中文部分为站长翻译，仅供参考，中文之所以放在前面，是为了方便中文读者 文章转自国外知名行业网站
1. 在生活中我们都需要一个目标，即一些强劲的激情以实现自我， 也就是说要做一些事情。
We all need a PURPOSE in life, i.e. some driving PASSION to make a difference, i.e. to DO SOMETHING.
2.我的目标就是教授、帮助、传递知识、理念、技巧、激励。
Mine is to teach, help, transfer knowledge, philosophy, skills, motivation.
3.我们都需要反馈。
All humans need FEEDBACK and the feedback from seeing plants better, more profitable, cleaner, neater, higher output because of the help, advice, guidance from Brently, is a great buzz - exciting, motivating and like an adrenalin or endorphin surge.
4.To HELP we have to be able to facilitate CHANGE.
5.To get someone to CHANGE we need to create a GAP between what they have and what they WANT. If there is no GAP (i.e. they already have what they want), then there will be no change.
This is basic human psychology and the basic premise of all motivational speakers, lecturers.
6.我们需要创造 /We need to create:
a) 激情 /PASSION
b) 热情 /ENTHUSIASM
c) 精力 /ENERGY
d) 安慰 /COMFORT (when they are pushed out of their comfort zone)
e) 高度自尊（非常、非常重要） /HIGHER SELF ESTEEM (VERY, VERY IMPORTANT)
7.自尊 /SELF ESTEEM
a）胆怯的人缺乏它 /Shy people lack it.
b)优柔寡断的人缺乏它 /Uncertain people lack it.
c)精神不振的人缺乏它 /Low energy people lack it.
d)提升身边人的自尊应该是经理人的主要目标之一 /RAISING THE SELF ESTEEM OF THE PEOPLE AROUND A MANAGER SHOULD BE ONE OF THE MANAGER'S PRIMARY OBJECTIVES.
8.高度自尊的人 /People with higher self-esteem are:
a) 效率高 /more productive
b) 出错极少（更少的废品）/make less mistakes (less waste)
c) get more done
d) achieve more
e) are "smarter" (a human can be MUCH "smarter", just by making them feel better about THEMSELVES)
f) more willing to take risks (and, no risk, no gain) (i.e. no pain, no gain)
g) more open to new ideas
Etc., etc., etc.
9.精力充沛 /HIGH ENERGY
我们必须拥有眼神明亮的人员，挺胸抬头，自尊心强，并且精力充沛，行动敏捷，反应机敏
We MUST have people with bright eyes, shoulders back, head held high, high self-esteem, and HIGH ENERGY and fast moving and fast thinking.
Lethargic, low energy, sleepy, slow moving people will KILL your business. In the 21st century, I'm sorry to say, there is NO room (in business) for slow, sleepy, low energy, SLOW BRAINED people. They will PULL YOU DOWN.
10.ENERGY, ENTHUSIASM, PASSION /精力充沛、积极向上、充满热情
Energy, enthusiasm, passion are ALL INFECTIOUS, i.e. you CAN transfer knowledge, energy, enthusiasm to another person IF YOU are excited, energetic, passionate, etc., etc, YOURSELF.
11.JUST A NOSE AHEAD /仅仅略微超出
我们We don't have to create too big a gap as this may scare the person that the task is too hard, beyond their capability, so they won't make a start.
We need JUST A NOSE AHEAD, as invented by Dr Paul P. Parker, who also said: "Success is not so difficult as there are so few people making an all out effort for it" and "The person who earns $300,000 per year isn't ten times better than the guy on $30,000 - he only needs to be 'a nose ahead'".
"When you get out in front of the pack, the going gets MUCH easier" and "The longest journey starts with a single step."
12.太高的利润？
TOO MUCH PROFIT?
Ask "are there any in this room who are making more profit than they'd like to?
Anyone with too few problems?
Anyone with too much leisure time?"
NO-ONE.
NO-ONE.
NO-ONE.
A normal day of problems, chaos, makes you TIRED, stressed.
DO NOT ASK FOR LESS PROBLEMS, ASK FOR MORE SKILLS!
Once you get the PROCESS UNDER CONTROL, then you get calm, less crises, less problems, more profit, more leisure, more growth.
13.我的工作 /MY JOB
我的工作、我的酷爱、我生活的目的是帮助你让工艺受控（制板/印刷工艺基本上“失控")
My job, my passion, my purpose in life is to help you get the process UNDER CONTROL. (The corrugating/converting process is basically "OUT OF CONTROL".
因此，我需要在你的现状与想要的（需求）之间创造一个差距。
Therefore, I need to CREATE A GAP BETWEEN WHAT YOU HAVE AND WHAT YOU WANT (NEED).
Pat Mafrici will be the GOOD GUY. I will be the BAD GUY to CHALLENGE YOU, AND TO CHALLENGE ALMOST ALL YOU THINK YOU KNOW. It is not a bad idea in the 21st Century to assume that half of what you think you know is probably WRONG!
14.PARADIGM SHIFT EQUALS BREAK POINT
There have been REVOLUTIONS in the box industry.
If you don't adopt most of CURRENT WORLD'S BEST PRACTICE (C.W.B.P.) then, HOW CAN YOU AND YOUR COMPANY SURVIVE, IN THIS ERA OF GLOBALISATION??
15.AVERAGE IS ONLY MEDIOCRE
A sign in our office says:
"BEING AVERAGE SCARES THE HELL OUT OF ME"
If you are only average in the first decade of the 21st Century, maybe you won't make it to the second decade. Maybe you won't make it if half the people/plants are better than you.
Dr Paul Parker says:
"DOING THE MEDIOCRE THINGS IN LIFE WHEN GREATER THINGS ARE POSSIBLE, CONSTITUTES ONE OF THE GREATEST TRAGEDIES IN HUMAN ENDEAVOUR".
My job is to challenge you and encourage you and motivate you and HELP and GUIDE you to:
DO BETTER!! - i.e. try to move into the TOP 10% (or 5%)
This may cause some of you some discomfort and I may upset you because it may appear I am criticising you BUT that is NOT SO.
I'm just trying to help you SURVIVE, PROSPER and DO BETTER by showing what is POSSIBLE and what is being achieved elsewhere.
If you don't change or want to do all or even any of these, then that is fine too - it is your choice;
但是 /BUT
请记住 /Please remember
“如果你一直在做你一直做的事，你只会得到你已经得到的”
"IF YOU KEEP DOING WHAT YOU HAVE BEEN DOING, YOU WILL ONLY GET WHAT YOU ALREADY HAVE GOT"
20. “触目惊心”/"INSANITY"
One definition of insanity is "to keep doing the same thing over and over, month in month out, year in year out, AND EXPECT A DIFFERENT RESULT".
Unfortunately, the Corrugated Carton Box Industry (worldwide, but even more so in Asia, and even Japan) tends to keep doing the same thing, same methods, same philosophies, same attitude, same people selection process, etc., BUT, THEY KEEP HOPING for a different result, i.e. they HOPE:
a) 纸价下调 /Paper prices will go down
b) 纸箱价格上调 /Box prices will go up
c) 废品率下降 / Waste will go down
d) 找到更佳的人员（已经拥有绝大部分人员，但在做着不适合的工作）
They will find better people (they already have most of them but IN THE WRONG JOBS)
e) 更少的坏帐 / Less bad debts
f) 客户付款特别及时 /They will get paid sooner by their customers
g) 质量提升等等等等..../Their quality will go UP, etc., etc., etc.
但是 /BUT,
他们往往不希望或不知道如何采取行动带来大多数的变化
They tend not to want to or don't know how to take the actions that will bring about most of the changes.他们往往不希望或不知道如何采取行动带来的变化
21. 浪费率-80% /WASTE - 80%???
Now, I have set the scene for the need for (DRASTIC) CHANGE so that I can put a proposition to you today that:
"THE TRUE, TOTAL WASTE IN THE CORRUGATED CARTON BOX MAKING INDUSTRY IS PROBABLY APPROXIMATELY 80%"
Galileo said "We can't teach people anything, we can only HELP them DISCOVER it for THEMSELVES"
And, so, it is my passion, purpose in life to try to HELP YOU DISCOVER SOME ALTERNATIVES AND SHOW YOU WHAT IS POSSIBLE.
If it is possible in the USA or Germany or the UK, it should be possible in Asia;
IF we help you to:
DISCOVER THE ROAD MAP!
i.e. HELP SHOW YOU THE WAY.
Unless I spent the time on the theories of the GAP, MOTIVATION, NEED FOR CHANGE, MOTIVATION, SELF-ESTEEM, etc., etc., then there would be NO FOUNDATIONS on which I can build to try to illustrate my (absurd?) proposition that WASTE IS 80%.
1. 为什么专注于废品？
WHY CONCENTRATE ON WASTE?
a) 因为在我们这个行业，总的废品率可能达80%。
Because in our Industry, TOTAL waste is probably 80%.
b) 在世界范围内，所有行业，专家说总的浪废率至少是25%。
Across the whole world, all industries, the experts say total waste is at least 25%.
c) Reducing waste is the fastest, easiest, cheapest way to REDUCE COSTS.
d) It is HARD to raise prices.
2."NEW" DEFINITION OF "TOTAL WASTE"
This is my thesis, i.e. my proposition for further discussion, that our Total Waste is probably 80%, if we define total waste as:
"WHAT IS POSSIBLE
MINUS
WHAT IS ACTUALLY ACHIEVED"
Some examples:
a) A 1250 x 2800 mm FFG on its biggest sheet size at full speed can produce approximately 35,000 square metres per hour (SMPH or m2/hr).
BUT
In practice, in most plants, it hardly reaches 2,000 to 3,000 m2/hr (SMPH (per total hour)), i.e. 1/20 or approx 5% or a 95% WASTE.
b) A 2,500 mm wide 300 MPM maximum speed corrugator is capable of producing 45,000 (SMPH), yes, 45,000 square metres per total hour, i.e. 300 MPM on a web width of 2,500 mm for one hour.
What is actually achieved??
6,000 m2/hr?
10,000 m2/hr?
15,000 m2/hr? (I doubt it)
i.e. a "WASTE" of 60-80% of its possible capacity on a typical corrugator in Asia. Even a 1,800 x 200 MPM corrugator could produce 21,000 m2/hr.
c) A large RDC can achieve 45,000 square metres per hour
BUT
Most are hard pushed to achieve 2,000 to 3,000!! - i.e. a waste of 90-95%.
d) New presses can set up in two to three minutes - while most are taking 30 to 45 minutes, i.e. 90% waste. ARE YOU USING HARLEY OPTI-CHEK MOUNTER PROOFERS AND ONE-BOX SET-UP TECHNIQUES TO REDUCE SET-UP TIMES?
e) New digital presses "set up" in less than one second, so if it is taking your plant 30 minutes, HOW CAN YOU SURVIVE (long term)?
f) Paper machines and canning lines and bottling lines achieve efficiencies of 98 to 99%, i.e. only 1% to 2% waste.
g) The wrong person in the wrong job is WASTE - how much? My guess 20 to 25% (see below on methods of people selection).
26. OLD WASTE DEFINITION
Have you ever heard of:
a) 吨买减吨卖(因为纸箱不仅仅是原纸）
Tonnes bought minus tonnes sold (as boxes, not as bales)(old definition). (How do you measure "tonnes sold" or shipped??)
b) Paid Waste
c) Unpaid waste
d) 可控的浪费 /Controllable Waste
e) 不可控的浪费 /Uncontrollable Waste
f) 看不见的浪费 /Ghost waste (Pat Mafrici will explain GHOST WASTE)
g) W.I.P. (Work In Progress)(MASSIVE WASTE)
h) 客户退货（由于错误、质量问题等） /Customer returns (because of mistakes, poor quality, etc.)
i) 库存的完工产品 （为平衡不合格品而多生产的产品）（原本应该“制造并发货的）
Finished goods in stock (JIC - Just In Case) (should be "MAKE AND SHIP")
j) 过量生产 /Overruns (we'll use it for another job - same day - would you believe RARELY or NEVER?)
k) 错误的尺寸 /Wrong Specs
l) 错误的材质 /Wrong Grade
m) 超等级生产 /Over grade? (i.e. upgrading to the next higher board grade)
n) 剥皮浪费 /Peel Waste
o) 残卷浪费 /Core Waste
p) 错边浪费 /Misalignment waste
q) 打包浪费 /Tie Sheets
r) 垫板浪费 /Bottom Sheets
s) Cap sheets
t) Edge Protectors
u) Dunnage
v) Corner protectors
w) WARP (one of the greatest causes of, sources of waste - see below)
x) Side trim
y) End trim
z) Internal trim (waste)
aa) Glue tab waste
bb) Slot waste
cc) 127 gsm paper from the mill instead of the 125 gsm you ordered! (they never ship undergrammage - always over grammage, because YOU BUY IN TONNES instead of SQUARE METRES or in LINEAL METRES for a given paper width ordered). When the mill gives you 127 GSM instead of 125 GSM, they give you LESS LINEAL METRES, i.e. LESS PAPER
30. ENRONITIS
We've all heard of ENRON ENERGY CORP and Arthur Andersen (the auditors) and the:
a) "fraud"
b) wrong info
c) bad data
d) cover ups
e) etc., etc.
At the risk of being cheeky, naughty, I propose (only propose) to you that:
"ENRONITIS" IS RIFE, WIDESPREAD, IN THE CORRUGATED CARTON BOX INDUSTRY" i.e. the WASTE being reported to management is only maybe 10-20% of the REAL, TOTAL WASTE ACTUALLY OCCURRING.
Is it any wonder we all have SO much trouble making a fair, reasonable profit and a fair and reasonable return on funds employed (of 15-20%) in the box industry?
How many plants make 15% after tax on funds employed?
How can we, with plants costing tens of millions of dollars, hundreds of employees, paper costing 80% of our sell price and TOTAL WASTE APPROACHING 80%, get a good return on assets employed??
MORE AREAS OF BIG WASTE
a) 使用仅做感应硬化瓦楞辊，而不是碳化钨瓦楞辊
Using only hardened corrugating rolls instead of tungsten carbide coated ones
(because chrome is "expensive"). WHY WOULD YOU DO THIS?
b) 使用镀铬瓦楞辊，而不是碳化钨瓦楞辊
Using chromed rolls instead of tungsten carbide (T/C) because "T/C is too expensive", even though T/C DOUBLES roll life and REDUCES MEDIUM
USAGE BY 1 to 5%, saving tens of thousands of dollars per year for an extra investment of just a few thousand (ROI of 500%)!!
c) Running with full bridges on the corrugator when, since 1970, i.e. over 30 years ago, CWBP (Current World's Best Practice) was EMPTY BRIDGES.
为什么？ /WHY??
这使我百思不得其解 /This one STAGGERS ME.
在欧洲，所有好的纸箱厂的瓦纸运行时，单面瓦楞纸板都不会在天桥堆积。但在亚洲，只有非常非常极少数的纸箱厂可以做到这点。
In the West ALL good plants run with their bridges on the corrugator EMPTY but, in Asia, all but very, very few run with FULL BRIDGES, when, for a few dollars a day in cost, they can run at a minimum and constant and greatly reduce waste and make MUCH flatter board (and get a return on investment (ROI) of 500%!!).
CID and TAPPI both proved, with flat board:
a) WASTE WAS HALVED (the old definition) - less jam-ups, less rejects;
b) Productivity, output of finishing machines (converting) JUMPED by 27%.
c) Corrugator output jumped by (from memory) 20% -
ALL FOR JUST A FEW DOLLARS A DAY !!!
但是 /BUT
For some reason, 98% of Asian plants refuse to adopt this simple, PROVEN practice! WHY, I DO NOT KNOW OR REMOTELY UNDERSTAND. All it takes is a COPAR BRIDGE SPEED SYNCHRONISATION CONTROL.
浪费是 /WASTE IS:
a) 涂胶机使用压纸辊，而不是触压棒
Using rider rolls in glue machines instead of INTERFIC CONTACT BARS.
b) 双面机热板部使用重力辊，而不是热压板
Using weight rolls on double backer heating sections instead of INTERFIC
c) using upper/lower weight rolls in cooling/pulling/traction sections instead of
INTERFIC TRACTION BARS.
d) Using high limit, low limit photocells on bridges instead of COPAR BRIDGE
SPEED SYNCHRONISING CONTROLS.
e) Using old flute profiles with HIGH take up ratios instead of FRIESE
ROCKPROFILES with lower TUR's, faster run speeds, less vibrations.
f) NOT doing DAILY iodine tests on your board to inspect the single face and
doubleface GLUE LINES.
g) NOT doing a MONTHLY carbon paper test between your two corrugating rolls And then between the pressure roll and the corrugating roll. WHY NOT?? This is a fantastic, quick, easy, cheap diagnostic tool.
h) Not cleaning machines and tightening bolts, which has been PROVEN to DOUBLE YOUR BREAKDOWNS.
i) Producing fishtailed boxes and/or false scores and out-of-square boxes which has been shown to reduce BCT by up to 25%, causing you to use more kilograms of paper than needed to make a given board of given performance.
j) Allowing CRUSH on rider rolls, feed rolls, pull rolls, plates, slot heads, etc., and thus weakening the board and thus forcing you to use higher grammage papers than you otherwise would need. Rengo Japan, TAPPI, FBI, The Paper Institute all proved that the current variation in BCT actually achieved is plus and minus 25%, i.e. on average you ship 25% more to your customer than they pay you for, i.e. 25% WASTE. It is like shipping 12,500 boxes but only invoicing for 10,000, because our process is not in control.
近年来，同亚洲相比，制种同样强度的纸板，西方所瓦楞纸的克重下降了10～20%
In recent years, the West has downgraded grammages by 10-20% compared to Asia, for the same end job/performance.
k) Not producing a good score with MAXXSCORES or PATSCORES and so producing fishtail and glue gap variation!
Etc., etc., etc., etc.
31.人员挑选 /PEOPLE SELECTION
We (should) recognise that the psychologists and HR experts have all shown that there are ONLY FOUR BASIC TYPES OF PEOPLE, i.e.
a) RELATORS (social workers, nurses, psychologists, etc.)
b) SOCIALISERS (salesmen, entertainers, comedians, playboys)
c) ANALYSERS (accountants, engineers, scientists)
and, finally
d) DIRECTORS (the bosses, CEO's, presidents, entrepreneurs)
I PROPOSE:
Each plant needs a SOCIAL WORKER for all the employees to go to, so they can pour out their feelings, emotions, complaints, i.e. someone who has the TIME to truly LISTEN to them.
快乐的员工将极大的增加产出/质量/利润
Happier workers greatly increase output/quality/profits.
你可能拥有最好的服务人员在操作打包机
You may have the best social worker operating the baler?
你可能拥有伟大的销售人员但做一个普通职员的工作。
You may have a great salesman as a CLERK.
在亚洲有多少工厂做过心理测试，以将合适的人员安排在合适的岗位上。
How many plants in Asia do psychological testing for the suitability of putting the RIGHT person in each and every job.
For those interested, read or listen to Dr Tony (Anthony) Allessandra on the subject of correct people selection and the four personality types.
不合适的人作不合适的工作是浪费-他们不快乐，所以效率低或出错率高，并经常更换工作。
The wrong person in the job is WASTE - they aren't happy, so aren't productive or accurate and change jobs often.
员工流动率是浪费
Staff turnover is WASTE.
没有受过良好培训的人员是浪费
Poorly trained people is WASTE.
没有激励的人员是浪费
Poorly MOTIVATED people is WASTE.
然而，不要试图培训生产员工。首先，你必须选择、雇佣培训师，然后培训培训师，然后让培训师每天每时培训操作工。
However, do NOT try to train operators. FIRST you must SELECT, EMPLOY TRAINERS and then TRAIN THE TRAINERS and then the trainers can retrain operators on a daily, hourly basis each and every day.
Well, that is all I have time for in this short presentation of a few "radical" (but old) ideas.
Pat Mafrici will now go into greater detail on how to accurately measure and control and reduce waste, train the trainers (and not the operators), ONE BOX SET UPS, i.e. how you can SELL THE FIRST BOX, i.e. zero boxes needed for set ups, etc., etc.
If you can't (or don't) MEASURE WASTE ACCURATELY, how can you control it and reduce it?
Thank you all for giving me all your valuable time today.
I do NOT take your time lightly - I tried to GIVE YOU BACK GOOD VALUE FOR ALL THE TIME YOU GAVE ME.
I hope I at least motivated you to go and really, really look at the TOTAL WASTE in YOUR plant.
多谢
THANK YOU.
