Document 23z122E3e0ZOmXxeKqE83Ga7

T. H. Huffman From Date: Subject: D. C. Skokna April 23, 1990 ABERDEEN MONTHLY PROGRESS REPORT MARCH, 1990 Safety There was one first aid care reported during March. As of March 31, the Aberdeen plant's employees have worked 3922 days (5,209,719 manhours) since the last lost time injury. FY 1990 Kev Statistical Information PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M March 40.2 93.7 98.2 1.0029 6.3 98.1 5.8 100.0 1.3 79.0 < 0.7> < 5.3> 204.0 Y.T.D. 219.8 86.3 96.7 1.0011 36.1 98.0 28.4 99.5 9.0 88.2 < 10.0> 135.9 447.8 Resin Flexible Compound Rigid Compound Plasticizer Operations 106.3 80.4 95.1 55.4 99.0 77.1 78.7 71.9 A temporary clean wall injection system was tested on D745, but it failed due to inadequate dispersion of the clean wall agent. A modified system will be tested in April. A trial run to make 5305 using decalcified water was successfully completed. Samples were sent to customers and BASF for evalua tion. In the compound unit, some twenty-four hours were devoted to PLENEX polymers development on Line I. Rigid compound demand continued to be strong with 2.5MM pounds being tolled for Gold Bond. VAB.0001190131 WPfffHJ mm mmBrnmmmmmmmmmmm*** j mm T. H. Huffman 4/23/90 Aberdeen Monthly Progress Report Page 2 - March, 1990 Costs Variable costs were favorable due to good raw material efficiencies in the resin unit and flexible compound unit, and to product mix effects in the flexible and rigid compound units. Fixed costs were essentially at budget. OMP 1. Ninety-five percent of the plant's natural teams met during March. Ratings for the plant's thirtyeight natural teams as of 3/31/90 were 5.1 - up two points from the last measurement. 2. The finalized version of the Q-Scorecard was presented to the facilitators. The facilitators are responsible for helping to communicate the details of the Q-Scorecard to all employees. 3. A full review of Uniroyal specifications was performed. These specifications will be proposed to Uniroyal by Marketing for their approval. The specifications include the most recently requested requirements. Doug Skokna Plant Superintendent rah DISTRIBUTION Houston J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin W. L. McClain J. F. Stokes Aus tin R. L. Foe X H. J. Hall Oklahoma City H. D. Garrison LCVCM Plant R. A. Conrad LCCP Plant J. Friend LCLAB Plant J. W. Ware X Baltimore Hammond. Blane L. R. Bauer J. Pavao C. R. Miller X X Aberdeen P. L. Foote RWS/DCS (File Copy), JEB, JME, SCH, MRK JEL. DAM. RBN. JEN. JDO. REP. RLT X X X X X X X X X X X X X X X X A VAB.0001190133 SAFETY - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Re ceiving/Warehouse Office Totals Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises S trains/Sprains Stings Other Totals March Fiscal Y.T.D. 1990 Fiscal Y.T.D. 1989 Lost Workday Cases Days Lost Last lost time injury - 7/5/79 Days since - 3922 Employee hours since - 5,209,719 On March 31, 1990, the employees of the Aberdeen plant completed 3922 days with no lost time injury. Topics for the plant safety meetings during the month included reviews of the new Plant Safety Handbook, Safety Attitude, Contractor Safety, Off-theJob Safety, and Severe Weather Operations. VAB.0001190134 1 * 4* SAFETY - Continued A seatbelt survey was done to see how many Aberdeen employees wear seatbelts to work. It showed that over 40% wear seatbelts now versus 27% in a similar 1987 survey. Annual physical examinations were given this month. The Health Examinetics van was here during the week of March 5, 1990. Routine dosimetry results for the month were: Chemical >_________________________ Numhar VCM Lead Total Particulates 77 100.0 17 100.0 6 100.0 0 0 0 0.0 0.0 0.0 Monthly Injury Summary Iniurv Class Department Description Laboratory Wasp sting, left arm. VAB.0001190135 The finalized version of the Q-Scorecard was presented to the facilitators. The facilitators are responsible for helping to communicate the details of the Q*Scorecard to all employees. Ninety-five percent cf the plant's natural teams met in March with 100% expected in Aprii. A full review of Uniroyal Plastics specifications was performed. These specifications will be proposed to Uniroyal by Marketing for their approval. The specifications include the most recently requested requirements. VAB.0001190136 s D. C. Skofcna A Variable Costs Product Total PVC Flexible Compound Rigid Compound Plasticizer $68.5 53.1 70.7 11.7 $204.0 $551.5 186.8 143.2 $900.8 $620.0 239.9 213.9 ____1LJ) $1104.8 PVC - Raw material usage and product mix were both favorable, Debox production was 55% below budget. Compound > Raw material use was $25.7M favorable, and product mix was $24.3M favorable. Essentially all of the favorable variance was a result of the product mix. High "VRP" production was the primary cause of the favorable variance. - VCM - Resin to Rigid Compound - Resin to Flexible Compound - 610P to Flexible Compound - Natural Gas - Other Price Variances Total Fixed Cost Variances $540.1 143.7 138.6 13.5 12.2 52.7 $900.8 Payroll and Benefits MM&C Miscellaneous TI&D Clearances Total SM <$37.3> 17.8 11.8 5.9 < 3.5 <$ 5.3> Payroll and Benefits - Overtime was high in maintenance for Welex repairs in the rigid compound unit, repairs to the Line III FCM compounder, and centrifuge repairs in the resin unit. Compound department overtime was high due to vacations, illnesses, and National Guard duty. M. M. & C. - Contract costs were below budget, but these were partially offset by material costs for compound unit repairs and centrifuge repairs. VAB.0001190137 COST VARIANCES - Continued Miscellaneous; Major variances in this category were: - Packaging Supplies - $17.3M favorable. - Operating Supplies - $10.3M unfavorable (due primarily to preparing for work s toppage). - Casualty Loss - $13.2M unfavorable (due to Workman's Compensation payments). VAB.0001190138 VINYL - J. D. Olson, J. M. Vinoski A The Vinyl Department had no first aid or OSHA recordable injuries during the month of March. The monthly safety meeting topic was "Off-the-Job Safety". General 1. The temporary BUS-80 injection system was tested on D745 in March. The system failed to keep the reactor walls clean due to inadequate dispersion of the BUS-80 in the reactor. The test was discontinued and a new test with a modified injec tion system is planned for April. 2. The decalcified water test run was completed in March. High resin calcium levels are believed to cause Klockner's graini ness problem. Tests show the 5305 resin produced with decal cified water had 4 ppm calcium (20% of normal) . Samples were sent to Klockner and BASF, and results are expected in April. 3. The resin raw materials in the 744 account were valued at $414.5M. - Production, MM Lbs. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime % Reactor Downtime March 40.2 1295.6 106.3 95.6 30.8 93.7 84.6 1000.0 98.2 Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks, New Module rinse/charge water conflicts, no place to dump, waiting on Q.C. data before charging, and 0-ring leaks). xm 219.7 1207.1 99.0 5159.0 28.3 86.3 75.4 90.2 96.7 Hours 241.3 Maintenance downtime (hydroblast reactors and drill condenser on D745, replaced agitator seal on D400, replaced control room Topaz battery backup unit, and mis cellaneous valve and instrument reDairs) 224.7 mmmmm wmmmmm Ml mm m VAB.0001190139 VINYL - Continued Dryer Downtime Reactor limited production. Operational downtime (centrifuge plugs, dryer cleaning, and flameouts). Maintenance downtime (centrifuge repairs, replace #6 Bird, shear pins, exhauster maintenance, sparge pipe replacement. Bird boot repairs). 78.2 8.3 13.5 Kev Maintenance Work - J. B. Autrey, J. B. Hegwood Reactor 745 was shut down for hydroblasting and condenser drilling during the month as part of the contamination control program. The S.A. module Westfalia centrifuge was shut down for pre ventive maintenance work during the month. A factory repre sentative along with a mechanic disassembled and recon ditioned the centrifuge. Number 8 Bird centrifuge was removed from service during the month and replaced with a spare. The centrifuge that was re moved was rebuilt and will be used as a sparge. The old reactor unit recovery condensers were shut down during the month for cleaning because of pluggage. The motor on the west fan of #6A cooling tower was replaced because of bad bearings and windings. Reactor 400 was shut down for seal replacement on two different occasions during the month. The two seal failures were caused by a plugged lip seal flush line. The line was plugged with resin which stopped the flow of water to the The vinyl control room Topaz unit was taken out of service and replaced with the Topaz unit from the compound control room because of bad batteries and a bad system control board. A Topaz service technician is being brought in to service both units and make any needed repairs. There were eight major valves changed out in the reactor area during the month. COMPOUND - J. E. Nickerson, K. G. Akins Safety The Compound Department worked without injury in March. The monthly safety meetings were conducted by operators. The topic of the meetings was "Safety Attitude Awareness". General Flexible compound demand continued steady in March. Line III was down for eighty-six hours for replacement of the FCM gearbox. Line V was down for sixty-five hours due to maintenance of the WernerPfleiderer equipment. PLENEX polymer testing was conducted for a total of twenty-four hours in March on Line I. Demand for rigid compound remained strong in March. Approximately 2.5MM pounds of tolled dry blend was produced for Gold Bond. Pro duction rates were limited during the month by mechanical problems with Welex #2 discharge gate. A total of sixty-five hours down time was due to maintenance required to repair the gate and replace bearings. The remaining two reactor agitator assemblies were replaced in March. Construction was also essentially completed on the API separator revision project. This project, conceived by a team of operators, allows us to recover waste oil from the API separator and re-process it as VRP. This waste oil was previously disposed of by paying a firm to incinerate the oil. Operating Compound Production Davs Month Line I 31 Line III 27.5 Line V 21 Total % Prime Capacity Utilization Factor 2035 66 3340 121 944 45 6319 204 98.1 .804 Downtime Fiscal Y.T.D, 12000 19916 4183 36099 98.0 .771 - Product Changes * PLENEX Polymer Testing - Quality Problems & Control - Dicer Problems & Maintenance - Miscellaneous Maintenance 88 24 19 13 7 COMPOUND - Continued Downtime - continued Line III - FCH Gearbox Replacement - Product Changes - Miscellaneous Maintenance - Quality Problems & Control Hours 86 62 21 8 - W-P Maintenance - Product Changes - Miscellaneous Maintenance - Startup/Shutdown - Quality Problems &Control 65 49 27 16 8 Operating Days Month Rigid Compound 31 5691 % Prime 100.0 Capacity Utilization Factor .951 Downtime - Welex Maintenance - Product Changes - Quality Problems & Control - Miscellaneous Maintenance Operating 184 toys 65 51 32 13 28269 99.5 .787 Plasticizer 28 % Prime Capacity Utilization Factor 1320 79.0 .554 9024 88.2 .719 Key Maintenance Work - J. B. Autrey, J. B. Hegwood The Line III mill was shut down for repairs to its FCM gearbox and rotors during the month. The gearbox and rotors, the reduction gearbox and the teflon orifice gate lines were replaced with existing spares. Also during this time, several minor maintenance items were taken care of on the mill. t r IMP I f VAB.0001190142 COMPOUND - Continued Maintenance Work - continued The #2 dry blend Welex was shut down for repairs to its bowl during the month. The bearings were replaced in the bowl and new pillow block bearings and a coupling were installed on the main drive shaft. .,, The #2 dry blend tfelex was shut down for repairs to its bowl gate during the month. The gate was sticking because of a misalignment problem. The gate was re moved, machined, realigned and put back in service. The condensate return line to the boiler house from the compound unit was replaced because of several leaks that had developed. A t VAB.0001190143 J. B. Autrey, J. B. Hegwood The old and new unit Lucidol day freezers were replaced during the month because of their deteriorated condition. Two standard chest freezers were purchased to replace the old ones. The freezers were modified to meet the appropriate regulations to use In these areas. The #2 water well was shut down for repairs to Its pump base during the month. The pump base had rusted out at the first coupling. The boiler blowdown line at the boiler house was replaced because of several leaks that had developed because of a corrosion problem. "i VAB.0001190144 ENGINEERING - R. E. Folk, S. C. Hillman, M. R. Kane PROJECTS IN DEVELOPMENT - GENERAL RVS Slftim JfoU Technology .a There were problems with contamination and reactor wall scale buildup when the initial closed reactor temporary addition system for D745 was tested. Modifications were made to this addition system and testing began again on April 11. After several batches, contamination and wall scale buildup results look promising. The class nAn design for permanent installation of clean wall technology was reviewed by the plant. PED has reissued this design and a partial AFE request has been approved to begin purchasing long delivery time items. Good Manufacturing Practices Manual A manual has been prepared to document manufacturing practices for making resin for FDA application. This manual was reviewed by the corporate environmental group. Their comments will be incorporated and the manual will be issued for review by the plant. The third fiscal quarter 1990 capital budget was issued. AFE's for all projects except the TC Compliance Project were submitted to Houston with the budget. 5305 Decalcified Resin A test run was completed during the month using decalcified water to make 5305. Calcium content of the charge water was reduced from about 80 ppm to 15 ppm and calcium content of the resin was reduced from 20 ppm to 4 ppm. The level of the competitor's resin is about 1 ppm. American Mirrex is satisfied with the results; Klockner has not commented yet. Wastewater BOD Reduction Baffles were installed in the biodisc to increase BOD removal. Modeling of the system predicts a significant reduction. Sampling is being performed to confirm the model. A VAB.0001190145 i ipawmmm Continued TC Compliance Project The class MAn design for the recycle of V-ll centrate and batch water stripper water to the cooling towers has been reviewed. The final design will be issued in April. Pete Markey (Quality Development) and Hike Kane taught a course in experimental design to employees at the Southwire plant in Carrollton, Georgia. The course was well received and very successful. *- VAB.0001190146 ENCHE IMCAL r ^ T CAPITAL PROJECTS 1 sssc Hi r 2*" K 25 82S8 e SS 2&SSS22S fiSfiS VAB.0001190147 ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were met for the month of March. Bioassay testing was also completed on our wastewater outfall. No toxicity was found in this test. The Mississippi Department of Environmental Quality (MDEQ) was in the plant during the month to collect samples from our wastewater and storm water outfalls. Results should be issued next month. Samples from the EPA were received for the annual lab performance evaluation. Results from the lab analysis of the samples will be sent to EPA next i onth. A baffle was installed in the biodisc to help increase this unit's efficiency to remove wastewater contaminants. Wastewater parameters will be evaluated in the coming month to determine if this baffle has made a significant difference in the biodisc operation. The biodisc consists of three rotating biological contractors which are highly aerated and remove a large part of the wastewater contaminants. Waste Waste shipments for the month included: Two bulk loads of separator oil to Systech in Demopolis, AL. h One bulk load of lead bags to GWM in Emelle, AL. One bulk load of API sludge to CWM in Emelle, AL. p One drum of phthalic anhydride spill to CWM in Lake Charles, LA. Sludge from pond #3 of our wastewater treatment system was sampled and analyzed for toxicity using the new toxicity characteristic leaching procedure. No toxicity was found in the samples using this test. Air The MDEQ did not review the air permit application that we submitted to become a minor source. Instead, they decided to take a different approach. They wanted us to change our air permit application to a con struction permit application for the VCSM project. When this was con sidered by their permit board, we would get both an operating permit with minor source status and a construction permit for the VCSM project. The construction permit application, since it calls for an increase of emissions of a toxic air pollutant, will have to go through a thirty-day public notice period. The public notice will be issued in April and we expect the new permits in May. r VAB.0001190148 r' ENVIRONMENTAL - Continued Air - continued The new operating air permit will have limits on all of our pollutants. In previous permits, the boilers and particulates were the only things listed. The new permit will include limits on vinyl chloride, plasticizer, alcohol, VOC's on the dryers and incinerators, and all combustion pollutants. A NESHAP authorization for the VCSM project was also submitted to the MDEQ. This authorization is necessary since we are modifying our plant and increasing the potential for vinyl chloride emissions. T Suoerfund Interviews were conducted with employees and contractors to determine what was buried on site. A file search was conducted to find any additional items of information on the sites, geo-technical information or groundwater monitoring results. A second meeting was scheduled with Conoco for April. During this meeting, we will also meet with a contractor who is interested in re claiming the resin in old pond #2 for recycle. Miscellaneous A notice was published in the paper for the Coker water wells. Proof of publication was sent to the MDEQ. 1 attended a meeting of industry and State MDEQ representatives during the month. We discussed the State air toxics program. A PMWwvqMMummnpmi PP^ VAB.0001190149 mm nar-90 H NAME K80CTHM IHKI SHEET OVEMU EIOINIM 'TOTN. KHIE MTEI* NOMECVGUS HASTE RECKLEI/MU MSIE 19HFY 7441138 3130239 4497113 P0UM3 1909PV 90 m 3 Until 8054439 3044204 5012235 3231151 1111217 2119144 1483101 448134 1215045 I. Offtitt. Hazardous Hast** 321409 329304 140443 62942 * Laid to ItutH ii. Hazardous Solid! c. Noo-Mazardout Trtattd as Hazirdoni 2412 79040 239930 6006 89445 233033 510 28437 139494 510 23540 38892 11. ftocvclod Hazardws daotto Ajn?oa 600000 240493 122266 III. Offtitt. Noo-tiazardooo Hast! a. Rocvclod M b. Nn-ftocvciod 2429430 2357718 844407 363982 247201 2112229 247500 2110210 119952 725535 60907 303075 IV. VosoraOlt Oy-ProOscts 3997454 4076654 1751210 1031893 V. Total Sait! dittr 4424917540 4270245041 2434170170 1190574094 VI. Air It Mattr a. SAM - Air b SAM - Hattr c. Non-SAM - Air d. Non-SAM - Mattr 644417 604602 234109 102019 73316 55 264206 309040 65494 333 244290 274344 29554 230 48735 157579 14703 88 19722 67505 VAB.OOOl 190150 ir-90 hmr interval man on; * okmu ezcuum tbth. mn war NMHKCYCLU IMflE R8VCLES/WJ HASTE 3 RMIM M.Z7Z 9MR 108.442 90 no 86.402 72.991 95.791 1999FY 103*512 94.941 109.511 1. Offaita. Huir4oui U*ttn 74. m 104.442 100.481 a. Ua4 lu Haataa b. Hazarioai Soil is c. Noa-Haiarioaa IrtataO at Haxardoaa 80.191 114.001 62.071 42.912 73.411 118.172 244.741 111.191 95.772 U. Ramltd Hazardaaa Haataa f' III. Offalt. Noa-tiazardoua Haiti a. Racivciad b. Haa-Aac*vcl ad 71.471 77.311 103.511 57.371 70.821 95.372 14.351 53.182 99.421 47.471 99.391 95.031 IV. Vwortbli Ir Proneti * 101.M1 99.942 111.342 V. Total Hast* Hatar 103.721 111.891 95.011 VI. Air 6 Hater a. SAM - Air b. SAM - Attar Hot-SAM - Air d. Noa-SAM * Natar 60.412 74.212 91.902 76.791 11.931 88.051 612.221 875.921 592.121 28.581 37.491 98.301 83.642 103.632 87.241 A VAB.0001190151 ENERGY CONSERVATION * D. A. Moore March. 1990 I. Energy Conservation Data(t) A. Unadjusted EUI <0.8%> fi. Adjusted EUI <0.7%> C. BTU/Lb. Product 2471.0 D. Total Energy Consumption MMM BTU 132.49 Fiscal Y.T.D, < 9.7%> < 10.0%> 2695.0 788.71 Plant Energy A. Maintenance There were twenty-nine energy related items completed in March, 1990. Twenty-five of these items were steam leak repairs. The remaining four were steam trap re pairs . Ill. Boiler Operation Boiler Mar.. 90 Fiscal Y.T.D. No. 1 No. 2 No. 3 83.2% (1) 83.0% 83.4% 83.3% 83.0% (1) Boiler number two was not operated during the month. ^ VAB.0001190152 None J. E. Btall fr- 5 James M. Edwards - Promoted to Chief Plant Chemist from Process Engineer. Jim Vinoski - Transferred to Operations Engineer-Vinyl from Mechanical Engineer. Robert Rickert - Promoted to Design Drafter from Drafter. ' Rita Holloway - Promoted to Secretary from Steno Clerk. Amy Vernon - Promoted to Cost/Fixed Asset--Accountant from Accounting Clerk. Teresa Pounders Promoted to Materials Coordinator from Accounting Clerk. Judith Frossard - Promoted to Analyst-Payroll from Payroll Clerk. Sharon Palmer - Promoted to Materials Coordinator from Accounting Clerk. Michael Kane - Promoted to Senior Process Engineer from Quality Management Coordinator. Debra Lemmons - Job reclassification from Steno Clerk to Analyst-Maintenance. Terry Sullivan - Job reclassification from Steno Clerk to Secretary/Receptionist. VAB.0001190153 Marofc, 1990 04/12/90 nlgt 2 Cremolia Wren - Job reclassification from Accounting Cleric to Analyst-Accounts Payable. Joyce Frederick - Job reclassification from Order Clerk to Analyst-Order Entry. +r Jim Jessup - Promoted from Lad) Trainee to Laboratory "A" Technician. Dale Wilbanks - Employee bid to Compound Utility position from General Helper-Compound. Hark Williams - Employee bid to Compound Utility position from General Helper-Compound. Jimmy Winders - Employee bid to Compound Utility position from General Helper-Compound. Robert Williauns - Employee bid to Lab Trainee position from Head Building Attendant. Jimmy Morgan - Promoted to Maintenance General Mechanic NB" from Maintenance Helper. Jeffrey Sykes - Promoted to Laboratory MAM Technician from Lab Trainee. Jerry Jenkins - Employee bid to Head Building Attendant from Compound Operator. None Kenneth Birck * None Salaried Enplnyaas 75* Hourly EidIotmi 172 Total Eaployaas 247 March, 1990 Minority Enployaas #, % Salarlad 6 Total 66_____ 72_____ 38Z 29Z Nan Enployaas 0 Hourly Min. Hlrad n . Terminations 0 % Min. Hlrad n Hourly Min. Tara. 0 % Min. Tara. DgSAETMEHTS PAR. atMWilTffS MTW WXP \HTS fflEg WMB YTD THUM . TURNOVER YTD. Warehouse 16 a 0 Gan. Plant 13 o Maintananea 41 ii 10 aa 24 00 24 24 5 22 0 Compound 40 38 26 67 0 0 Vinyl 33 33 10 30 0 0 a4 Flasticlsar 5 5 2 40 0 0 Nuubar of Applicants: Month 0 Yaar To Data 0 APPLICANT BREAKDOWN: # Minority Q % Minority q # Fanala 0 % Faaala 0 Hiras (Hourly): Month 0 Yaar To Data 0 Tarminatlona (Hourly): Month 0 Yaar To Data 0 Overall Turnover 0 Projected Annual Turnover 0 VAB.0001190155 M ( CO 'JLA *X LU CO Ui CO CO tb tJi* tL? I j.---* J t 1 CO I 1 t o CO l 1 1 o ! 41 I CM 1 MX 1 4^ L o. 1 a* 1 J mX * CM 1 o I 4 ro 1r ro 1 00 i o. CM 1 CM t 41 i 4 1 MX i 1i fi Pi ii LCN 0*4 ro CM rJ I I I I a? t i i i t - I * CM I - I I t ii ii o i i o O II I4 I4 4| C4 I in ! in t I O MX t 1 On 4i CO i i iitn ro i i i ! 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II i cc i 1 CJ 4i <r i 'O 4 i i 4 1 4 CK 4 i * 11 ( <r I 00 1 ir- CJ 1 CJ 1 in 4I M I 4 1 4 -t-- i 1 1 r in i CO 1 kCl I MX I 4| I1 MX * o cm i KX U tuJ 1CJ *Z U-U `CO I to i CO i LU i SC i i CJ i i to i I t in 4 < CM oa t f ro i ro <* i -I *4- | I I I * 1 OI 4( O4 4 t 1 P I ro T Ck i ro l CM l I I CM It 4( CM I I I I I cm i 41 4 cm t i I 1 I i i in i CO i ai i* --*J * I CM f i in CO i i CM in in in in 1 in I CM 44 4 <1 I ms I ro I tn I in m i in I I CM i rI I 4I 4 n* i ro I I i r* cm i ro 1 t 4 \ I I M3 I oc i i I i II I II <J o w I LU *I LU i I CO i i ro K4 p i H* * ro I CM t cd i 1i CM ro in i in 4 fO I I4 i ro O4 1 CO H i i I O CO i I On On I rH t ICO wd 0 IO I 1 o ad o i i i i i i p m i i in4 i i i i i in CM4 in oo CM in \ 1 1 1 1 \ O1 in4 1 1 CO 1 CM 1 1 <D 4 ro oa i i i i i i in CM4 o m i i i i i i in 4 oino i in oo i i i i i i i in CM ro ii 1 ILU I f If 1 IUI cj i 4 CM in CJ i i i i i i 1 1 41 1 <*-- 1 1 tn r- fN* ro i \ i t i o CM ro i i i i i i i t i t i i i i i I i in I CM 4 II I MX i ro I 00 I 1 I CM 4 4 I t in i 4| in i t i i in i n i in i CM I 4| CM 4 I * CM 4 i i MX I i t CM i irno ii r- ro t i CM I i i i i i I CM i in CM I I P i i i i i i i i i i ii ii KTt t l in i in i r*- i LTi P CM i r-- * -- cd i * i i 4i 4 4 f-- xx X CO * i i ! 1 `T i in i l in CM i i i p i \ in i-- >-- Od I ax 1 rO l CM i i CM roxc i 1 l ro i ! 111 1 1 in i 1 in 1 iff 4 1 i r4 i i n 1 1 1 4I in 4 ii in4 >o 1 i CO \ 1 ICK 1 M3 i CK \ ClN 1 CM 1 CM 1 i 1 On 1 i CM 'O 1 1 t in 1 m 1 00 I 00 l 1 1 ro i ro t I to 00 4 ro 4 *pn oo tn CM 4 CM in CM CM CM in in 4 ro CM 00 in CM MX C O'J *-U cj 1 Ui J P UI f ! p 11 1 3C 1 XC 1 1 ad 1 p 1 Ou i LU 1 1 a p-- 1 1 cr JZ 1 J 1O Ui 1 --J 1 i -U t 1 Q0 1 o 1 1 UJ 1 Cd 1 UI 1 1 1 ad 1 a t t 1 I cj <x l <X 1 P ui i ad 1 o i 1 1 1 i 1 CJ p 1I LIMUJ I LU i --J I - 4 <E 4 CO I A t I L_S Oo 4 44 CM CM CO**- -- ro ZX <E LU to to to cl <r<r VAB.0001190156 mb- A DEPARTHfcNlhL HOURS ANALYSIS REPORT DISTRIBUTIONI f LIST RWS, JFC( JVU, DEPARTrlEWT HEADS, FILE 5/90 THRU M 1/VO MARCH, 1990 2: 1 O i 9 1 9 1 1 QCO 1 O t 9 1 9 1 9 1 9 f 1 t 4 1 4I H-20 f t 00 t 1 cm 1 9 *z 0 1 r-4 1 1 CM 1 r*- 1 1 f 1 'O 1 1 <r 1 i l1 I i1 1! I O <* 00 9J 9t *I I I CM I I I in CM I * l11 tn if ro1 1 ro t CD O* 1 1 ro Q UJ 1 <_ i1QEi<C 1 1 1 1 C44 CM f t 4\ 1 NiJ t 11 O* 4 1 I 1 I 4 C-4 1 1 1 1 r-j O4 4 cm "-O 1 o*- i rO i i 4 Cm NO 4 LU LU !1 1 *1 t 1 ^ P 1 rt ICS 1 1 1 11 9 1 11 O 1 O <> 1 1 9 1 O* 1 ro t jn in 1 in 1 9 1 l M3 1 9 f 9 ro *n E f O 1 O 1 f 11 1 CJ 1 i1 1 1 1 11 tO 1 CM t 0 t 0 CJ 1 + 1 C4 i. - r rH pfj i in n 1ten t t r-j 1 1t 1I LTi I 1 9 1 ro 1 On 1 OO 1 1 9 1 ro 1 O 1 CM 1 9 1 4f 4 1 91 1 CM 1 9 1 9 t1 LlJ t 1 t I1LO I 0 t O 0 11 9 1 9 1 1 919 9 0 !91 O 1 0 1 9 1 9 1 Cl CM 9 iuj <z icj ilu ICO ICO I I I I I cn 0 in 191 11 1l 1l l1 O1 1 191 9 o' 9 rO 1 9 1 9 i1 91 91 9 1 91 9 11 1 1 t1 1 1 11 1 1 11 1 1 nO 1 To" 1 9 t 9 1 9 CM 1 0 i 9 1 9 1 9 ro 1 CM 1 9 1 O 1 9 CM 1 1 1 1 co 1 t 1 ICO i \ I I tIUxzJ |H-1 luc IUJ I I I i LUCO cjo 1c1n1 en <r 0 9 1 91 tO1 1l in f1^ 1 1 1 in 1 CM i e 9 1 1 in CM 1 1 O O 1 1 O in 1 ! O 9 1 in 1 1 CM 1 9 O O1 1 O1 1 1 9 O 1 9 I 00 1 CM 1 9 1 9 1 GO 1 9 1 9 1 1 9 1 ^j 1 9 1 f i CJ 1 1 CM 1 1 1 11 ! CM 1 1 i 1 1 o>1 1 *0 1 1! l 1 1 1 l l1 1 1 111 1 1 1 OLU CM CM co co 00 in 1 cm cm 1 11 -o 11 CO I 1I ro 1 r 4 CO 1 I 0-4 00 I I I O 1 1 1 9 9 4 1 1 i 9 9 m 1 1 1 O 9 1 1 91 in 1 in CM 1 1 1 in 1 9 9 1 1 in r- 1 1 in r-- 1 1 in CM 1 1 9 in t 1 9 in 40 OC 1 C4 1 C-4 1 09 1 00 1 O-- 1 ro 1 <1 t D* 1 1 1 i 1 I1 1 o- 1 CM 1 1 m3 1 1 ro 1 0 1 CM 1 11 1 m3 1 11 f 1 pro. i 1 M3 1 -0 | OO % 1 1 l 1 i 1 1 1 1 \ ! LUO 4 CO JO 19 IO I4 iin 100 1 PO 4 w <M 1 LUO i 0 1 1 in 1 in 1 1 i 0 1 9 i CM 1 r-- 1 1 1--; i 1 i91 1 ro 1 ro i 1 1 CM 1 CM 1 CD 1 CD 1 1 as od 1 ro 1 M3 1 9 i 00 1 1 H Of 1 t 1 in 1 CM i i enz 1 11 11 ! in 9 V 9 1 in f 0 1 9 1 9 19 in 1 9 1 CM 0 1 9 1 9 iin 11 J 4 ro ro ro f CO 1 ro 1 0 ! CM 1 O 1 9 1 *h3 r Cm 1 9 1 On 1 9 1 1 On 1 C- 1 iro i-v IO* 1 1 in 1 m 1 1 un 11 1 1h ICM 1 t 11 11 1 * 1i 11 1 t 11 i1 1 11 *1 CO i 1 1i ff 1 i 11 it i 1 1 1 LU * 1 1 t 1 1 eji 1 t * i 1 1 1 t 1 z1 1 <c i j 1 LU 1 i to 1 07 1 1 J UJ 1 1 O 1 1 1 1 1 * H -- 1 \ 1 1 0 i 1 1 t >* 1 1 Mi t- t z LU z 1 1 1 1 \ dO 1 <e 1 11 ac O)m M 1 1 1 1 O UJ * 1 1 <0 UJ ac J 1 i t 0J LU 1 i 1 1 Uuji oa 1 1 1 I 1 Cl. 1 OC 1 i 1--4 1 i 32 i 1 O1 1 CM cj CO UJ 1 1 LU 1 1 < 1 1 2 1 1 <c sc 1 1 CJ i car 1 <C 1t1 <r 1 1 U1 1 1 UJ O 1 1 O' A 1 l1 O <c 009 *** CM CM CO U4 COCO <E VMMUfNWf MP P VAB.0001190157 ADMINISTRATIVE SERVICES - J. E. Little Safety There were no safety instances this month. Cost Savings Savings due to competitive bidding were $891 for March, and $72,355 for FY1990. Savings due to prompt payment discounts were $2,300 for March, and $12,817 for FY1990. Savings due to using were $8,121 and $14,306 materials (AFE and work order stores) March and FY199Q, respectively. Warehouse - Finished Goods Inventory Slow moving and off-grade inventories still remain a major concern. Slow Moving Flexible Compounds (M Lbs.) Rigid Compounds (M Lbs.) Total 931 1063 Revised list has been provided to Fred Will lams 481 41 522 Employee Development Ann Wren began cross-training on the Materials Coordinator position. 0739 Janice Minga has been training in the Stores Supervisor position for vacation relief and development. Meetings im Central safety meeting. 3/06 Lab Natural Team (Pat Wells) 3/08 Tommy Cummings and Judy Frossard assisted Kerr McGee with payroll questions related to a twelve hour shift. 3/15 Quarterly carrier performance 3/15 3/20 Guards Natural Team (Tommy Cummings). Activity-based cost accounting. SERVICES - Continued Meetings - continued 3/27-28 OASIS presentation in Houston; Jack Little, Amy Vaughn, Linda Michels and Amy Bagwell attended. Numerous negotiations/preparation meetings for the 3/19/90 vote. A VAB.0001190159 - J. M. Edwards, Jr. A. Safety - There were no safety incidents in the Laboratory for March. The monthly safety meeting topic was the "Phillips' Plant Explosion Film" with Billy Paul Sizemore in charge of the meetings. B. Customer Contacts - There were no customer visits made in March. 3/05 Localized contamination was found in the tops of two compartments of a 5415 railcar. The material was accepted after further sampling. A Southwire technician reported that the contam ination samples had been thrown away so there was nothing to analyze. It is suspected that the contamination comes from jarring the loading chute after the silo goes empty. 3/28 The customer, Chemical Resins Corporation in Toronto, Canada complained of a "foul aroma in Vista material". A sample was received and was found to contain blue/white dry blend. The product was sold as sifter overflow/resin offgrade. Requests There were no requests for corrective action during the month of March. Customer Product Blane 5395 Blane 5415 D. G. Moulding 5305 Essex Group 5415 Southern Plastics 5385 Reason Static Flow Static Flow Particle Size Static Flow Particle Size No. 4 R/C 1 R/C 1 R/C 2 R/C 1 R/C VAB.0001190160 LABORATORY - Continued F. gyp"*TM The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVGK during the month of March, 1990. Number of Samples Average RVCM, ppm 956 125 39 0.437 47 0.365 The following is a summary of the residual VCM analysis of shipment samples for the month of March, 1990. Product 5265 5305 5385 5395 5415 Dry Blend Debox Pond 51 84 55 8 76 60 19 0 Average RVCM. oom 0.135 0.149 0.440 0.148 0.024 0.095 0.472 (based on dryer "regulars") 5265 Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Drytime Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle fize, microns 1.42 0.81 -- 6.17 3.33 3.00 2.83 -- 1.74 -- - -------- -- -- 139 5305 0.89 0.80 0.47 3.25 8.00 6.00 0.56 -- 0.44 -- -- -- ---- 135 5385 1.40 0.79 4.22 2.67 1.67 -- 1.63 2.00 -- 26.4 164 5395 0.23 2.25 13.67 6.00 1.38 -- 1.44 1.00 6.97 -- 4.3 158 ^415 1.36 0.67 4.67 6.67 3.78 0.44 5.44 1.00 3.08 1.92 -- 172 A m mm VAB.0001190161 mmmm I at LABORATORY - Continued Hardness Color Hard Particles Contamination Dicing Cross Contamination Streamers Metal Totals M Lbs. (%) 31.0 ------------------- -- -- -- ~ --------- 31.0 <0.48> -- -- -- -- -- -- ---- <0.48> M Lbs. (%) 28.3 10.1 72.3 4.3 27.9 18.5 0.8 2.8 165.0 <0.43> <0.16> <1.11> <0.07> <0.43> <0.28> <0.01> <0.Q4> <2.53> Torque Rheometry Color Total 72.8 .3^2 81.1 <1.27> <Q.15> <1.42> 1. The IBM xT computer that was being used to store compound and dry blend data was moved to B. P. Sizemore's office (Q.C. Lab Supervisor). Here it will be used for certificates of analysis, resin shipment data evaluation and natural team reports. 2. Dave Cox assisted with the new administrative services computer installation after the EDS line was assigned. Dave also helped train the operator on how to move from one application to another. 3. The laboratory procedure to operate the new tensile tester, Sintech, was completed. Technician training is also complete. 4. Jim Edwards attended a three-day course in Interaction Man agement . All six natural teams met once during the month. Five of the teams were trained in problem solving techniques. The Chief Plant Chemist's Natural Team reviewed goals, the QScorecard discussed the Supervisory Development Program and presented the Vista Environmental Policy. 6. Ruby Boyd attended the United Blood Services Recognition luncheon in Tupelo on 3/22/90 representing Vista. mrnmm (HI VAB.0001190162 RESIN Ship Date 3/01/90 3/05/90 3/05/90 3/07/90 3/08/90 3/08/90 3/08/90 3/12/90 3/13/90 3/19/90 3/20/90 3/21/90 3/23/90 3/30/90 3/30/90 SAMPLE SHIPMENTS MARCH 1990 Product 5265 5305 5385 5415 Pond Resin Pond Resin 5305 5305 5415 5265 Pond Resin 5415 5305 Pond Resin 5465 5385 5415 5415 5385 Amount 2 lbs. 2 lbs. 2 lbs. 2 lbs. 20 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 100 lbs 50 lbs. 100 lbs 5 lbs 5 lbs. 50 lbs. 50 lbs. COMPOUND Ship Date 3/13/90 3/13/90 3/21/90 Product 39012 BLK 17121 WAT CLR 17462 GRY 545 16841 NAT 452-31A WAT CL Amount 250 lbs 200 lbs 200 lbs 50 lbs. 200 lbs A Custoner Imperial Research Ronald Mark Assoc, Inc. #* NICOLAS MARTINO Nibco NOVA PETROCHEMICAL INC. Tenessee Eastman Co. Arlington Mills Inc. Kare Plastics Cerro Wire & Cable Co. United Tech. Automotive Conex of Georgia Vista - Austin Plastomeric CELMAR TRADING CO. BATA SHOE CO. OF THAILAND Customer Superior Cable Trim Plastics Flexible Technologies r VAB.0001190163 COMPOUND (Cont.) Ship Date Product 3/23/90 18961 NAT 3/26/90 34311 B6E 10 3/29/90 17462 BLK Sample Shipments/Mar. 1990 Page 2 Amount 50 lbs. 1500 lbs 50 lbs. Customer Florida Central Extrusion Superior Cable D. G. Moulding in/ioi vx DniiumSnmu Ship Date 3/12/90 Product 90172D WHT 110 Amount 1400 lbs. Customer U-Brand VAB.0001190164 NUMBER OF INJURIES ABERDEEN CHEMICAL PLANT INJURIES (TwcMe Month Running Totals) 40 35 30 25 20 15 r J`87F MAMJJASON OJ'aBF MAMJJASON DJ'BSF MAMJJASON OJ'dOF M TOTAL INJURIES O OSHA RECORDABLE VAB.0001190165 ABERDEEN ENERGY CONSUMPTION 12 MONTH AVERAGE VAB.0001190166 n