中文部分為站長(zhǎng)翻譯，僅供參考，中文之所以放在前面，是為了方便中文讀者 文章轉(zhuǎn)自國(guó)外知名行業(yè)網(wǎng)站
1. 在生活中我們都需要一個(gè)目標(biāo)，即一些強(qiáng)勁的激情以實(shí)現(xiàn)自我， 也就是說(shuō)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.我的目標(biāo)就是教授、幫助、傳遞知識(shí)、理念、技巧、激勵(lì)。
Mine is to teach, help, transfer knowledge, philosophy, skills, motivation.
3.我們都需要反饋。
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.我們需要?jiǎng)?chuàng)造 /We need to create:
a) 激情 /PASSION
b) 熱情 /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）膽怯的人缺乏它 /Shy people lack it.
b)優(yōu)柔寡斷的人缺乏它 /Uncertain people lack it.
c)精神不振的人缺乏它 /Low energy people lack it.
d)提升身邊人的自尊應(yīng)該是經(jīng)理人的主要目標(biāo)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) 出錯(cuò)極少（更少的廢品）/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
我們必須擁有眼神明亮的人員，挺胸抬頭，自尊心強(qiáng)，并且精力充沛，行動(dòng)敏捷，反應(yīng)機(jī)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、積極向上、充滿熱情
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 /僅僅略微超出
我們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.太高的利潤(rùn)？
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、我的酷愛(ài)、我生活的目的是幫助你讓工藝受控（制板/印刷工藝基本上“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，我需要在你的現(xiàn)狀與想要的（需求）之間創(chuàng)造一個(gè)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
請(qǐng)記住 /Please remember
“如果你一直在做你一直做的事，你只會(huì)得到你已經(jīng)得到的”
"IF YOU KEEP DOING WHAT YOU HAVE BEEN DOING, YOU WILL ONLY GET WHAT YOU ALREADY HAVE GOT"
20. “觸目驚心”/"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) 紙價(jià)下調(diào) /Paper prices will go down
b) 紙箱價(jià)格上調(diào) /Box prices will go up
c) 廢品率下降 / Waste will go down
d) 找到更佳的人員（已經(jīng)擁有絕大部分人員，但在做著不適合的工作）
They will find better people (they already have most of them but IN THE WRONG JOBS)
e) 更少的壞帳 / Less bad debts
f) 客戶付款特別及時(shí) /They will get paid sooner by their customers
g) 質(zhì)量提升等等等等..../Their quality will go UP, etc., etc., etc.
但是 /BUT,
他們往往不希望或不知道如何采取行動(dòng)帶來(lái)大多數(shù)的變化
They tend not to want to or don't know how to take the actions that will bring about most of the changes.他們往往不希望或不知道如何采取行動(dòng)帶來(lái)的變化
21. 浪費(fèi)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. 為什么專(zhuān)注于廢品？
WHY CONCENTRATE ON WASTE?
a) 因?yàn)樵谖覀冞@個(gè)行業(yè)，總的廢品率可能達(dá)80%。
Because in our Industry, TOTAL waste is probably 80%.
b) 在世界范圍內(nèi)，所有行業(yè)，專(zhuān)家說(shuō)總的浪廢率至少是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) 噸買(mǎi)減噸賣(mài)(因?yàn)榧埾洳粌H僅是原紙）
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) 可控的浪費(fèi) /Controllable Waste
e) 不可控的浪費(fèi) /Uncontrollable Waste
f) 看不見(jiàn)的浪費(fèi) /Ghost waste (Pat Mafrici will explain GHOST WASTE)
g) W.I.P. (Work In Progress)(MASSIVE WASTE)
h) 客戶退貨（由于錯(cuò)誤、質(zhì)量問(wèn)題等） /Customer returns (because of mistakes, poor quality, etc.)
i) 庫(kù)存的完工產(chǎn)品 （為平衡不合格品而多生產(chǎn)的產(chǎn)品）（原本應(yīng)該“制造并發(fā)貨的）
Finished goods in stock (JIC - Just In Case) (should be "MAKE AND SHIP")
j) 過(guò)量生產(chǎn) /Overruns (we'll use it for another job - same day - would you believe RARELY or NEVER?)
k) 錯(cuò)誤的尺寸 /Wrong Specs
l) 錯(cuò)誤的材質(zhì) /Wrong Grade
m) 超等級(jí)生產(chǎn) /Over grade? (i.e. upgrading to the next higher board grade)
n) 剝皮浪費(fèi) /Peel Waste
o) 殘卷浪費(fèi) /Core Waste
p) 錯(cuò)邊浪費(fèi) /Misalignment waste
q) 打包浪費(fèi) /Tie Sheets
r) 墊板浪費(fèi) /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) 使用僅做感應(yīng)硬化瓦楞輥，而不是碳化鎢瓦楞輥
Using only hardened corrugating rolls instead of tungsten carbide coated ones
(because chrome is "expensive"). WHY WOULD YOU DO THIS?
b) 使用鍍鉻瓦楞輥，而不是碳化鎢瓦楞輥
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.
為什么？ /WHY??
這使我百思不得其解 /This one STAGGERS ME.
在歐洲，所有好的紙箱廠的瓦紙運(yùn)行時(shí)，單面瓦楞紙板都不會(huì)在天橋堆積。但在亞洲，只有非常非常極少數(shù)的紙箱廠可以做到這點(diǎn)。
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.
浪費(fèi)是 /WASTE IS:
a) 涂膠機(jī)使用壓紙輥，而不是觸壓棒
Using rider rolls in glue machines instead of INTERFIC CONTACT BARS.
b) 雙面機(jī)熱板部使用重力輥，而不是熱壓板
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.
近年來(lái)，同亞洲相比，制種同樣強(qiáng)度的紙板，西方所瓦楞紙的克重下降了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.人員挑選 /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.
快樂(lè)的員工將極大的增加產(chǎn)出/質(zhì)量/利潤(rùn)
Happier workers greatly increase output/quality/profits.
你可能擁有最好的服務(wù)人員在操作打包機(jī)
You may have the best social worker operating the baler?
你可能擁有偉大的銷(xiāo)售人員但做一個(gè)普通職員的工作。
You may have a great salesman as a CLERK.
在亞洲有多少工廠做過(guò)心理測(cè)試，以將合適的人員安排在合適的崗位上。
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.
不合適的人作不合適的工作是浪費(fèi)-他們不快樂(lè)，所以效率低或出錯(cuò)率高，并經(jīng)常更換工作。
The wrong person in the job is WASTE - they aren't happy, so aren't productive or accurate and change jobs often.
員工流動(dòng)率是浪費(fèi)
Staff turnover is WASTE.
沒(méi)有受過(guò)良好培訓(xùn)的人員是浪費(fèi)
Poorly trained people is WASTE.
沒(méi)有激勵(lì)的人員是浪費(fèi)
Poorly MOTIVATED people is WASTE.
然而，不要試圖培訓(xùn)生產(chǎn)員工。首先，你必須選擇、雇傭培訓(xùn)師，然后培訓(xùn)培訓(xùn)師，然后讓培訓(xùn)師每天每時(shí)培訓(xùn)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.
多謝
THANK YOU.
