This is the story of how I challenged the plant manager to go to the Gemba to verify his assumptions about the factory floor. Spoiler alert - he learned something he wasn’t expecting.
During a changeover reduction Kaizen at a gummy vitamin factory, the team learned how to use “Tell, Show, and Do” to solidify the training for the crew.
The crew wasn’t interested in reducing scrap, as it was too vague a concept for them. Once I compared our losses to amounts of beer, the light bulbs of understanding came on.