased brand loyalty.
  6. Engaged and Empowered Workforce: The implementation of these methodologies fosters a culture of employee involvement and empowerment, resulting in a more motivated and dedicated workforce.
  7. Sustainable Growth: The integration of TPS, Lean Six Sigma, and a Master Black Belt’s expertise ensures long-term sustainability, as your company embraces continuous improvement as a way of doing business.

To embark on this transformative journey, I recommend the following steps:

  1. Leadership Commitment: As the CEO, your commitment and support are critical for the successful adoption of TPS and Lean Six Sigma. Leading by example, you can inspire the entire organization to embrace these principles.
  2. Executive Training: Provide training sessions for the leadership team to understand the core principles and potential benefits of TPS and Lean Six Sigma. An introductory workshop can ignite enthusiasm for the transformation.
  3. Master Black Belt Engagement: Engage a qualified Master Black Belt with experience in manufacturing to guide the implementation process, mentor Green and Black Belt teams, and ensure that Lean Six Sigma projects deliver significant results.
  4. Pilot Projects: Begin with small-scale pilot projects to demonstrate the impact of TPS and Lean Six Sigma methodologies. These initial successes will encourage broader implementation.
  5. Continuous Learning: Encourage employees at all levels to participate in Lean Six Sigma training and workshops. This will create a pool of certified professionals capable of driving improvement initiatives.

I am confident that integrating the Toyota Production System, Lean Six Sigma, and the guidance of a Master Black Belt will position your company for unprecedented success in the competitive manufacturing landscape. As an expert in both Lean Six Sigma and the Toyota Production System, I stand ready to support and guide your organization throughout this transformative journey.

I would be delighted to discuss this further and explore how these methodologies can be tailored to suit your specific organizational needs. Together, we can build a future of manufacturing excellence and sustainable growth for your company.

Thank you for considering this proposal. I eagerly anticipate the possibility of working with you to unlock the full potential of your organization.


Jim FitzGerald

Toyota Production System & Lean Six Sigma Master Black Belt


Apply the Tools of The Six Sigma Toyota Production System to Manufacturers.

Build Your 6+ Sigma Manufacturing System.