The above statement underpinned the desideration from John McBride MAIP and Principal of John McBride and Associates when he addressed the July meeting of Australian Institute of Packaging in Melbourne following the Annual General Meeting of the Institute. John's inspiring address was followed by an equally informative coverage by Charlie Hong MAIP Sales Director at Titan Packaging.

Colin Simpson the first Life Member of the Institute had graced us with his company for the AGM and one could not but reflect on one of Colin's mantras "we always have a good meeting when one of our own is the presenter".

John McBride was to tell us about best practice and tell us about he certainly did.  Having worked for over two decades in packaging plants addressing issues with can making and filling lines John determined that benchmarking is the greatest tool management can have. He advised that a computer program will not fix problems and to never trust data collection, and to be also be careful with Manufacturing Requirements Planning and the like systems.

John has experienced as much as 3.5% difference between the performance reporting data collected (and relied upon) by management and engineers. Manufacturing linesthat are straight can be up to 15% inefficient. He showed photographs indicating how a "cranked" production line can be flexible and reduce the number of personnel to deliver the finished articles. His message was "analyse the line before bolting it down"!

John has been involved with the Government Innovation Insights programs. Improving operational excellence amongst Australian firms lies at the heart of everything Insights to Excellence does. Uniquely operators do not advise or consult which allows unprecedented access to leading firms through which best and next practice is showcased to all.

An event, called an Insight typically lasts 3 to 4 hours and is structured around a site tour or Gembawalk (the idea of gemba is that the problems are visible and the best improvement ideas will come from going to the gemba).

Many times we were reminded that anything visual are the best way to communicate and John reinforced this with many visual aids. He raised concerns about benchmarking in Australia as there are often only a few operations to compare whereas overseas as many as thirty plants maybe available. His best case experience is South African Breweries that got into the Toyota developed lean thinking and has now become the dominant brewery in the world and owns our own C&UB.

No matter what, it is hard to stray from the three P's [PPP] and again they came to the forefront but in John's experience they are People, Plant and Process. He showed factual data that incorrect diagnosis or treatment is the second biggest mortality contributor in Australia. In manufacturing he has seen mortality due to inactive management and failure to understand basic principles. Exampled was General Motors which had total access to Toyota Technology through a joint venture operation but failed to adopt even the basics. Kodak failed because "it fed itself its own manure"!

Car manufacturers profitability range from plus 5.9% of profit to sales to the one with minus 17.7%. In the soft drink industry 83% of the cost is packaging and John demonstrated that some critical analysis could reduce these costs and improve profitability.

Quality yield by availability by performance is the equation to success. If a workforce is more than 15% of one ethnic group productivity will be overrun by second agendas. The best performers in the food industry are those that had the least waste.

The global expertise of John McBride was evident but his time had come to default to being an audience member and listen to Charlie Hong. It was a unique situation where a plant visit was combined with a stand-up presentation but Titan Packaging managed to do exactly that when each delegate was given a package of sweets in a Flat Bottom Bag.

Simply by looking at Our Signature Flat Base Box Pouch one was visually shown (which would have pleased John McBride no end) all the attributes of a flexible package for 21st Century FMCG packaging.

The easy open-ability and reseal-ability advice and instruction gave way to a listing of the Key Features. They are:

• 100% Flat base [no more wobbles]
• Unique box-like silhouette
• Suitable for automatics packaging
• 5 surfaces for branding identity
• Space saving design
• Save 30% on storage and distribution.

The automatic packaging attribute was shown on the reverse of the pack where an advertisement for a pouch packaging line was depicted in words and image. The available materials and the typical transmission rates together with Titan Packaging product range were encoded in the folded side gusset panels of the pouch.

We could have taken the package and had an innate knowledge of Titan and flexible packaging but Charlie and his colleagues wanted to let us know that their mission was "bringing real solutions to companies".

Humour was displayed on some of the slides used during the presentation but the company attitude to critical examination was depicted when two international packaging standard symbols were shown side by side. The umbrella indicates keep dry and the goblet signifies fragile contents. Titan Packaging bent is, when it rains drink wine!

Charlie explained that flexible packaging goes hand in hand with flexible contents when he said that the contents do not conform to a specific shape. Spouted packages are a growth product as are retort pouches. Particularly in tuna products and baby foods these and other flexible packs are eroding the traditional can and glass containers. 

Clear films are becoming popular and can now even be used for retort-able packs but the real advantage is to allow consumers to actually see the contents and not be guided by graphics that may not be true description.

Interactive and promotion friendly packs that are truly portable for on the go lifestyles are part of the burgeoning inventory. Modified atmosphere packs can work to improve shelf life and reduce packaging and product wastage. With sustainable and biodegradable films available the effects on the climate is enhanced as the mass of the used package was already ahead of the field in the waste stream. Comparison with glass both in original manufacture and the waste recycling streams was discussed.

Charlie Hong is really an advocate for flexible packaging but displayed synergy with John McBride's gospel. He advised that there are around 100 alternatives to get an optimum package but cautioned "flexibles may not be the only solution but certainly a good alternative".

The evening ended with a question session after which Chris Fice thanked the presenters in word and kind whilst handing them a certificate of appreciation.