For nine months their flagship product was coming off the floor malformed. Every engineer in the building, every manager with a mandate, every expert with a theory. No solution.
During cross-functional training — part of our methodology, not optional — a young machine operator stayed behind after a session. He said he knew what the problem was. He'd been waiting. Quietly. Until someone made it safe to speak.
We took it to the shop floor, called an impromptu huddle with the COO and the engineers, and let him talk. Ten minutes.
Nine months. Resolved in ten minutes. By the person nobody had thought to ask.
The answer was never missing. Neither was he.