Document 0jEL76gprzmoew19jyGDZVGk
CH-25 REV. 1240
E. I. d u Po n t d e Ne mo u r s & Co mp a n y
INCORPORATED
Ne w p o r t . De l a w a r e 19804
CHEMICALS AND PIGMENTS DEPARTMENT
cc: F. B. Bredimus J. R. Gibson L. Deming M. Williams
W- Bauer, C&P
Newport II
Wilmington
January 29, 1982
DU PONT CONFIDENTIAL SPECIAL CONTROL
To: P. A. Wriede Jackson Lab
From: S. A. Dombchik
1981 COST REDUCTION ACCOMPLISHMENTS
Attached are 1981 Cost Reduction Accomplishments at Newport totaling $1.7MM vs. 10/80 forecast of $0.65MM firm and $0.8MM goal. These reductions represent 53% of the total site cost reductions of $3.2MM. Most of the accomplishments are shared between R&D and Production. Included are $0.56MM of reduced Technical Assistance. Explanations are included for > 20% deviations from forecast.
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DUP050145864
N 26484.01
1981 COST REDUCTION ACCOMPLISHMENTS PROGRAM WITH VARIANCES GREATER THAN 20%
CPC
Pigment Losses ($136M vs. $88M fcst.; $155M vs. $50M Yield}1982-85) Results represent average loss/day weighted for
production rates; actual loss/day increased in 1981; additional opportunities identified.
Crude Consolidation ($410M vs. $320M fcst.) Improved manpower efficiencies achieved.
Finishing Consolidation ($0 vs. $158M Goal fcst.) Work terminated; Investment too high with inadequate
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Kerosene Reduction ($0 vs. $30M Goal fcst.jSlOOM vs.$150M 1982-5) Double decanter started up - did not reduce kerosene
consumption which actually rose 33%; work to remove CPC from decanter IQ-82 is expected to improve kerosene re covery; several causes of kerosene losses were corrected in 1981 to bring usage close to historical levels at year end.
Membrane Press ($42M vs. $118M) Presses installed; labor savings obtained; energy, water,
and yield savings postponed to 1982 pending installation of improved plates 2/82.
Energy ($168M vs. $30M goal; $250M vs.$150M 1982-5) Results obtained from overall economies in CPC
operation and minimization of "Dowtherm" boiler use; additional opportunities identified. o Technical Assistance ($117M vs. $0M; $180M vs. $0M 1982-5)
Technical Assistance reduced vs. budget and historical levels.
DU P050145865
N 26484.02
Low Cost Beta ($210M vs. $400M 1982-5) Product in market development; opportunity diminished.
Reduce Substandard ($6M vs. $60M 1982-5) Substandard reduction will occur at Newport, work will
allow reduced sales inventories; neither of these items on 1981 cost forecast.
DUP050145866
R&D COST IMPROVEMENT ACCOMPLISHMENT REPORT
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DUP050145867
N 26484.03
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1981 COST REDUCTION ACCOMPLISHMENTS PROGRAM WITH VARIANCES GREATER THAN 20%
Sodium Methylate ($75M vs. $124M; $200M vs. $0 1982-5) Reductions implemented late and in only one of two lines
due to Production Division concern over depressed yields; $200M additional savings potential exists with further re ductions identified through limited plant trials. Dowtherm ($15M vs. $70M goal; $300M vs. $100M 1982-5)
Work delayed-priorities; pilot plant work has de monstrated $100M+ annualized savings potential - basic data complete for II Q/82 MCN Aughorization. $200M opportunity defined to make Dowtherm from lower cost com ponents - will implement in 1982. o Energy ($0 vs. $150M in Firm + Goal; $165M vs. $0 1982-5)
Work delayed-priorities; $150M/yr. opportunities identified; at implementation and/or project stage. o Technical Assistance ($446M vs. $0; $170M vs. $0 1982-5)
Technical effort reduced vs. budget and historical levels. o Reduce Substandard ($47M vs. $0 1982-5)
Additional opportunities identified.
DU P050145868
N 26484.04