Document 2jXbby2bezVam1QMkDz8VydKr

UL3TLALI, GYPSUM COMPANY K,, w. 'Brown * Ac me v J, n Lorenzo - Akron c. R, Googe *> Blue Rapids Ml Mn P owers - Brunswiek Ho 0V o Seims - Port Dodge J, Ba Moss Gra nd Rapids A o il Edmondson - New Orleans T( 4i M v O die haz'd s - Sigurd M, S. Jorgensen - Wilmington January 12s 1962 Paoli Laboratory Sub j i PLANT MANAGERS* HFETXIQ C 0 G Shu111e wor th/md 0, P0 Grieve - Paoli G,, A. Hoggatt - Paoli E,, Bo Hollingsworth - Paoli G, V c Wilson - Paoli E,, J. Cole - Paoli Ma tt Fink * Paoli H,, G,, Puckett - Paoli J,, Vanda*8 Hout ~ Paoli You Lava seen Mr* Wilson* s letter of Jan. 2nd* outlining the agenda for the 1962 Plant Managers1 Meeting0 Attached is a tentative outline of the various subjects to be covered in the Quality portion of the program, SGP 0020837 \ ) SGP 0020838 1962 PLANT MANAG5RS meeting AGENDA MONDAY January 22nd 10:15? A0M& - Report by Mr. Schrara on results of the nationwide survey conducted on our board products versus cornnetition, followed by demonstration of samples and discussion* 1:00 PaPL " Reports by Messrs,, DrownB Di Lorenzo, and Goose on the quality picture at their plants and program for 1962 to improve the picture* 3sl5 P^M* - Reports by Messrs* Powers, Zelms, and Moss on the quality picture at their plants and their 1962 program to improve the picture* TUPSPAY - January 23rd 8;30 Aoli - Reports by Messrs* Edmondson and Richards on quality picture t their plants and the 1962 program to improve the pictures 9:30 AMe - Demonstration of control tests on stucco and plaster, and the reasons the tests are made* J* R, Watt and T,, L0 Ravins* 10s 30 A* "T 11:30 A.Me Demonstration of control tests on board and lath and the reasons the tests are mad E E* Schram* Summary and conclusions ~ G 0 Go Shuttleworth and 0,, Grieve* SGP 0020839 \ V 4 SGP 0020840 RBSTU'ALL GYPSUM COMPANY PAOLI s PA. January 2,, 1962 Re: PLANT MANAGERS* MELTING G,, lii Wilson/hra \ TO" All Plant Managers cc Messrs 0 F,, Grieve - Paoli , B, Hollingsworth * Paoli Go A. Hoggatt '* Paoli C, Go Shuttleworth Paoli Bo Jo Cola ~ Paoli Matt Pink * Paoli li0 Go Puckett ~ Paoli. J0 Vander Hout - Paoli Attached is a copy of the agenda for the 1962 Plant Managers5 Meetings A change has been made in our arrangements since our original letter and the meeting will be held in Paoli rather than the Downing!" own Motor Lodge * Also, reservations for rooms have been made at the Treadway Inn in Radnor instead of the Downingtown Motor Lodge-, To reach the Treadway Inn, you should take the Paoli Local Train from 30th Street Station to Wayne and take a taxi to the Treadway "Inn* ATT. SGP 0020841 SGP 0020842 1962 PjUQT MANAGERS - METIN'G 23, AND 24TH AGENDA MONDAY - January 22nd 8:30 AM Opening .o. P Grieve 8:45 A*Mo Welcome and Comments . . u <- o o Malcolm Meyer 9:00 A.M Review of 1961 o <i o o o 19 0 0 Oo F. Grieve 9:30 AMo Out Quality Picture C. G. Shuttleworth 10:00 AMo Break ^ ^ 10:15 AM. Quality Discussions a o ) <a o q 12:00 PoMo Lunch ,,***,, o <? o o a 1:0G P.Mo Quality Discussions 3o O 3:00 PMc '0 a. (z ak o 'j o <5-0 0 '3 O >O O C. O O 3:15 Ft,M, Quality Discussions 0 > 3. .V * O Ot t> &> 5:00 P s M. End first day ,, . . <> CO TUESDAY January 23 re. 8:30 A.M,, Qua!ity 0is cus s 1 or.s a a t& & o o o o o 10:00 A,NU Break , ,, o v it & gu u o 10:15 Ao.Mo Quality Discussions O O OO 12:00 P ,i M Lunch ,, 0 = o o > O a e t) o Si 1:00 P,,Ma Relationship of Quality to Cosfs-E* Bs Hollingsworth 3:00 P.M. Break > <2- o a 5> o 0o 3:13 PMo Training Program , G<, li,, Wilson 4:30 1>,M. Summary * ^ - <A cj 0 0 0 0 9 0 0,, F Grieve 5:00 P,m, Closing >* o 0 0 0 0 0 09 6:30 P M. Plant Managers5 Dinner Treadway Xnn SGP 0020843 Page Two * Agenda -- PLAN MANAGERS1 MINTING WEDNESDAY - January 24th 8:30 AM - Group A to Wilmington Group B Paoli Conferences 1:00 PM,, Group B to Wilmington Group A ~ Paoli Conferences SGP 0020844 ) SGP 0020845 BESTWALL GYPSUM COMPANY PAOLI $ PA, December 22, 1961 Subject: PLANT MANAGERS MEETING TO: Mr, W, Brown ^ Acme for Mr, Jo Di Lorenzo - Akron"* Mr, Co R,, Googe - Blue Rapids Mr, M,, M, Powers - Brunswick Mr, H, j, Zelms Port Dodge Mr, J, R. Moss * Grand Rapids Mr, A. E, Edmondson ~ New Orleans Mr J, il,, Burkhart - Pryor Mr, T ,, W, Richards ~ Sigurd Mr, Mo S, Jorgensen - Wilmington Mr, J , W,, Hart - Thorold E, Wilson/hm .mJ i cc% Mr, <>,, P, Grieve - Paoli Mr, H<, B, Hollingsworth - Paoli Mr, Go A., Hoggatt <- Paoli Mr., C, G, Shuttleworth --- Paoli Mr, u J Cole - Paoli Mr, j, Yasder Hout >- Paoli The 1962 Plant Managers*'' Meeting will be held at the bowningtown Motor Lodge in Downingtown, Pennsylvania* on January 22, 23* and 24, Reservations have been made in your name for arrival on Sunday, January 21st, We x^ould ask each of you to advise us as soon as possible regarding your arrival schedule* and we in turn will advise you as to arrangements for transportation to the motor lodge, "Quality and its relationship to Sales and CosiC* has been selected as the" theme of this meeting. You should be prepared to discuss this subject in all its aspects, along with your own objectives of process, equipment and personal improvements for quality..control. Please"" advis e us ot~~SLnyr~specific topics that you "'would like discussed at the meeting so that these can be included in the agenda. SGP 0020846 SGP 0020847 3ESTMLL GYPSUM COMPANY PAOU, PA* November 29? 1961 Subjects PLANT MANAGERS MEETING 0 \ TO: Mr K= W. Brows - Acme ^ Kr J Di Lorenso ~ Akron Mr Co Ro Googe - Blue Rapids Kr. M. K. Powers - Brunswick Mr Ho Jo Zelms - Fort Dodge Mr Jo Bo Moss - Grand Rapids Kr T. Wo Richards ~ Sigurd Mr Jo Ho Burkhart Pryor Mr A. E, Edmondson - New Orleans Kr M So Jorgensen - Wilmington Kr. J. Wo Hart - Thorold cc: Kr 0. F Grieve - Paoli Hr E B Hollingsworth - Paoli Mr Go A Hoggatt - Paoli. Mr C G Shuttletsorth - Paoli Mr E, J Cole - Paoli Plans are being formulated to hold a Plant Managers* Heating in Paoli during January You will be advised shortly as to exact dates* The main theme of the 1962 meeting will be quality? and you should be prepared for any dis cussions on this subject As in the past? you should bring along your annual review of plant performance concerning quality and costs. ^^These mll be discussed if time permits"""'Also? your cost savings program for 1962 should be prepared for submission at that same time We plan some minor changes in this program for next year and will advise you as to the details of the program in the very near future* SGP 0020848 SGP 0020849 DESTWAIX GYPSUM COMPANY PAOLI, pa. November 30, 1961 Subject: CONVERSION COSTS AND COST SAVINGS PLAN Go E. Wilson/lim TO: Mr* K* Wo Brown Acme ^ Mr * J.,, Di Lorenzo - Akron Mr C, R* Googe - Blue Rapids Mro Ho Jo Zelms Fort Dodge Mro Jo B,. Moss Grand Rapids Mro Jo Wo Hart <* Thorold cc: Mr. 0o F. Grieve - Paolx I am quite pleased to inform you that substantial gains have been realized in conversion costs during 1961, and that we were able to re verse the trend of rising manufacturing costs for the first time in several years, Contributions to this reduction have varied from plant to plant, and I am sure you are each aware of your contribution Al though these gains have been made, I. feel that we have just scratched the surface of the potential and further improvements can be forthcoming during 1962 These again will vary from plant to plant, as the areas are more fertile for improvement at different locations. You have been advised to submit a cost reduction program for 1962 when you come to the Plant Managers * Meeting0 This is to be prepared on the basis of improvement in conversion cost itemsu As we did last year, we will set objective savings in the areas of Saleable Perfects, Machine Delays, Wet board and Grinding Waste, Machine Speeds and Board Weights. In preparing your cost savings program, this should include enough items to offset wage and fringe increases and still produce conversion cost reductions at your plants. These should be the goals for conversion cost reductions at each plant: Acme Akron Blue Rapids Fort Dodge Grand Rapids - 4% - 9% - 10% - 4% - 8% Thorold - 10% V I would suggest that you calculate the amount of savings involved, based on 1961 volume, and in turn prorate this savings by departments, based on the areas of improvement in each phase of your operation* This will not be an easy job, but with the help and cooperation of all your supervisors, this can be accomplished* SGP 0020850 SGP 0020851 i/.uAi>rr iiiK'i i mi JANa 22-24* 1962 OPENING REMARKS In the 1959 meeting at Brunswick* I pointed cut that the gypsum business had changed from a seller's to a buyer's market9 that there was plenty of productive capacity in the industry* and that quality would be of increasing importance in the future* in the ability to obtain our fair share of the marks! It Is plainly evident that the analysis was correct* as we are now in a very competitive market? and one of the prims factors controlling sales is quality. This is why Mr. Grieve has set quality as the main theme of this meeting* Our record in 1961* in general* was poor? although there are a few bright spots. Comparing 1961 with I960 we find as follows? 1960 1961 Total Comi laints Total Adjustments 953 $62,928.46 922 $74,607.93 By Plants? Acme - ~ Number Dollars 168 12*516.06 130 0*864.30 Akron - Number Dollars 9? k9970.56 96 9*021.58 "Blue Rapids - Number Dollars 42 2,457.49 95 13,992.70 Brunswick Fort Dodge ~ Number Dollars ~ Number Dollars 58 3*767.17 186 5,700.97 77 3,020*87 166 5,798.20 Grand Rapids - Number Dollars 191 7*689*60 138 5*031.82 Sigurd - Number Dollars 211 25,826.61 217 17,691.66 *Not comparable because of incomplete operating schedule S Joint Cement $11,186,80 ($20,051.10) L W fe SGP 0020852 On a defective basis, the record is as follows? Per Million Ft. of Board & Lath - i61 Number - hollars NumS'er - hollars Acme Akron Blue Farids .^Brunswick 'Fort Dodge Grand Rapids New Orleans Sigurd 0.253 0.497 0.256 0.355 0*821 1.042 22.84 19.76 21.8? 30.99 69.20 120.61 0.398 0.584 2.851 0.130 0.373 0.839 V?,0.435 49 19,73 27.29 290.15 9.78 26.73 44.08 21.77 94.22 Per 1000 Tons of Plaster 1950----------------------- ----------- I95T" dumber - Dollars Number - hollars Acme Akron Blue Rapids Brunswick Fort Dodge Grand Rapids New Orleans Sigurd 0.931 0.836 0.531 0.733 2.897 - 1.202 157.26 8.59 a. 14.34 40.18 60.34 - 203.11 0.747 0.861 1.047 0.691 0.574 1.222 1.647 1.252 322.06 31.74 168.85 27.64 34.73 13.75 184.25 57.07 On this basis* our biggest jobs are at Slue Rapids* Grand Rapids, and Sigurd on board and Acme and Blue Rapids on plaster. However, there are extenuating circumstances on Acme's record, which will be covered in more detail later* As a result of this meeting, I hope we shall all have a better under standing of the problems we face and what can be don about them,, CGS/v-id 1/17/62 SGP 0020853 r l.. i noli aol .Ill mi:a .useetoa::- ? ,. ipol 3-il>; ociIIOIIOT 1111,1 .1- iyz.ri?::z^'-is s;rt:...' nls :; .1;ic v .ring lepr -licit 13 nee iirrieted cirepariiire ieid-s on .Hint. ; ': r ti::;, m . ill cl on ?2 seles els in. ill the mi ini the i 1 id -.hi.*. n in toed Only 1.1 sit erstied in ir lyiiiiXe :i. nl e ; iiiiillli- e'C-plGted.. I 'blllm ms iulnd !.. :iiV teed is/: >ofe.:-- : iln ill:. the ulin; eh the ee airy 7y ihii: no have soles odlim The : ; n seek si l/2n Beilrli'l r2121 en1 sod the asm i.i . each si /a? ;.- iiyii leis '.'i :' mi nlss district.; ..-. ,y r = h on i-o moy ;-co yyiiiuiy re3 U. :t, <;>, nd : Kcl:' cenciioj.'ed- a v ..oigi iyee n.sy g/yysn mt'Cl i'hs ;usilty cl vest;' 'id oberivitiii; -re r 27 . H ii? tr-m nyor n'patxii 0 TJtrra ce iU.m m hV;:-'' ; : 1: bm.L lx?'denn L .L:2 27 01 linden; ' Cf.f, 7.123 71 tl Over SOfe 2CC 20S2 Odd-a. . - it r e; inf lilt : 7- c i.;n C 77; 7 nil.' 11 limn ol m 10c Vine less7- '-7 neo.; Col bill ns OOii end.l-mni.lv' xinul.sv?' ;...;yc-iti:n... '.,. S ; jl, it;. in ** i tel, 0ci.ii r:i lily Icll. LcVe ;..-'`'7. 7;. _ - ; m ,- . .... _ Ji >'; 1 5 ,, ' ' 1 1 *-: 2 _. mil lirijnei `~iyn 7/ Id 1 sndn 1 ns: :: hsinp:; 20cl iyi-c SGP 0020854 t vO-jJ Ji'/iiil'.Sj.' JUS The diincmsions of all boards xer<3 within permissible tolerances except one from Los Ax. gales 3a':.os (hcstwail Sigurd board} that was 5/3.6" narrow. The number of board?, cut cot of square and the amounts are listed below:-* Bests'll TJ, 6... G, .national -1 l/h !S 1 - 1/8 i! 1 - X/lS!t - 2 - X/lS!s - 5 - 1/8 " 2 - l/l$" ''ho caliper of all board;:; tested were within permissible tolerances although quite a fm had high shoulders- This condition is noted in the individual analyses.. IdAGZ-J&tSk STHEhdTH Ths transverse strengths f -11 hoards tested, wrra fairly close and. well within tolerances, Two ancles v/er-; broken in each direction for each board tested. The average of the Irererarse strengths are as ?ollovjrs: 11TK Gl,-1G ' lasr Average GROSS GRAIN' I fee* Kin* Average toatwall b . 3. Go, : National 78 68 69 Ul hB 66 5/. 57 5 226 I/O 227 166 219 163 18? - 185 188 ]J 1VG17S3 OF EG AGO The falling ball text is .: friction of boob core density and rock purity and they varied considerably ~d.Gh board free) all oosnanios,, No correlation between corn- gagv board ooiih be acta-?, hove-* lU3 to the f set tier bob'; 11 , G= rr;i National make a hard sdge board, their edge harduvrjs ras slightly hotter than ours, Although not greatly so. lixeept xn the few cares where an edge of the board was burred, penetrometer readings rarely -a over / . bDG};J5gBlT10h llge formation of g-aeiicxllc all of the board? vxs good except the few oases men tioned in xls xmli-ldr?1 ;rxf g?3. SGP 0020855 Oscm ev An " A t:;i k;djj ;t _ survey .Til Tbe rap&ret? rdy-a of r cb bos.nl tested was decked, for width and depth* The depths 3?,"'?; Aiotfd Selcm ha;;; imps Minimiaa Average Best-wall !J C Vr fir AT ^ Nationgl 002" 07.5" \}-}G" ,0:?0is s0:?2i: *0'2" a039 6036t! ^Oh.8" Nc average was computed. c the taper riclth, blit Iron cossrvaiicn it is noted that National h. ; a ":Tv.c;h \m*m;. vsriation than BnstpeAl or BA 3, G Las^.^\s And. tnocOArr was good on prsci .cally all board 'received, but from observations made it arpeare-i that lb to 0, had i slightly tighter bundle than, any of 'the other com paries* boards. `Bit balance Xoolced appropriately the same* TEA1 ST.diAS The srrieed aid tear .strips 3/8'h. l/i:L r./8r;j 3AH and 1/8" wide-.- However, ptiObiesily all of A, S,, LU ti bationrl vrac 7/r! and dstwrll was l/2!C The ten sile strength of th.. -" strips TQpeareU to bo prrsnrdlT a function of the width as the calipers ware q ;:.te rxdforja* One observation made was that the aucce.vs or fdlrro of a teas- s drip to pariorm sdlsfrdoril.y was hew it was centered in tie tdr wexu-tiry drn If If van well contend} t.i.3 fatso would be torn in shear anti it would tear off of ear!pa, Tf -ip -, -ft' ~rntsr ;,jnd the tape had to be torn in tefaton.. if . tear a laxp rcnld creak. C A dddGS I;x. :dg bo;.rdr xssh.d fiat bed face :whirrs wart: -.A 3 G-,, s'.minisA fror Tensas City ard 0jr-ma srl-s dirf-rids (roari Manufactured at Ft., Bode, Inn and Sperry, low ., The: vaarkinrr ewisirr of dinmaia Jr s and Gbs, iy! cm center, X/1a,! high, m ring Jentnvlse ft the beard Xon Iron each snlsr CXI fAA;K:.fd CL.. C'Ctrtpftitive \wX tested had coda auXw* one/ printed -on back, with the follow-iry rnriArus; I. Kaiser Ayosw wl their Tw/fGrark nKf on IfC?f'f.5.rG - 2f v,- If .-. board iron Mow York Galas had ralendf :1 nr A?;;- 5'intai.. 3 A-, :.f I., foarf Aron bars; Pity, rrabo, arid Ar.rtrv: rr print m A:r 2;Ar!!j,3lXc In rrfrra 'X;: fiirir 'yrrht to pra'/sat split pAy of SGP 0020856 .1.5; J5A ^ PgCgUGT SIgVE? DRY i HUI'IXu BOND The dry bond, was perfect ir. practically all cases.. The humid bond results varied considerably, hut in listing them all it appeared that BestwalX was slightly 'setter than National and both contcidsr.rbly better thar. U G* nCE PAPER In evaluating the hoard,I:ana paper was not considered as we thought it to be a raw material and did not afreet the quality of board products as manufactured by our gypsum plants. Samples of each board tested have been saved and will be painted both by brushing, and rolling for comparison. A separate report will follow con cerning this iicom observations made, it appears in most instances our face paper is not as smooth as that of oimpetiilcn. Samples of the roughest paper found have been saved lie were also asked to rate the boards from each sales district as the best (1), next best. (21, and worst (3). The results, in our opinion, are listed below:*" Bestwall U, 3c National Blue Diamond Kaiser JL JL 3 85 10 10 9* rCv 2 5 11. 1 1 * One board mads by Barrett, Mgewater, N. J, BesiwsXI boards from individual plants were rated as follows~ 1 Total Aetna Akron Blue .Rapids Brunswick Ft* Dodge Grand Rapids New Orleans Sigurd Kdgawvtsr 12 21 3. 2 3A 23 .i. u li. 1 The reasons for rating the boards as listed above ir- covered by sales districts in. Appendix Ac SGP 0020857 Deesjiber 13 - E9K PRODUCT SURVEY APPENDIX A CHICAGO !c Bestwall *0*4UVTV*#Bua-^t&zei/Tj>*\V- Ho U So Go good beard shoulder one side 3 o i'i ri 0-LOTic-.'- r.arrow tapers (ll/27! 1 1-7/8w) WASHINGTON . U * good be ax'd Bestwall "" fairly good board except email shoulder one side 3-- National - high sho-alders both sides, Narrow taper, l/8r cut of squareo SALT LAKE CITY `u Blue Diamond best of 3 but had one shallow taper and X/l6,? out- 02 oquare U* So Gw ~ I'dgh shoulders, narrow tapers j* Beatwall Mgh shoulder both sides. Rounded edge*. 1/8T out of squareo SAN FRANCISCO uatamuum> 1, US,, Kaiser 3- BestwalX fairly good board but one taper shallow j&Ty light board, l/lo!I out of square heavy board, ll/2" spl.it on edges SEATTLE 1 Kaiser to J5'S Ga vuii.ryr' vtrvw-iPsS. .5-J good board but- sb:s11 shoulder one side cupped taper- l/2,! split on one end one edge burned 1-1/2" one taper l-"?/8!i wide .'2`- 5,!f end op'-it on cbc end. SGP 0020858 Deec^fc-sr 1$ > ISo.- PRCDUGT SURVdX NjM YORK .U Uo S.^G - bast of ,3 but end grinding rough and had high " shoulders 2. National < end grinding roughs face paper burred. High sH^Tders both sides. Bestwall end grinding rough, face paper burredo High shoulders- One edge rounded. Narrow tapers (1-3/8r` & 1-3/8")- Tills board x<ras made at Barrett/a plant in Edgewater, N. J,, /iTLAINTI 1. Bestwall - good beard So bo Sc Ch - heavy board, $4/16" out of square 3^ National - uneven caliper, one taper 1-7/8" HOUSTON Sasiwail - good beard except ssnall shoulder one side 2. U. S0 G - and grinding rough, paper burred one end. One end split l/2n 71 National - high shoulder one side. One narrow taper (l-l/2,;)-' 1/8" out of square. l/h'A end split of face paper IQS AHOEXt-S ?.* Uo So Go good heard 2 KsLsev fairly good board except narrow tapers (1-1/2n 1 ,U Best-wall shoulder one side. One taper narrow (l?/8,!). l/lost 0 Sq^ai.=G-, One and and one edge burnt 2!1 5/l6,J narrow GLE'/b-IlND .L -i L''83T*t-aI.-X best cl 3 but edges slanting a little. Paper split National oxis high shoulderi Corners burnt, tight board slanting edges, very heavy board. Tapers l-?/8iS wide SGP 0020859 December 15s 196a. WtODIJS? SURVEY BUFFALO 1* Beatwall ~ best of 3 but one high shoulder* One taper cupped 2* U. S G. - tM.sk in noddle*. Shallow tapers. One taper cupped 3* Hatlonal - uneven caliper. One edge and corners burnt. Mon of these boards were good INDIANAPOLIS 1 National - beat on but had high shoulder, narrow taper, slightly rounded edge 2. U S. G -> edge and end burnt 3 * Bestwall ** edge anu end burnt Nona of these boards wars good BRUNSWICK 1. Bestwall -* good board. 2. U. S. G. ~ fairly good board but 1/2" paper split 3 National ~ slanting edges, narrow taper, 1" end, split CINCINNATI 1. National - good board except one taper narrow (l3/li") 2. Ua S. G shoulders both sides 3a Bestwall > end grinding rough. Paper badly burred. High shoulder one side. Very heavy board KANSAS CTTC 1, U. S 0^ - good beard except end grinding rough on one end* Face paper burred a little 2 c Bestwall - Fairly good board except one edge slanting slightly 3* National - narrow taper, 3./16" out of square, high shoulders I) AllAS *atf(hB.raSw. I-.-. U. S*.G. 2 > Bestwall good board one end burnt ~ 2" face split SGP 0020860 3 > National large groove k" from one edge 2-1/2" wide. Heavy board December 15> 196, DDUCT SURVEY PHILADELPHIA 1. P S G> - good board except one high shoulder 2. National - very thick shoulders l/8" out of square 3. Bestwall - one edge badly burnt. Pentromater reading 12 OMAHA 1. U. 5. G. - good board 2o National - one edge slightly roundeds l/8" out of square 3. Bestwall - end grinding rough. Paper burred. Out of square 1/V NEW ORLEANS 1. IT. S0 G. - good board except small shoulders 2, Bestwall - edges maided, small shoulders 3* National * end grinding roughs paper burred badly. High shoulder. One narrow taper (1~5/8R). One end calcined 1/1$n DETROIT s Uo S. 0. - good board except l/l6n out of square Bestwall - end grinding rough. High shoulders National -* high shoulders. 1/16" cut of square. One corner calcined badly. Bestwall - good board except l/Un paper split one end National - A little heavy, 1/8n out of square 3o U. S. G. one edge slightly rounded. Thick shoulder. One edge badly burnt,. 8i! split along edge TWIN CITIES 1. Bestwall - good, board except heavy 2. National heavy board - l/2" paper split one end 3* U S. G. - 1-1/2" split one end and edge (burnt) SGP 0020861 C.T7C7.7,- X? 77a 7^-7^r2-^-^^'' P fi * V TV < /, <*<* ry `^/' . /^7>" / f *y?4? & . //Pc^7^^^777, 7^? 3> 7 t'*?<?,,& 7d -,Z,, 7 7^ .* --`Sr- yL^\PZ* ' 7<-;//3 <^zT7- /^'^44/\sp; ^A-*-f-eriX 77 A >. #"' <,.# rfff_ , (7 7" y /l -y^a/Xj 7 /' /"/ /fc a 77 7''. "~f~' z/7 77 7 //</""TV-^'d ,.^.v- 7^- "ir-^-it * X ? 7 *T-*77 7Y cf <tV 7/<77 < ^ 77 ;<^P-?,' c//l A 'A S s -' `"-//^k%Zr'~y%- "'"* x ^ ;~ /. ,--d V 7' 77? - . ~. 'P' '"' A-' ^' ''" :d~'i ' 7^ /3, c gpf ,Z d. /'.- --(7^ -' t Sf - /dV<f. '//A..* {/> :/ . ^< >'-.7 ' 7' X;.. / / .' .f *' i y' ': -f, Cf..s..... >A. C/1 7 .- ' - '~?~~'c( J Si, <; X- /) ,. yzt &'*> , .,; V-\ l,, 5 i s /V, fV' //?7c d,i6.,. d ? dti., ' /?7- <<*".' ''t-'J:~-/7' /7-f 7 <7 7. ,/ ^ / f- -^f- X 7 -'7 7 7 - - ,/7' SGP 0020862 /& % SGP 0020863 SGP 0020864 ' 'Ij _ y y *`,S f '/<Z?-Cvr r J.V- 3 G?L-;\A /) i ('di& j "* / uJL...... C/s? "**1/4- la\} *K*,, V ~i " if L' ! '**- *% . . Vo lo<J . K-( o rj V UVf. 7^-y llio ryAd7 * A / <a )7:, C\ ; ^ ,./a a 7/ /. /- /! jL. > t .:. i o (s '-Hc'.^S-~/ t>'::/ v - d, r-//; Ua- 7a a .. 7 'U '/7f // < l. * y**> <'{<.* , U,, . , ^l/G, To... `-7 - <Vtt/6wv 6 - y ,\a. ji.-A 7w / j i-T / ,\ '"'J ` ' CD,, / 7'*-k'' ,x. SGP 0020865 SGP 0020866 Grand Rapids Ft. Dodge Akron Acme Blue Rapids Brunswick Totals Grand Rapids Ft, Dodge Akron Acme Blue Rapids Brunswick New Orleans Totals I960 Humber of Rail L & D Claims Filed Total Value Average Loss 15 3630.80 $21*0,72 22 913036 lil5l 32 2119.10 66.22 60 7297050 121,62 15 6UCUS 1*2.69 20 830.45 1*1,52 16U $151*11,66 $ 93 0 9? 4 Number of Rail L & D Claims Filed 1961 Total Value Average Loss 12 iUMoQO $120.50 51 2902 M 56.91 12 522,8? U3o5? 85 91*21.36 110.81* 13 -60.55 35.U2 20 1108.56 55.U3 1 113,36 113.36 19U $15975.16 $ 82,29 Cars shipped 12/1/59 to 12/1/60 1562 U712 1876 6038 1226 ia63 Ratio Claims Cars Shipped o0096 .001*6 o01?0 ,0099 .,0122 oQ0U8 19577 cOOBli Cars shipped 12/1/60 to 12/2/61 1613 U915 1282 5629 1905 5935 580 Ratio Claims Cars Shipped .0071* o 03.03 ,0093 ,0153. .0068 ,0033 .001? 21863 ,0088 SGP 0020867 RAIL LOSS & DAMAGE CLABE FILED OH GYPSUM PRODUCT SHIPMENTS (Claims due to wrecks & fires excluded) Year Humber of Claims Filed Total Value Average Loss Cars Shipped 12/1 to 12/1 Ratio of claims to 1961 1?U $ 15975.16 82.29 21863 .0088 1960 l6h l5Uil<>66 93.97 19577 .0081= 1959 203 11*918.39 73.1*9 191:35 *Q10h 1958 1957 177 1511*8 0 78 85.58 . ?220 19021.12 86 2 18725 1907U C09li .0115 1956 266 1779Uoliit 66.89 21:061 .0111 SGP 0020868 J- \: , P j r'i- rvp ; "f y.: SGP 0020869 B CARD Pliulf; XnproYi-Kl tape printing ~ rubber covered elio rolls --* M5ycafiln dies trial* Installation of stucco feed recorder control* (Esterline Angus} .5 Installation of new 2?f! form roll fox- improved caliper bettor edges and taper* !io Saproved stucco feed for improved. uniformity and board UTS tgiltBo b Edge positioning CQuipassnt fog? improved edges, particularly on. 1? & C? Sheathings 60 Installation of paper tension device or dancer roll to maove paper pell on mobile * JOOT SXS1EM: 1* Master batching of Glioma si additives to ipppovs milting and final. quail-Wc 2c lEpreved pallet:istag and ar loadinga uT "4 ^-L-'t MT M^/l- '/ -V 3. 1 ! [J <* G,c^v-^ , /-^ SGP 0020870 ? .,* * tin iMCWT' The $r,eXea@a Complaint Summary indicates e. general Improvement in on? Joint ftyatem quality. Hcwaver* a direct comparison is not possible due to the fact that each of the other plants are nrm handling complaints a material shipped by thorn* Under the category of SoMAdhesi939 the $X?9*32 nag paid on ora complaint traced to a leaking gat below the blender* As the xm materials were fed to tho blendorj a quantity of the ^proportioned Biaterisi would leak by the gate* ilaao^-uisg that this possibly secouatsd for other previoue complaints* t*;a instituted additions! sssispliag and. tasting to detect the esmsrxiy of this condition* In tbs eoorc of tslz tenths we detected 18 hatches which would have previously been passed* We recegsiae that acre positive sealing gates would be the answer to tills problem* Under th category of dipping Enws, we have included two adjustments fro the previous year end ok In the year 1%X amounting to a total c $i60*5& which resulted from shipping a reject batch undetected by the Laboratory* Tfe3 81i8O*G0 policy payment was mads against a 10 bag Sample Or&iir of Lasiaat&sg Cci^ouud which was used in an application which the mataxdal was not designed forj embedding of elsctrieol boating wires* In reviewing this summary* we not that the factors involve human and mechanical failure almost axclnslmiy. Very few caiplatnte nave been made against the products themselvse* This reflects th exellnt quality of our present formulatioBs and raw materials* She ?ive Sts*' complaint are included separately as they did not enter into the comparative picture* Concerning the production sumaxy.. we weald like to mention that th 1961 tonnage set a new record over the year 1959 by 5t}0 tons or 5*l5'l Part of this may be attributed to th addition of Johna-Karivill, Fliatkote* and Big Horn, as well as the opening of cur New Orleans* Blue Fapids, and Wilmington plants* W@ have also noted tba increase of 0*79% In perfect production especially in view of the iacrsaeod quality standards mentioned previously. Kuch attention has been given to this matter over the psst year, both from the quality and cost viewpoint* and wa are extending our goals for iha coding year is this direction. Four possibilities immediately in view are outlined as follows; 1, Th addition of th Bulk lir&ste&ft System ellssicstas ems?a teds la coat of bags per ton* It also reduces th possibility of paper trash in the finished products. Tfcesa two esusas for rejects have fcvsan frequent the past* SGP 0020871 t -< i "I i'i.u ;.**3 ie V have long coiYteapl&tad an added operation to preblend all of the small ingredients and weighings eclustered ia the asm'iffccfcurs of those products* By reducing the nuabsr of Individual weldings v should be able to reduce &the nunfeer of reject batches* In addition* we feel that sore uniform finished product would result fro this operatic* Means of accomplishing this are new available and ws will institute an extended trial this year* 3* As already mentioned, more positive gosling gates w&uld be desirable in our system and we will continue to work on this problem* 6. Additional automated equipment sad interlocking controls* would eliminate many causes of rejected production, as well as increase the total potential of our blending operation. However, our limiting production factor comes from the packaging operation* Xa this overall program, we are presently investigating mesne to increase our packaging rate in order to fully justify installation of such equipment* See/d CCHPU1NT StJHHAET I960 Adj. Policy "" ~ 2961 uhmhhhiimi MWffliiewiimiVinwiii hSF. ~rSc*<F~ Poller Dtf. Lumping Photogrephing,Buriii?ag Beading, Distortion Bond, Adhesion Edge Cracking Working Properties Miscellaneous Shipping Errors Total 5 12? 1 7 1 2? 5 9..... 2 3 1 6 0 1 0 ? *00 92.00 692.00 30*00 *00 .00 .00 75.00 ,00 00 85.02 *00 26.15 *00 619.22 . 0 6 3 6 0 6 1 5 .. . 0 1 0 2 0 1 1 a -ML- 18 J22s&~. 25 13 .00 *00 .00 ,00 .00 (X) 680.00 .00 .00 .00 *00 179*32 *00 38.57 *00 616.33 680*00 8>.23 Five Star 13 H $00*00 9372.58 I960 1961 Increase Total Production % Perfect Production 9,292 Horn 97.2555 11,031? Tons 98.06* 1$.28* 0*7955 SGP 0020872 mmXXas i$6i rM.urri & plaster The enclosed Complaint Summary shews or Quality Performance far 1961 vs. I960. The sum&zy indicates that am* board shipments during 1961 wera deem by 5k% ever the previous year and nr cost of heard complaints during 1961 were down by 8*98^, showing that soma quality iaprovements were realised during 1961* Coat of board complaints in 1961 was $ .019 per thousand sq. ft. of board while our cost in I960 was f .0202 per thousands Cur greatest area of complaint cost for board was under heading #1, poor bond and clean peelers &1,QU6.83 was paid to two accounts, S6JI&.72 to Construction r Coeponenta oi* ?mil, Arizona and 392H to the Bams Lusher Cospmy of Dallas. In the second instance, the board shipped was found to be defective because f a kiln stoppage during a production run, but no absolute decision has been made ae to the cause of the defective board found in Arizona, although it is thought that the defect was partially caused by wet boards Under Item #2, cor splits and blisters, a total of 896*50 was paid out during 1961. V feel that the reduction of complaints under this heading was due mainly to the adoption of calcium chloride as an aridiziag agent during the latter part of I960. We still oxperienoe core split to some extent, but for the most part, these are calcined cor splits or wet cere splits due mainly to our inability to hold a constant weight of hoard a the wet end. Quite an appreciable inerees in cost has been noted under Item #5, split ply paper. Pryor was notified of this condition at its inception, and hag since made great improvements in the quality of the paper shipped to Acme. At the present time, split ply has been reduced to the point idler almost all ecd-splitting is eliminated by our end grinding operation A large increase in cost also occurred under the category of off dimqpsiop bemad during 1961. No doubt all concerned will remember the complaints filed by our customers for *are cut" board Of course, this is strictly an end grinding defeat and am overhaul of the twin mounting equipment has minimised this defect somewhat, but "arc cut* beard i still a problem? W@ have instituted nm methods of inspection which enable us to keep this board from our customers, but w feel that a complete rebuilding of our twin mounter will be the only way to eliminate this condition once and for all.. As can be seen from the sumary, our greatest problem in the board plant is boards which suffer from the defects noted under heading 1 and 2. these defects are almost always due to calcined or wet board and we tel that these result from our inability to keep a top constant weight of board on the wet mod. We have checked quite a few series of 10 boards each and find that weight variation in each scrims is about 100 lbs. with all controls in a constant position. W feel that if w could eliminate this variation, we could mors closely control the weight of the board entering the kiln s that, in offset, wa would have a more constant weight of board to dry from hour to hour in the kiln and thus eliminate overdry and over-wet board. We would also be able to lower the average weight of the board by installing this closer control of amount of stucco fed par thousand square feet. SGP 0020873 f : < *!*.t-* '.Mi'; AJM,a **.* .. >*-.,^r.v *jm jin) ) Page s' Our only step in thle direction that is boh planned is the installation of a recording tachometer on the screw conveyor to the pin miser* Our intention with this device is to determine whether the actual speed of the screw varies at a predetermined setting or whether we have different amounts of flooding of the screw from time to tine* We realise that a system for closer control of stucco would require a good deal of expense but the resultant lowering of the average weight of board and the elimination of reject boards due to calcination and wetness should more than pay for the system in a short period of time* Although our total cost of complaints in the Plaster Packinr & Slipping department shews a decided decrease la actual money spent by 20,,9# our plaster shipment* have fallen eff by 31* during 1961* Da reality, then, we hod a poorer performance in 1961 than in I960* Cost of complaint per ton of plaster in I960 was P.323 per ton while In 1961 that cost rose to $*33U per ton* 95*2$ of all complaints filed in the Plaster Department and gl*6 of all money paid out in complaints during 1961 was due to a faulty formulation for acoustical plasters issued by the Peoli laboratory* We are sure that all concerned will remember the complaints filed because of "Ught-eeneitlRity* was certainly the introduction of Sanlobriie fines into our formulation for acoustical plasters as a mold-preventative. Cost of Shipping Errors in all departments is up by 6*1$ over last year* Host of tbs complaints filed under this category were due to shortages which were traceable to miscounts in the board plant or to failure of the salesman to give proper loading instructions for loading of customer oars* Loading foremen have been instructed to check-count all loads before wrapping, @0 we are certain that we can look for a decrease in this category in the future* It is our opinion that we have made quit an improvement in our board package during the past year* We have gone to better dies for our Tape Printing machine and have begun to use a much metre satisfactory printing irk* We have also started to use a 3/8" tear tape in bundling of our l/hn board and this has improved the appearance of our l/l* package to a great degree* In the beginning of 1961, quite a few complaints were registered for shallow tapers. Since that time we have narrowed our scoring cutters on all board products with the resultant deeper tapers preferred by the trade out of the Acme plant* Our present plans for 1962 call for Installation of multipoint recording thermometers in each of our calcining kettles in order to maintain a closer control mi our calcining process* SGP 0020874 0 okp3xivs r::xvrc 1?S1 vs 1969 ' SGP 0020876 QUALITY - 1961 Following is the BsTtaswick Plant Annual duality Report covering the first eleven months of operations during the year 196l0 MATURE RECAP OP COMPLAINTS rJALLBSM; LATH t. SJE/lTHINO ostw-si .................................................................... . NO. % OF COMPLAINTS AMOUNT % OF TOTAL Shipping Errors Surface Imper fections Calcined Off Dimem ion 12 10 ' 7 5 25.0 20.8 1U.6 io,,U $ 81,78 331.13 1118.90 177.88 3*6 lit 06 it9,5 7o9 No Core ^dbesiTe 1 2.1 XiiOo98 6,2 Edge Taper, Mge Formation 2 U,2 155,00 6,9 Misoellansous TOTAL 11 US 22,9 100,0 wmi&s 255,92 2s262059 11.3 100.0 NATURE Setting Tine KC0 6 % OF COMPLAINTS 26.1 AMOUNT % OF TOTAL I4.8I4.088 U2.8 Contamination Shipping Error 3 2 13 .0 8.7 170,13 U.52 I5c2 o,,U ino'ustioal Plaster Discoloration *> J d03f Plugging 2 Q.gcellansotiE 1 TOTAL S3 13 e0 8.7 30.$ 100.0 mS3 0,00 30,00 1136,16 393 o,o 2.3 100.0 SGP 0020877 Total ooard product shipments in 1961 amounted to 210sli0?3U?3 sqvare feet,- Total bagged goods clipped during this seme period amcuuted do 3.,238eOC tons... Included in this tonnage is agricultural gypsum.. This .la an incrs&ss. ow I960.shipments of iu'j91??3hl square feet of board products and 2*0oU tons of bogged commoditiesQ The total value of all complaints settled during the first eleven months of i9'6ls including policy and defective adjustments amounted to *3 *35*8 *73 The tot.al adjustment for the same period in i960 amounted to Q5,43905* In general,, two wallboard defect categories, calcination and face impc-re fections, contributed, to the total major dollar adjustment of 1,1*50 *03 ATI other w&llboacd. defect categories accounted for? adjustment totaling"- 1B'L2.>56,. 'live Plaster defect categories5, setting time and discoloration, accounted for 1931^61 of the total of SL,13el6 momentary adjustments In addition to this, ouo complaints will ba settled for approximately $*5000 on glusa fib3rei pump application plaster manufactured and shipped towards the and of that resulted in plugged and burst hose SGP 0020878 ourr-lAKx 'UALI'n COJ'irLAlhTS t }'ALL::VA r.DJEP^C}IINT .1 Shipp5 ng Errors Twelve t'.&r loading .nd shipping errors were settled for $8lo?8 The largest single error was a shortage of 30 pieces of Backer Board accounting for $33*3!:>-> Two additional car shortages were settled for f.l).^99a On two occassionss. improper car loading methods in which the plant failed to comply with instructions contained on form 36 > cost !)33oUi>.i- A number of Adjustments of reported, car loading errors were disallowed due to extenuating Ksircunstances; more particularly where specific loading instruc tions could not ba followed 'Without creating either a unsafe load situation or unusual arrangements of board products which could not arrive in good condition at destination^ Total-$8lo78o fill;1;E BgEPJECT 10^3 fw< of the ten complaints raceived under this heading were due to asphalt spots In the ivory liner and ware settled on a $&=5>0 policy ->--defect.ive basis with the .Oistriet Sales Office for an over all holr-I adjustment of :|2C()r.9h-. Had the applicator used a primer or mil sealer prxor to finish painting* the asphalt spots would have been properly sealed ir and viould not have bled through the paint SGP 0020879 1 i. v.' V- hi' n l V ccjvpjcdn:. "ii-'rr.i v; 3c3 A c~c; - .-h'-h.-A.a yyyda. a:y, ,t`\. .3 V ' , A'-C i;0 - ;y AdctO hcAA v"vy CA hh I ... :' 0 Add C;}L } j 1?, ' d `} j`7.; '0. '?. ` ' t ' C , < .( rz.`j: ): '.'Ol?. tci .,.L,y/J.. ho dcrgerc hng.'-V ociaolaAih 3.;o- CV-.; - } ' .fv;..:. yoXor Lo h hard.3. r:f -hi doh :. h :3; dooxh op;pooda v:a ,-'r GOT Or c ly- coheir of o;h. ``'O -Szt pit or o coo d a; ahahe;1,0 hoped .. dloridr- dpi Vo v.r:..'lX; ' :0. do 4V;'l",:69; Vf.? yashoichio g rearly l/d of 1:3 : to cal tv of cho oo.ai.:o y- sir y.'.pyvpd.airh r,, The A, L e a c C-AC...C -P Pv-'C;f'L 003 ayi o Ay.ooao: oc crovi.de diehar r e.rvioe oo a a.! -,'' d'i rOd. 0 d 3B dpi, i tho d ay-ore the CCApisirt:> properly acl 'h'3 dio '1 or hlooo *' ; err have ivet'A. cars ciisrahiv leso dr SGP 0020880 jsoarj^ The nsxt major single ssttlement of $21':. *4? was credited .ro the Ted Lansing Supply in Richmond, Virginia, and was due to end aaci edge calcination on SU pitscee of 1/2" board,. Dial Guilders Supply in Cullman, Alabama received 9k pieces of l/2M board wish end and edge calcination and the complaint was settled for $285 *6? r. The remaining four complaints involved minor calcination or, several books of wallboard found in the field snd were settled for small dollar amounts* Tofcal-f1,188 o90,, OFF DIliSiiSlONS Five formal, complaints in this category ware settled for $177*880 One complaint involving 65 pieces of oat~of-squaye 5/8s- Firestop resulted in a single adjustment of 5l38?96n This was settled on a <0--p0 policy-^defective basis with the District Sales Office rince the customer scrapped the entire amount of board and it ms generally coneeeded that a $0$, salvage value was not unreason able co aspect from this situation,, Four additional complaints involving wide lath were settled for 538.->92* ?Gtal-$l?7,88,> The single complaint in this category settled for $2iiO<98 was amtiu :m 80 pieces of J-T-I Firetard Board containing no core ftr, a result of this complaint the method of feed:*ng SGP 0020881 \n it 0.'; b t ibbi iyt \r, rd ;d} j. ; 0 rr,.;J ".a. v r. Truer ar'dv odrotS TCH UGrpletoly r-an a;'.' : mi no irrirr.- irr:ricrr.o or this x- .VT'i: ,, Corrrc a-; i bln uror-ms 'nT moyaa in the bf./Th boor{ ia--imnessye f m;, . .rrrimi by im btlanb-j. district ialm Office vrith rsference i be; 'b aldth of tyrur bpp'i ie atom in thin ary a considered tin imT-uyl Layr loir'Cli re anions it nuleUod boat of the uf 3,, C-v; :.. u-:urury, Trio orobleT did not 3|rear in any ether of the v&rioi; ; areas oi1 t/is pli-nfcc racdi Le.b. appro-vac; a tapered tape t : at v-j; .nob m ;o:ni l in a dor'par and aioo- ' tmnr-. Board made v/ith tils rrm.mn aa,,iLea ;ions tape her; anpnovau to resolve thAt problem, A; s -.ib::/ ! ooopnra^inp with the Disunite 3el ~s Office an adjust^ rn me :c biyi-OO uas al .Lowed, a:; a result oi the above descried d i'fr vul lies.- E .0 too .. orri&l uotx) ainls in this cal. egcry vara a tattled for $P>6n<?2,v T a.- ,iu opoaf ci b.>-:.->'i rm for ,ydil;,80 in rhreh the Plant absorbed t75-..3i O'; a '-.bovin'-'- S'}.b:ria 1 basin and Sales allowed ll66,id: on a policy s i"-or' ; .Tm rum g rum (ink u Brut , of Tucker, Ck-orpir eompl mined r' y. ;.i got rir colds on I/m board user in loo coartraa- ,,;.o: - ' v- ,:v ol bore. The nature of '.'he siruataor p; emoted this SGP 0020882 settlements Two additional complaints involving substantiated shiver pockets vers settled for $X5sl2e Seven complaints were settled on a no allowance basis when the- complaint could not be substantiated^ such as brown spots appearing over painted walls six months after completion, and Backer Board failing to bond Hard-Cot HLasier* Total. 3256*92. SGP 0020883 ANALYSIS Two typas of complaints experienced in the past year have been a source of concern,., These are Calcined Board and Face Imperfections, j.n that order of imr.'ortance. This cause for concern is not based tin the fact that we have manufactured sane calcined board and board with Face Imperfections but more important that inspection at the taho-off area was not thorough enough to detect the defective materialo There is always a possibility of manufacturing some defect ive board, however, it is inexcuseable to ship this defective board to the customers An improvement in the over all inspection lias been made with further improvements to be expected. Continual training, periodic review of inspection proceedures, and the determining and placing or responsi bility to tho individual or individuals is the method that has been followed. The most important of these are regular and periodic reviews and short seminars in inspection proceedures. B. IHlTl HILL PACK & SHIP 1, COIITAIGNATIOU Two complaints in this area were settled for i|17013 and were due to a carry over of wood shavings in glass fibered plaster shipped to Adobe Brick & Supply in Hollywood, Florida during December of 15?60 The major dnabion was eliminated with tho installation of a slide shavings feed screw leading to the mixer. Total 1170,13 SGP 0020884 i rn 20 SETTIHG TIMS Six complaints involving setting time were settled for $U8Iu88# The latest single complaint involved slow setting gun plaster shipped to Jlinil 3odka in C' arleston, 3# C# and settled for &320#00# The next lar* est complaint involving quick setting plaster shipped to Harrell. 1. Haywood in Ft* Lauderdale, Florida# One charge of regular fiber plaster was shipped un~retarded and without stabiliaer# The cost in settling this complaint was :}113097: Arnold U Dobson in Greenwood, :* C, ware credited for 13cpU8 when encountering Slow Get Lite Mix0 lilPPZHG ERTORS Two minor shipping errors were settled for $Ua2o One involved short tag weights and the other involved a shortage of several bags of plaster on a truck shipment* Total- - U52. h. ACOUSTICAL PLASTER DISCOLORATIOH Three complaints in this category, totalling ${jU6063, were settled on s. policy basis sines the plant and the Paoli Lab# failed to establish s reasonable basis for an adjustment# These three complaints had one fact in common, a discoloration of the finished acoustical plaster talcing the form of brown and yellow areas developing from six weeks to six; months after the Acoustical plaster was applied* In all three cases, the Acoustical plaster was applied over concrete and there is a possibility beat corrosion of the reinforcing steel could be the cause# Iotas. .. 1116.63, SGP 0020885 HOSE PLUGGING Tso serious complaints in this area occurred in the Atlanta Metropolitan District and were settled for $1437*. 5?0o Since the complaints and the aelitlensnts occurred in labs Dec-ambor 1961*, these amounts were not entered in the He-Cap of (ksaplaiats Tie two other complaints covered by this report were taken as warnings, in that the Span Borings did not perform in the same manner as Textile Barings previously used. Actually the diffieulti.es seem to hare started with tee use of Pittsburgh Plate Glass fiber, teat on ocoassion tended to pack and looked In appearance In the hose More like angel hair rather than a d@fiai.te fiber that dispersed well in the mix* As a result of this serious complaint in Atlanta we have discontinued the use of Pittsburgh Plate Glass fiber in plaster formulations0 MISCELLEMOBS Seven complaints wera entered in this category sad six were closed on a no-allowance basis * A $3Qo00 policy settlement on lumpy moulding was paid to Marion Hardware in Ocala, Florida, The plant did not allow this complaint on a defective basis since the material was six months old, The remaining six complaints varied from a ad.nor case of plaster bag breakage to paint shiners produced when applying paint ever a ocmibination of leenoe oessant, lime and Perlite0 SGP 0020886 C.n;\,a; i\c<: l.-rqfei abrek hr she eacslloat quality complaint eirperierice : I' C'O nr i hie freter ia she poor plaster quality complaint perform mo? r'.'Sl. foo .'.vci. rcl.:;. j/K-c or eqripnc-nt csriPrcorce ia this hr re imt either;. -pnl prey: daily checks and iaspnctions resulted :, 'em rids -rtt;- huctc* Tuo hoii-sf that defective raaicerel simply could not > ? ;!r :;cJ ur-crod by the Brunshick Has ter Department, is a pood way as 'V " cov/ribo this art.ld y& is reli to report thif.it the poor o isi..tv plssier pcor'orrrmee to ii:. first half of l$6l was very humbling av: : hed moor seeps have Doan taken to completely reverse this trend,, me Tat., ry eeeocrj'eea hone ere.; t5 orovghly ro'/ie:esdContinual checking ob" nr. ring pt c- i'iedr.rcss end wdcing cry foment is practiced . he can further ..o.,v.ti- with consider solo confidence that a definite improvement in the q;ol:by qvi rnr.fcce of this deportment is so ho expected in the coming q : nr 'iGLUdj.O/j did,. iVde- . uu; Pci cl :.i:.pv-ove.-macs here beer, initiated as a, result o.f gaining :-.rtk or crocriercr rn she manufacture of boarda One of the most cpo. ka.ri rf bheer is she :La-xv.;iii'acion of regularly schediilod quality ari ; wring, ritV: scifo eorvovry let tod headmen and Tako*-- r: 'm ..r ,yy.! o:.ecr-urt: moe ovary th.ro-.; rortdiy sash ahifo,. ir i ;r\: r,l to cc,;,. :>; v^a/fees ,-.cd 'rsebocs in their rospre- SGP 0020887 Page- 11 five area o5? raspousibility,, This is dona daring a non-operating periods When a particularly bad ran ia experienced on the machine., that portion of the machine craw that is responsible, is brought in at the first convenient tires and the whole experience is reviewed and a BDyy lhmK is followed through* Tm performance of each mm on the machine is reviewed by the Plant Manager sad that Departsnb Supervisor and the potential of each smployse on the machine is forecast* Previous forecasts are again reviewed to deterrains the best slot irfes which an employee may flt0 The establishing of rasponsibility for defective material out in the field is traced back to the employee or employees who may be responsiblet This is done in a com tractive but a positive manner* Every department has a large Quality Bulletin Board g this includes the Plaster Depart ment* W&llboard Department, the Wallboard Machine Wet-End Section, and the Wallho&rd Machine Take-Off Section0 These Bulletin Boards are used exclusively for the pcting of quality, comments from Plant Managementj Customers, and Sales Offices * All report of complaints and final adjustment, forms are investigated very thoroughly and are initialed by all personnel connected with the particular' complaint* Tills proceedure has resulted In a favorable quality excperienee* The Foem iSystem has been modified and expanded to incOUule the use of tandem fat generators which permits the immediate change over from one generator to another should trouble develops9 SGP 0020888 Page 12 CGfilAJFTXOW (Coated) A glass: cruffcar of improved design h&s been fabricated by the Maintenance Depa?trsent0 We aro of the opinion that this present system is superior to 'iha previous one since the cutting action was diaperceraent of fiber Into strew conveyor is sadly observed at all. timeso The use of a new plaatlc- cot further results in excellent cutting of the glass fibers without the necessity of replacing cots at short intervals During the manufacture' of Firestop board dry starch was fed by means of a r.Lbri.--W$crw unit Since dry starch tends to arch mid hold up3 we have expsrienced incidents of interruption of proper starch feeding into the dry stucco screw conveyor %ifortunately8 when this fact was discovered 'board had been fabricated with no core adhesives, This problem has been ell td.ru ted by prefixing starch and water and feeatng. it through the asphalt emulsion equipments This is a positive method and has adequately solved' the problem of core adhesive feeding into Firestop products Haring 1962 the rapid deteriation of Coe Kiln bearings caused consider^ &bl3 difficulties A crash program for bearing replacement has been is* progress with 000 bearings being replaced in the last half of 1961 Vit.* the rapid wearing out of these bearings* rolls in various areas of the kiln tended to drop enough to cause problems in proper board tracking sod the inability to properly butt the beard This condition also tended to jau-'-e same kiln jane With the bearing replacement program currently An ffoct this pro'olsM has been generally resolved SGP 0020889 V-: : i`" i* tit . or ' :/" t.}../: o-rrivr.' S ' \y X : or: cor.,: a. ac eea:V nr.peco-he on - v:c a .. o varus).'x-. ; era ret; in oieroiao ; .W^'l y.' y= ?' J.''A?' * A.'.y-.'1 'v 5'V . **y ' ` ' ' : h . i t. - : ` ' . . .V'"l \1~0I' y.'yrV O V'-tC : - `V. ' ->.U' aA. 'X: i ; - ,.;e a: iir. ra:' ''arrive tin Xvnoioy ynoakae oni ore pictorrs too Xi riohe' com Van; pkcvsn: ophe er^ iimrynlistoXLy mi a! - v:ls- '-e;i 3:-;V-s OXynt oihh 7 - COtenat tha. ihe: is ? n,en aeccaet na-::X hint o-.-X tlrt ' : pyotravyra irnicarn vis ratore of hr O/nr - :: ihn o-orni: hinn .ri th-s Iran p rior i:> cousiyiaip it 'fs iX a nr. oraer or; a on .a ovimd rioa crihir.i.s!r by the arrorm moo o ' :J viova it ymbom ihc~i with iniorioation should the ;.str:n.on :.r; nao-iaoiXlon y t: a 5e.:ll77>oc and intanos to crc-aas in tha tvi.no. i too cue-a,:.:..'ir X:;-7 i: o-orsioaor XX-.X ' i: initial hendbad -ou s U'i-.'V.O.!/ p.i-ao ooXiasa bo^ix-. Vbt. o-oot 0? this prosu-ra is nep'- ic/ibla,. too ore . ;,;'';t.ov.:::o loosas,. 0. oioot check ie roaintrinod d;rh;p an -xxrp:,'; onci th< corohoo.'; oo o;/V.rp',i-dv!'. that rcoaiis : o'-'-p: to .chov.ac r,7\vh:ct:a io rot toiaraia'h. SGP 0020890 '-^LLBOARD '.1A.HKHOUSE (ConVd) \To material is accepted by the warehouse fros the maehias unless it is a saleable perfect.. Should material be found is 4hs warehouse that is in my wey defective 5 the board is immediately returned to the machine arm and. reolassified* As a result of this arrangement g losses incurred through the warehouse have been quite moderatec On of the more significant problems in the wallbcard warehouse is the matter of ear shortages during the months whan shipments are in (access of twenty million feet As a result of these shortages, it :la difficult to maintain an orderly loading schedule and orders have uo be revised to fit available equipments The Ardmore Traffic Departneat is intimately awsre of this situation? G,, UffITE MILL PACK & SKI? DEPARTMENT 'lia basic cause of the uraatis factory quality performance of this departs at was failure tc apply the various cheeks and controls that are sr integral part of formulating plaster products to strict specifications * Toe much reliance in alledgely fool-proof devices on the mixer floor further contributed to the situation6 The quality procedures were completely overhauled and revised,. Additional training of all personnel was instigated and some personnel changes were made*, Vs can abate with some confidence that a significant improvement is **peted during the coming year* SGP 0020891 mit;:: ;uii mack i in? difartkia' (Cont5d) A nurbor of ir^ai-ove/'enhs have bean r/ade in, Aha itLLi arel racking .Depart/ie/on that will tears to anp-rxve the over all o.slity0 Infnua-txou of sll kettle tops nave been recently concladt-do This greatly , :d c vi build-up xvmr fha Settle tops and '/ill bond to ine/rsasc: ujiifor-n.it.7 of kettle aiuecc setting timsc Installation of }xerraarier?t aiiuinefS on the plaster packers f--*eiliiaiis3 the bloving out aril cleaning of the sxruipreni when changing pCtestcr for-:n:u3.ata<>Kut. This a/raugsienn has sharply reduced the incidents of the coaturination. of one pro-doet by anot/Oig Installation of to- rrsaaininr sections of the piaster collecting screw conveyors to enable the operator to empty both aides of the plaster birr, eliiaLnates 'da? load leg of one bin and prevents surges of old plaster fro:/ eonlsr-inatiag finished mivterirl, , 3KIF ^UrtipIlJG & JtjCK JIARELIIK Since Ah/: -Jypsuw Ora ear: hr oontarranated by salt in B^rahons. and also during transit by ssa voter, each ship hold is thoroughly inspected for si; ns of this ro-itajvination prior to iriloadingo Aether any contsird.nG'iion is evident or not? representative salaries are secured f:rorn cpel:. holes and a quick salt analysis is raade* In the past year this ps-rcredurs? 11B.3 helped us anticipate and avoid problems in the :;:..i /hr raif cox-bii/inalicr: vf.fi, /viKonto Continual blending of the 0-=e ;/ hr-:? van/ absd sturts! in 19-60 xs standard prceeedare,, SGP 0020892 qui:- hhio/tift .. eoik piifiihp in n ry inker of fac'Lafyx v;vtoe pteaor.ce ci unexpended blasting <:ao i i retire rtantly ware round by the custor.se s' of screened rock, to extonsiro in\o-:xb?y>or,ion ucr vania bo noc '-nether a non-`ferrous vastal ext ontor could Is ioolailed 1) elilian&ta ibis baser;.;c bona has 'boon forth tu date pr:ljr.Hvily because of the nature of the &teria! tha; is to fa dstaatsdo fir; only solution to this probieia is the <v >p . 1 o of' of a - on'- d?al of vipiliarK-e on the naxt of the : -i-?.hu"n f'nrsonn.'rl ard the pertoatel banality the rock distribution at bs nsvri.ck Hi artft! ITlil, k n rdr-t --tf developer ante si: ice ;b,il to fcrouyrvt to som conclusion d\n tn^ t'lf-2 till toad ic perorate problems relati'-t. to board quality0 Tt.= lop bill speed, of 1"3 rff till .be initially increased to 220 PPM to ill on net lor spaed outtr-ol an 3/8K beard and 3/at; 1 ath since these ivc prod-ufa a:ns e urxorhviy being manufactured at the absolute top Unit of for bol.t lira ,spoach, Whan these change}.? r rc concluded it is oil y not,trot lo exp a et that spend iticroas-ss on these two products will be alieiupled .and there? is no ovidencs to indicate that these iiicreasrs will not be e rwdnrsl deyelopejnsnt.. Tighter weight and ore o oration control rill bacoiK- a absolute necessity for the proper dry i.or of toast too 7 rennets,. Tao recent approval for the install ?.v~ tic . oi i Aon j.r-ay unit on the waliboard line villi c;-rtain2y provide a r osi f ytytaoh cont-rcl in the area of wein rite !Io Kiln shnofes wens SGP 0020893 novo yyr- dar:.,vy Ipdl duo u> a large number oi p&rsoi tvsl shifts she p'.:. =ud:>., ko /Prlyd in om5 lq6l report, assistance fron the Pfto'li Lab '-rdlj b; rjnaii'sd as proparly ereuute a Kiln studyv Sinsa pvchnfcs q-iaiitT is a mit-o:c of prites importance; all speed iv-c peases 'Pill ''ov o bo hs objectively scrutr.rijsed and only put into afffpi if the quality of the product remains at least equal to ihat is currently being produced. SGP 0020894 {W H S ) OR GAIN BASED UK f it f u l' ELEvem nOin'HSj 1961 COMPARE TO FIRST ELEVEN MONTHS OF. I9 6 0 y offt r~i 9 3 t-*I O- 5c>tfff*i \A 8 sCpA Cs CM o ON 1(AA sO CM f-s sOo fA CN OS C*5 \-OrP~n4A4cx* V\ UrHNc sOat CA sHOc rCHM oOOoS(A XCfAOA U-=\r r--i c?--*0OCrF*M3AAs -UCS0J \v0O *0sa# cas OOr<(*HAsssa vr=O% tO--SrHa% PA COO<s- CoPCOMAt* A3 ca \qi--0ii MO3s C*N o* S3 Os CVJ 3 H 1i\ H oC c ITS If* O CO fN CO US XT\ 3 o ft o ~3r Os fA Os |] o 'J 6 '3 C*~ U\ u\ os Cc o^rs* CN 0s| O o CO tsj CM r* i iMj -j u\ o c -P 03 S H* O Oj cm! VO at CO VPv 'O o cDi C*i{ S'. C4* fA -4 CM e"i CO CN -=f -- o sC -s? a 3 o <t r; c 6 n) Oo o a IA -'|t \n CM v3 CM vO CM rA A CO CM sO UN -if A; PAc \0 3j co vO CO O xr\ CO &CM cs r,j 8 1X3Of H O *PS CM | c* pa cm 3 m3 CO PA FA C* irv UN c-4 & CQ ON CM PA Co CM CM sO r~\ r*3 -3" o O G\ OOs' FA CVS -'LA CM O'* o' FA 'LA CA Os On u\ H -cij c3 j P' oU a OpC^.a63V*fS^|i \A CO <Al 3 VGr\. d'sA oD Ani rP*At O0 rCMr> rF"Ai q * q fl o3 P 0o41 o vS c> CJ sO 8c 1 *H | sC Of CO 5>-- Xf* JsS< CV j o O; rH O Cv .--if CO a'; O Oc eH CM \0 CCvVJ O O IS Os O CM ^to ^45.i %*! o -ao0[] JL j *A ' 0\? "?3 fA; C^0fC~Mi ii -4* AFAL CQCOV\ .'.* <x Xfi -Cf C*4 /-*s Vs2'S; f3G3^ CO?A*s-''' CMj COA POAS Os FCMA Os o vC-Mv rH-S CA i'J\ --iiorf <ICs5M*s uCc\\ 0s o 0s -C=VJ WFCHCMMAo Hs--? rs- >--y PAo COm--D'S oo rs. *0rv~^>t\ cc J-SOJti US Vr*Oi OO0s FA Ce^os -CDMj og V-*J* -Tt fC0sM-s\ CO 0 -HCiMf rH vjc3A0ur 0\ 63 CFA* rr'*yA co o> vC0s -lC>iMir CPMA COOc . rH*- toD] A 1 r'Oc~j.-1*. CCOM ` H! oCH*l*. s0 ".sO.--~AsT -J* s*%o A. <--S. GvwHrCH0Ooi CM PA Q o) C--! 'Li'S CCOO CO CO CO i 8f-1. T~\ CM r~i ^3 OJ G\ o WXTo'. sCO0 -d \SAO XUC?ANs CCOrsK\ A cS C<WO- CVJ r~~\ cCcO qrH xr\ HrOHJ \OAn q -*`MA o'3! C1?j 6 r"i ;j 'Si : j \ SO VD O o0 CM CO CO sO sO C1OA3 CCOM '! Q CoO0 D;.---jHs O3 j oc CcOv ' \ p5~-M*'N<N w cr > ocv.' j-. v0 sccOvv cOos -CiAfjS.yi? C 0*0 itf CMSCM <3t* CK*fSii-O* f vO sOl C>> gs r- * Q? H OH VO vO o Os 0\On p*H s--4 v--4 S3 SGP 0020895 mm rapids m? Q?mi,IT3f REPORT 1961 SGP 0020896 quality rspoj BLUE RAPIDS^ K&KSAS 19*0. PUSHER PRODUCTS NATURE OP COMPLAINT MMBSR OP COMPLAINTS COMPLAINTS ADJUSTED AMOUNT Setting Tlffl Working Properties Softy Week Cracking Broken Bags IfeLscailaneovcs Shipping 7-k 5 2 0 3s ? 6 t3,586J*8 5 lP070o80 0 2 72*30 3 1Q&*53 6 3*t6c03 TOTALS 37 20 $6*320li* SGP 0020897 Of the 3? plaster products eosgpiaiats) received over 5h$ have been settled idMi an avenge cost of appraacSaiateSgr #306o00 per Qoapl&mt The table belosr trill iadloat the trouble areas shssing a breakdown of the eosplaints v& aosis& mtam of CCS!PUIBT Setting Tis*a Working Fropertia* Soft, Weak Cracking Broken Bags Shipping MieesXlaneow* PBR CBHT Of total cmpuxBfs n,8$ 13,$$ $&% e 8t 16,2$ IBM PER CENT 0? TOTAL COSTS $8 M 17 M *% * 1*2* 5o6JS 1?^ SGP 0020898 DISTEXBOTXGS OF CCMFIAIHTS BT SAXES DISTRICTS S10ES DISTRICT hdmber cf COUPUIHTS SWK PER CMS or TOTAL COKPUIHTS SUBMITTED Ssuasaa City Atlanta Sto Looist Dallas Cl&'mlmd Philadelphia Salt taka City Buffalo Hm Tosk Omaha los Angelas 6 3 6 1 7 3 % X X 6 1 16023S 8,,lS 1625S 2a7* 19*0* BolS $ok% 2.7% 2.7% l6o2% 2.7% SGP 0020899 swmm rsm Using the number of coaplaints received as a guide* setting time control was the most difficult problem encountered at this location during 1961a Setting tins complaints number XU for this year* an iiaprovemaat of four complaints or six percent over last year* Three of these setting time complaints were closed with no settlement being required<? These lU setting tin complaints are on several of our different products as shewn in the following table MATERIAL NO* OF COMPLAINTS AMOUNT Plate Glass Stucco Wallplaster Pottery Plaster Denslte Statuary Impression Plaster Molding Plaster Gauging Plaster Lite"Mix Metro-Stlx TOTALS 1 &59iuOO 3 No Settlement To Date 2 $992 oi*8 2 No Settlement Required 1 No Settlement Required 1 No Settlement To Date 1 No Settlement To Date 1 No Settlement To Date 1 No Settlement To Date 1 Ho Settlement To Date yk *3S86<4t8 The largest single settlemant in the setting tins eoaplalnt category was filed by the Libbay~Owens~Foz& Glass Company of Toledo* Ohio* This complaint covers three care of Plate Glass Stucco shipped to this account during the months of June and July of 1961* This complaint settlement was held up for sometime in an effort to deter** mine the problems encountered by this account* It was never clearly estab lished just exactly what caused the problems encountered* It was thought that aging entered into their problems* We have been able to combat this aging problem by setting a minisB amount of accelerator that can be added to obtain the proper setting time* SGP 0020900 The second latest settlement in this area was made to the Lapp Insulator Company of LRoys Hsw Tosko This w a settlement of $96UoOO and since this did not prove to ha defective material this settlement was made on a policy basis o The largest number of eosgslaints received under this heading of Setting Tima Complaints involved three shipments of wall piaster Two of these com plaints are from the Omaha Sales District and the other me from the Xansae City District*. The quality department is doing extensive work along with the Paoli Laboratory to control this setting time problema Fe feel that it is of significance to note that one of these complaints is in November and the other two in Decenbar of 1961*. These setting time problems may bo a result of the winter months and cur inexperience regarding the amounts of retarder required at this tin of the years As indicated by the above table the two Danslie complaints required no eeltlerasaato The Metr-Mx complaint on setting time could not be justified on the basis of samples received and should require no settlement on a defective basis* This is also true of the Lite"Mix complaint* Since this complaint was entered in June of 1961 and could not be aubatantu&ted by the samples submitted we would assume no adjustment would be required* This department feels that when the proposed dust collection system is completed and we are able to vmt all of the bins* elevators, screens, and conveyor we will not experience the erratic setting time problems we ar now confronted withe This venting will also allow us to fill our wallplaster bin to capacity instead of having to operate the tuba mill each tiro we need to fill an order* Under the present circumstances a full bln of wallplaater will sweat out so badly there is an ever present danger of ruining the entire bin of materiala SGP 0020901 SHIPPING ERRORS We receiwd six shipping error complaints in 1961 against three for I960. These shipping error complain.t3 have all been adjusted for a total of $3lt603 The majority of these complaints involved plaster products that vers included in wallboard orders* A better system of cotrununicaticgis between the board plant shipping department and the plaster shipping department should be estab lished la order to control this situation. WORKING FROFSBTXBS This complaint area accounts for a total of five complaints in 1961 against two for 1960o Ctae working properties complaint on Gensite was settled for 1569.10 on a policy basis o Again tire claim could not be substantiated Another complaint in this area involved a car of wallplaster shipped into Denver* Colorado<, This material did not work in the same manner as the wallplaster being shipped from our Sigurd plant* We did not learn of this difference until the conplaint was filed o ^'e now have a special formula for the Denver area that has been tried and proven to be acceptable. One working properties complaint was received on Xlte-Uix involving coverage and required a settlement of |2870e The other two complaints in this category list one on gauging plaster and the other on laboratory plaster. The one on laboratory plaster will require no settlement and the gauging plaster complaint has had no settlement to date MTSCSHANSOOS list seven complaints in this category for 1961 against 16 for 1960c This Involves such items as bag weights, bag breakage, packaging, etc* SGP 0020902 GSNEB&h Several changes in equipment operation for 1962 should result in lowering the congjlalnt rate in plaster products <, The planned market survey to he started soon win acquaint the plant with area requirements and expectationsa As stated above the dust collection system will probably be the greatest single help In quality improvement in our plaster product & SGP 0020903 -2 - 2o Defective Co~rolaint3 Per Million ft. of Board & Lath Acme 0.3 (0.398) Akron 0,,4 (0*584) Blue Rapids 0a6 (2.851) Brunswick 0.2 (0.209) Fort Dodge 0.3 (0.373) Grand Rapids 0.6 (0.839) \ New Orleans 0.25 (0435) Sigurd 0.6 (1.249) Filmin.-ton 0J4. Shipping Complaints Acme Akron Blue Rapids Brunswick Fort Dodge Grand Rapids New Orleans Sigurd Wilmington olO (ol44) .0$ (.04) <*15 (.428) .02 (.024) ,1 (.122) ,,1 (.132) 15 (.311) *1$ (.434) *1$ - Per 1000 Tons of Plaster 0.8 (1,,671) 0.8 (1.222) 0.5 (1.047) 0.5 (0.691) 0.5 (0.574) 0.8 (I.222) 0.8 (1.647) 0.8 (1.252) 0.8 e* .10 (.134) (0) (0) .2 (.248) 0 (0) .15 (.218) .2 (.285) .2 (1.647) .2 (.312) .15 - The figures in parenthesis represent 1961 performanceo CGS/md 1/17/62 SGP 0020904 QELOT REPORT BLUE RAPIDS, KANSAS' 1961 BOARD PRODUCTS NATURE OF COMPLAINT NUMBER OF COMPLAINTS COMPLAINTS ADJUSTED AMOUNTS Poos? bond, clean peelers Core splits, core blisters Cracked, broken Edge taper, edge formation Split ply paper, end splits Off dimension Surface imperfections Joint system Shipping errors Miscellaneous 16 2 1 8 8 3 h 2 10 -J&3L. TOTALS 67 8 H,197086 2 313.20 X U77.08 7 937.11 8 X38U8o01 ?. 8ii.OO X 36o37 2 66.00 1 31a3o01 10 m $6,8630U SGP 0020905 As a further breakdown on seise of the factors Involved in our board cose-* plaints it should bo noted that almost 72$ of the board complaints received for 1961 have been settled, Of the i*8 complaints adjusted the average cost per complaint settled was approximately $11*8 *00* The table below will indicate the trouble areas showing a breakdown of the complaints vs cost* HATURK OP COMPLAINT * Poor bdnd, cle&n peelers PER CENT 0? TOTAL COMPLAINTS 23,9$ PER CENT CF TOTAL COSTS 17*5% Core splits, core blisters 3,0$ kM Cracked, broken lo5$ 7,0$ Edge taper, edge formation 'nM 13,7$ Split ply caper* and split Off dimension JIM h*$% 26,9$ 1,2$ Surface imperfections Joint System 6,0$ 3,0$ 0,5$ 1,0$ Shipping errors 15,9$ 5,0$ Miscellaneous 19M 22,6$ Of these complaints listed above over 63$ are out of the Kansas City Sales District* The Omaha District was next having entered 22$ of the total number of board complaints * The balance of the board complaints were entered as follows* St* Louis 9$, Salt Lake City Sales - kk$p and Joteis-Maavill complaints - 3$= SGP 0020906 POOR BOND - SOFT EDGES - CALCINED BOARD This one area of defective hoard accounted for store complaints than sy other single complaint area and ms second highest in costo Soon after the start up it was thought that operating the machine at speeds above the liad- tatlons of the kiln was a major cause of this problem.. In fact it mar yet be a contributing factor Also the fact that at times we make change overs from one product to another resulting in two different aisses of material in the kiln at the same time may be a contributing factor to this problem area later this year it was determined that we had an unbalanced condition existing in our kiln resulting in a board that was vary dry, even over on one edge and damp on the other This resulted in a bow in the board that was quite evident in lengths of ten feet or over Several baffles have been placed in the kiln in an attempt to obtain a more even balance in the air flow This baffle installation has been successful in stopping the bow problem however we still have one or two decks that do not dry the board as dry as the balance of the kiln* SPLIT PLf PAPER This complaint area was not one of the largest in rasher of conplaint# but was largest in a matter of cost, accounting for almost 27% of the total board complaint costs to data ?.re ran into split ply paper in both face and back paper about the middle of the year Our more recent shipment of paper are much improved regarding ply separation and it has been nearly three months since w have received a complaint of this nature-. SHIPPING ERRORS This complaint area was the second highest in number of complaints received and accounts for nearly 6% of the total board coE$>laint8j however these complaints SGP 0020907 account for a vexy snail portion of our total complaint costs in board products* accounting for only % of the total costs* Improper loading and shipping either wrong material or wrong amounts dosnaatad tha complaints in this area* To date W9 have only one complaint on fils involving damaged board due to load shifting and this will probably be closed with no cost to the plant* OTHER COMPLAINTS Core splits* core blisters* cracked or broken board* off dimension* and surface imperfections have not been major problem this past year* All of these conditions have accounted for 15% of the total complaints and 16$ of the total costs to date* There are only four complaints outstanding involved in these four arease The complaints listed under sSiseeH&aeous rated second highest in number accounting for more than 19$ of the total number of board complaints and also second highest in coats* accounting for over 22$ of our total costs. The majority of these complaints have involved grayb&ck paper rollers. This problem has lessoned to a great extent since we have had a better paper supplied* have installed another talc applicator* and have had better kiln controlo GENERAL CfMMEHTS We have had very few problems with customer service. In most cases we have been able to work out our service problems with Sales resulting in good customer relations. In most cases car shortages were involved in these service problem. One problem involved in this service area that we have had no control over is the problem of maintaining the various produets not manu factured at this location such as foil board* pinhole lath* etc. We have increased our line somewhat to combat this problem 'ey adding such item as SGP 0020908 punched lath sad X/V wailboard and -will add pinhole lath to our Ha sometime in 1962 ,, The proposed construction of an addition to our warehouse will reduce this problem considerably* There will be severe! innovations made in some of our board plant equipment in 1962 that should result in a batter quality board and relieve many of our complaint problems Such items as changing our water softener equipment over to an automatic system should improve our foam control considerably* Also the completion of the constant head water flow tank will be a big aid in controling the weight fluctuation in our board products that we are now experiencing* Thi constant head water flow also should relieve the problem of the asaehina nan having to alter the speed of the machine in order to control the head at the forming rolls which in turn will result in a more even drying of our finished board produsts * The installation of the new equipment on the levalator has resulted iss inprowed appearance of our warehouse and carloads of material shipped* The quality control department has discussed each of the complaints involving the board plant with the foreman and cress* la the future we plan to sugraflat this by holding amthly quality meetings with each of the shifts and discussing any quality problems and complaints that may exist at that time* SGP 0020909 196 QHS PROQR&X Blue Rapids* Kansas SCOPE* This program will be utilised by all plant personnel as a guide toward improving the overall quality of products shipped fro this planto I, TRAXNim PROGRAM Ac Bold monthly meetings ia all departments with operators Xo The following subjects to be covered in these meetings as deemed necessary by the Quality Supervisor and each department heads slo Specifications ba Equipment Co Complaints * Cause and Correction do Saar Materials c Evaluate Current Production f 0 Market Survey Results Bo Report to Plant Manager on each quality meetings Co Folic*? up by supervisors II. CAPITAL EXraTOITORES Tbs following Job Orders or A.Fi>Eaa will b subisittsd or completed to correct known existing quality problem e Ac. Board Plant water surge tank Be Plaster Mill & Packing venting and dust collecting system Co Board Plant stucco re4mndllag system D Bensite filter system Ee Semi*.utOEsatic water softener for Board Plant foam system Fo Board Plant lighting to improve inspection tllo QUALITY XK8FBGTXQK The Quality Supervisor will make the following checks to ascertain the quality performance in each departments A. itei'iy quality check list B Quarterly quality audits as follower la Dansite sad Mill 1st Quarter ta Packing and Board Mfg ~ 2nd Quarti 3 a Densite and Mill 3rd Quarter lu Pack and Board Mfge - i*th Quarter SGP 0020910 I, mm'U.TWE fBS'fBIS Principal competitive products will be tested, aa the following schedules January ~ Wallplaater and Lath March => Induetrial Plasters May * ?-allboard and Density July - W&llplasber and Lath September - Sheathing Hoveastber =Tfallboand and Dsnsite Vc aKKRT SDKFEfS The Quality Superriaor and/or departmental supervisors shall arrange with the Salas Department to make vaarket checks for the purpose of evaluating the performance of the plants products in the fielde The following schedule of aaricet aurvsys will be followed* February ~ Kansas City District l?ay - Denver District August - Omaha District Further checks will be made should the need arise c SGP 0020911 NET;f ORLEANS PLANT QUALITY REPORT 1961 SGP 0020912 Page 1 The New Orleans nlant operated a total of 6 days in 1961. this time, fourteen com/.laints were received by the plant. following is a summary of these complaints During The BO/RD Type of Complaint No. of ^ No. of Complaints 1961 Ad.1. 1961 Amount Cracked - Broken 4 Surface Imperfections 1 1 -$113.19 Shipping Errors Miscellaneous 5 2 1 214.27 2 31.00 Total $35^.46 PLASTER Setting Tira 1 1 $ 36.39 Shipping 'rrors 1 1 Tc.al 2 2 $111.34 Grand T tal 14 Q $475730 In ord.:r to more clearly show the plant complaint situation, a brief explanation of each particular type of complaint will follow. Included with :his explanation will be the measures taken by the plant to correct any c'iffic..lty0 Boa/d _ Cracksc - Broken Crack'?! board accounted for the largest number of defective material eonpl'ints received. Of the four complaints, three were Johns "Manvi lie Although the type of cracking varied, all four complaints were on l/2,v x 4* x 12! wallboard. In me of the complaints the cracking was established to have bee. due to fork track and strapping pressure on the tapers. To help deter recurrence of this complaints the railroad tracks were r;i sed so that the fork lift trucks are on level with the car dying loading. Alsos the tapers are reinforced with paper at the p'Int where the strapping is applied, the loading personnel were rationed about this type of damage, and the cars are carefully inspected for this type of damage. SGP 0020913 Of the three remaining complaints on cracked boardf only one was investigated by the plant. It was obvious on this complaint, that the board was being mishandled by the dealer. Although it was established that the board was not handled properly, the pulp content of our long length boards was increased to 15#`/M in order to make our board more rugged and less subject to breakage, even though it is mistreated. It is felt that the precautions taken will greatly reduce, if not eliminate cracking problems. Surface Imperfections - Blisters One complaint was received on blisters in 1961. /Ithough we received very little information, we believe the use of vibrators at the forming table has eliminated any change of blisters or voids in the board. Miscellaneous Both miscellaneous complaints were on bundles of board sticking together. This complaint occurred as a result of hand bundling with regular twin mounting tape and glue. We have now received an are using regular hand bundling tapes. Shipping Errors All of the shipping errors received in 1961 were on shortages. Of the five complaints received, three of these involved a total of nine bundles of board. In order to help prevent all shipping mistakes, more careful checking has been initiated in all phases of shipping. Piaster Setting Time One complaint was received in 1961 on plaster setting time. The plaster complained of was actually plaster which had been previously rejected but was included in the car by mistake. better system for disposal of reject material was instituted and is now being used. Shipping Errors One complaint was received on plaster shortage. This complaint could not be verified by plant investigation. SGP 0020914 .-age Improvements k Plans Severe], improvements were made in 1961 to help us produce the highest quality products. On the board machine, the scoring cutters were completely reworked so that a better and more consistent edge was possible. The cutters and arbors were trued so that there would be a more accurate cut. /'Iso, the spacers on the cutters were moved from the inside to the outside so that a thickness change could be made by simply changing the scoring cutters and not resetting the entire apparatus. Shims were made for setting the forming rolls so that it is possible to change thicknesses with accuracy. A head tank and pump was installed for the mixer water. This gives a more reliable and consistent flow of water to the pin mixer. Electrical timers were installed on the kiln pull-in-section to replacd the mechanical switches. This enables the operator to accurately space the boards going into the kiln and eliminates the varying gaps from deck to deck. This helps prevent the possibility of calcined ends on board as well as allowing more accurate speed settings in the dryer. made by During 1961, a survey of plant loading operations was/the Signode Steel Strapping Go. In the course of his visit, the Signode field engineer gave the plant personnel many valuable pointers on how to improve our loading and strapping techniques. During the survey, modern and more efficient strapping eq\iipment was introduced which will make our operation more efficient. Included in the new equipment was an electric tying machine ivhich will enable us to have more uniform tension on the straps and thus reduce the possibility of damage from strapping. Although there have been very few complaints on plaster, very little plaster has been produced. This lack of production is, in itself, our greatest plaster problem. Stucco which remains in bins, screws, hoppers, and elevators between shipments, is subjected to the high humidity conditions of the area and thus becomes quick set. Due to this idleness of the plaster packing equipment between shipments, we have experienced quite a bit of difficulty in stabilizing the setting time of both semi-finished and finished products. In order to help offset these erratic setting times, the tube mill is now being operated for an hour before starting production. In addition, the first bit of production is being discarded. This procedure has eliminated the quick set material from the tube mill and has given us somewhat more uniform setting time. Careful sampling and testing of each individual batch of plaster produced assures us that the plaster is of the correct setting time before it leaves the plant. SGP 0020915 Page 4 At the He-rf Orleans plant we are now working on improving our board mix in order to lower the evaporation and to lower our board weights, This lower evaporation will enable us to dry the board easier and thus have a higher quality board. This will also enable us to raise our belt speeds which will result in higher production as wall as savings in natural gas costs for the dryer. At this same time* we expect to lower our board weights significantly and thus have the savings in freight'as a results The first step in improving the mix will be the installation of a metering device for the stucco feed. This will allow us to make very accurate changes in the stucco feed as well as enabling us to preset the stucco feed in thickness changes. This will also help us in metering the correct amount of water for the quantity of stucco being used, Jork also will he done on the board core ingredients in order to obtain the best possible mixture0 We have experienced quite a bit of difficulty with wavy edges at this plant. In order to help correct this problem we plan the installation of infa-red heaters over our present strip heaters. This should make it possible to remove the moisture from the paper in the short time available. In the plaster packing department we plan to continue work on our plaster setting time. Chutes are being installed on the dust collection equipment. This will allow us to clean out the material which was collected during the "clean-up" charge without introducing this material back into the packing system. Vibrators are to be installed on the weight hopperss mixers and packers so that this equipment muy be thoroughly cleaned between plaster shipments. The vibrators, along with the dust collector clean-out chutess should help cut down on the amount of accelerating material vrhich would accumu late in the packing equipment between shipments. To keep our high standards of quality for the coming years, we plan to initiate a monthly quality audit of all plant operations. This would involve a monthly inspection of all equipment and testing apparatus. A report will be made to the plant manager covering the general quality situation and a summary of plant testing and inspection results for the month,, . SGP 0020916 BBSTWRLL PLAIT MANAGERS* EESTIIG PAOLI, FSMSYLVAHIA JANUARY 22, 23, AHD 2lffH. 1962 #2 QUALITY REPORT PRIOR, OKLAHOMA J. H* BURKHART SGP 0020917 A) PAPER COKPLAINT MCAP - ALL BOARD PLANTSt X) CGKPLAINTS - FREQUENCY: 1959 I960 1961 1961 - % DECREASE 153 163 123 DEFECTS BY TYPE - FREQUENCY: 1959 2$% I960 1961 1961-$ CH. 1. Slime, surface defects, holes: 2, Cockles, wet streaks, crush, wavy edges: 3. Split ply: lu Telescoping, winding; 5. Off Width: 6. All others (less than 5 in any specific classification) 1*6 26 7 12 62 58 Wi 29 26 15 12 13 21 73 hi l? Total 153 163 123 - 2h - 12 - 20 / hk - 57 - 58 - 25 3) DEFECTS BY TYPE ~ SEVERITY: REJECTS BOARS FT2 l. Cockles, wavy edges: 2 * Surface, slime: 3. Split ply, bond: h. Splices: 5, Cores, nlur:s: 6. Winding, Telescoping: 7. Wise., slitting, etc. 8. Pin holes: 9. Crushes - Spots T.L.: 10. Tensile: 11. Damage: 12. Thin Liner Total 1960 205,321* 73,858 116,lU9 ** 19,372 6,Uoo 200,806 2li,256 * 101,056 71*7,221 1961 161,100 106,600 229,300 2,700 5oo 36,100 5,ooo 103,200 5,600 656,5oo BOARD PLT. DEMY BOARD PLT. PAPER FI NOTES REJECTS # 1960 ;1961 I960 1961 -- 23 200 lU,i*67 25 - 5,53-5 3,600 -- 5,500 15 9 3,10*0 -- 26 1*2 3,800 18,537 61 10 8,000 26,223 - - 65,035 - - 18,700 8,115 -- - - 2,560 - -_ 127 81* 107,250 76,1*82 APPROXIMATE COST OF PAPER DEFECTS: a) Reject board b) Delays o') Reject paper - Ivory Gray Lath Sheathing Total I960 $ 10,83U 209 U,580 h9 136 26J* 0 16,072 d) Tons 5it e) % of approximate delivered cost of paper O.SU 1961 0 8,810 250 1,626 268 61*0 683 $ 12,277 38 0.32 % CHANGE $ - 18.7 / 19.6 ' 6iu5 / 14*6.9 f 370.6 / 158.7 - 32.7 " 296 *S <j>3 SGP 0020918 OL-Ji h:\ : R Tp\-y?-rp The majority of those troubles are primarily at Ft, Dodge, however more plants did encounter these troubles more in 1961 than I960,, Tendency to ran finished paper above recommended moisture content of 6% to increase production contributed to the wavy edges, Less moisture (5$) content and more even moisture across sheet has tended to decrease this condition. The more absorbent 70# Lath has increase complaints of cockles as it has a tendency to pick-up more outside moisture from storage here at Pryor and Board plant storage * b) SURFACE DEFECTS; Asphalt contamination was held to one complaint from Board Mill, However vie did run Grayback if found in Filler furnish until asphalt spots ceased and then return to Ivory top. Better cleaning at shut downs and reject at Pryor prevented this type complaint,also the use of double pulping of Top Liner for Ivory has minimized the colored spots from milk carton stock in Top Liner of Ivory* Better cleaning of Filler furnish on Ivory has contributed to less surface defects, c) PIM HOLTS s less pin hole contamination has been noted in 1961 as better clean-up procedure have been established and cleaner filler stock and test procedures at start of runs has kept this type complaint at minimum, d) SPLIT PLT: This has been a major problem during the middle months of 1961 but has been corrected with the use of cooked starch in #8-7 and #1 and #2 cylinders while running Ivory face paper. The use of Kymene in #1 and #2 cylinders while running 7S># Ivory has corrected split ply especially noted at Sigurd where the problem was always acute, be are continuing with the above procedures as a safety factor in elimination of split ply at Board plants,. Crushes were a major problem aspecially on Ivory face paper. Tver, loading and adjustments in vats and reduced speeds on Ivory face paper have tended to reduce this type complaint. Running a drier sheet tends to eliminate some of the jncounuerecio SGP 0020919 This is a problem which must be worked on in a different manner on each run of Ivory, as machine conditions, stock, etc., are changing to a varied degree each run* f) THIN TOP LIHER; This has not been a problem in 1961 as vie are running 006-00? points of top Liner on Ivory which appears to give best results for coverage. g) SLITTING - WISDXNGt Slitting troubles were confined to narrovi width roll products. Slitters would ride occasionally causing paper to not be cut through, and off widths, both causing trouble at Board plants)* The winder is equipped with a special valve arrangement which is supposed to prevent this condition, but timing of the action was checked and it vias found that it did not always prevent the problem. Special air flow adjustments were made to the cylinders actuating the slitters and the condition was corrected. The use of National starch P.esyn as a calender treatment for Grayback did cause some loose winding as it caused a slicker sheet at the reviinder* We are now using this material in with regular starch treatment and winding of Grayback has become better, h) WISCFILArFOUS: Splices, cores, plugs, and other items not mentioned such as strength, weight, scuffing, folding, transit damage, densemetor, and sizing were not a significant source of trouble during 196l. SGP 0020920 1961 FELT QUALT1 JlSCtiSSIOH Generally 1961 was a satisfactory year from a quality standpoint* Strength of felt was good, with occasional trouble from holes, and cracking New laying line equipment was installed making wider lines Brightness of liras has been a problem but it is believed to be corrected now Very little loading damage was reported with cars being received at Dallas and Kansas City, No outside felt shipments were made to Ruberoid as previous year However we did. send 7 cars to W. R* Meadcw at Elgin, Illinois of 27 x $la felt# Loading is a problem on this type package New overflow pump was installed which helped formation the latter part of year# A separate broke chest was installed but not put is operation until 1962, This is to feed broke evenly to stock at all times -when available, to reduce furnish variation# Telescoping of 27 felt was a big problem during she first part of year* Corrections were immediately instigated such as better brake bands and grinding reel drums for more frictiono Finally a new positive drive and lagging of winder drums corrected this situation in the latter part of the year and tal isc oping has been practically eliminated. SGP 0020921 THORQIDo ONTARIO mw*iiun*jiw w.'litiw>nniiWiM -- JoWoHART SGP 0020922 Ic PLASTERBOARD PAPERS (A) IVORY^ *> Q^rqcjO^Ml Generally goodg and on a par with i960,-. Surface defects in finished gypsum board caused claims for value of rejected board,, rather than the value of the faulty paper alone. In one instance,, drips at the calenders was reported about 3 months after shipments due to high customer inventory, and remedial measures were not effectively applied on interim produetiono It is believed that customer surveillance is more critical than ever before, and that some of the claims would not have been made in previous years 0 Top liner sizing was lowered in May 1961 and appeared to be satisfactory until soft surface complaints out of kiln developed early in 1962, and higher sizing was restored,, Liner quality was improved as to cleanliness,, through reduction of Newsblanks by increasing groundwood.and improving control of groundvrood cleanliness,, 2o Atlantic Gypsum Specifications for weight and tensile were lowered from 76-30 to 72-26,, in order to obtain lower customer paper costs,, Early in year,, low tensile problems were followed by overweight paper,, Minor surface defects were not a problem,, but unequal expansion of Face and Back papers requires an excessive amount of water on back of board,. Gray has normally been rna.de on No,, 1 Machine,, whereas Ivory is made on No0 2 Machine,, Experiments to improve '`match" of paper expansions is scheduled for X962B with weight, sizing,, and change of Gray production to No,, 2 Machine, if necessary, modifications under consideration,, (B) GRAYS`1J 'Trtfr 'rfciirnrrwi 1 o Gyuroc (G,.L0A0J One serious complaint at Caledonia in August involved a hard spei which affected the Ivory side. Trouble was attributed to calenders which were reground* and related reel building difficulties? One Montreal complaint involved `'split-bond'*,, a narrow edge ply separations or blew,. SGP 0020923 (B) GRAY (Continue 20 Atlantic One serious complaint of cracking was attributed to spreader bar at stack being improperly positioned Weight and tensile problems existed, but were not as severe as on Ivory0 (C) LATH; Ip Gyproc (G0LoA0) Adequate tensile at proper weight was a continuing problem0 In particular, low tensile was experienced with Manitoba paper, when a Miami Jordan was taken off Filler and tried on Top Liner on the other machine0 Return of unit, helped tensile, but business is apparently being lost to "integrations"0 2c Atlantic First two runs were made during year, with requirements probably previously furn ished entirely by Gair and a small Maritime mdll^ Surface absorbency of first run was not up to desired level, and second run was further softened with lime in top liner0 Customer findings are not yet available,, (D) BLACK SHEATHING; !o Gyproc Montreal business was lost ostensibly due to having too hard and stiff a sheet,, A trial run on Nfo<> 1 Machine produced a sheet customer said worked well, and some return bus iness is expectedr. It Is understood that national Gypsum has supplied oiled paper, and while it works well with "rag-like" properties, clean-up after a run is a major problem^ <E) OTHER lo Bestwall Ran Ivory, Gray, and Lath, in Augusta Quality was considered good except for Akron comment on low tensile Latho 2- SGP 0020924 Ho PLAIN CHIP Several curl complaints from May to July0 New Top Liner pulper enabled better stock preparation, and Paracol wax in filler helped curio Trouble with unbeaten stock and uniformity of color helped by increasing use of news0 Complaints on off-size sheets were reduced by closer control inspection, although cutter is old and worn, and it is difficult to maintain sheet dimensionsD HI oWHITE VAT LINED Orders for chip--back and screenings-back were mostly trial runs and involved a lot of trouble, primarily due to the very short runso Sales is attempting to improve tonnages per runo IVo PATENT-COATED(KELLOGGS & SHREDDED WHEAT) The most serious difficulty occurred the latter part of I960, and was not diagnosed and remedied until February of 19610 Flakes on surface were attributed to the presses, and a water bath at each press provided correctiono Cracking complaint in September was corrected by increasing sulphite, changing refining (to Morden), and increasing moisture,. Caliper variation on the edge of 14 5/8,? trim was corrected by eliminating production as a ''side trim"o Vo LAMINATOR No adjustmenta on complaints G VIoCOST SUMMARY U) Gypsum Papers; 13913 tons - $0o22/ton (Continued) -3 - SGP 0020925 Vic COST SUMMARY (A) Gypsum, Papers (continued) IVORY CUSTOMER DEFECT Jan,1961) July 1961) GYPROC Caledonia Made Novu ,Decu, I960 Water Drops May 1961 Manitoba Made Maro1961 ~ Dry Edge July 1961 ) Caledonia Surface defects -'`flour" "Water drops, to water streakers cratch mark(spread bar) Dec,1961 ) (8 complaints) etcO0 Montreal 1 Complaint 0 OCtnI96I Montreal Made SeptQ27 - Wrinkle SETTLEMENT $ 600,00 100,00 986000 223oOO GRAY May 1961 AugoX96l Oct,196X GYPROC Manitoba Montreal Caledonia 0etc1961 ATLANTIC GYPSUM Made March -Splitters (lew bond sizing) Made July - Split bond (ply) Made August - Wave (Hard Spot) Made August 3rd - Crack (spread bar) 90,00 274,00 1,222,00 488,,GO LATH May 1961 GYPROC Manitoba Made Oct,1960" Soft sized bond '#* *)(- TOTAL 100,00 (B) Boxbcard Papers; 5214 tons - $2,33/ ton CUSTOMER WHITE Vat LINED (255 tons) IngersoXI DEFECT Low caliper PLAIN CHIP National (2408 tons) Somerville Schaefer-Ross Wavy0g amount resold(freight) High moisture Wave and warp PATENT COATED (2551 tons) Kellogg s Dec 01960 Jano1961 Feb, March May June August August Crumbs(settlement Jan,X96l) Crumbs Crumbs Crumbs Crumbs and asphalt Split bond Crumbs Caliper variation SETTiEHEBr $ 451 .-,00 900o00 55oOO 78,00 7S235000 l,600o00 ip.65c.CX} 210,00 .100,00 105,00 25,00 215,00 TOTAI. $ 451,00 $ 1,033.00 10,655,00 TOTAL BOARD 1 12-i39oC0 SGP 0020926 (C) JLaainator Boar, - 3*876 tone - $0/ ton No adjustments* (E) All productions Total Tons 28*000 Total Adjustments $161217c. Total Cost per ton " $ 0*58 VIIoPLAMS FOR 1962 ln Trial of a spreader rolls, In place of spreader bar,, at calender stacks9 to eleminate surface defects due to bar scraping and droppings* 20 Improve tensile-weight relationships through better preservation cf waste paper stocks* (Lower inventories9 faster turn-over,-, and urging of provision for adequate covered storage,-, 3* Use of cooked starch through jet~cookerp to improve effectiveness and decrease costs0 4o Reduce fresh water consumption to improve system temperaturesaimproving stock prep atation*water removals, and chemical effectiveness and losses* 5,. Continue Hercules study and implementation of findings on mere efficient sising,, 6a Improve consistency control through routine testing for control purposes,, 7* Find a satisfactory chemical defearner? to eliminate use of fuel oil and its adverse effect on formation and sizing* SGP 0020927 QUAl/ft! PROGRAM 1962 SIGURD PLANT OBJECTIVE To reduce overall complaint costs due to defects and errors by at least Also to reduce complaints received by %0%* IHTEIJTIOH This is a working plan for all supervisors to refer to and enable them to have a planned approach to quality and service in each department QUARK! la Stripping mil be carried out in advance of drilling to insure removal of clays and organic material 2o Drill hole cuttings td.ll be analyzed in the lab for purity, salt and anhydriteo 3* Head teeter or quality supervisor will visit quarry with plant manager a minimum of twice per month to check rock faces, stripping and correlate drill hole information on map* U A map will be kept in the laboratory and a log of drill holes to maintain a record of rock quality* o A daily inspection of blending operation will be made by the Quality Dept* to insure uniformity of b3.ending and that percentage purity set for particular periods is maintained* 60 A minimum of two grab samples per day will be taken from conveyor feeding the Raymond supply bins. This is to keep a close check on board plant stucco purity, results to be plotted graphically* KEEHES XG Sized rock from quarry to be loaded in kiln* Rocks larger than 16" will be jack hammered to insure uniform size* 2* All thermostats on beehive kilns to be checked once each quarter to insure their accuracy* 3* Samples from each batch will be tested in lab* Culled material will bs sprayed blue and used for bricking up or sealing kiln only* Up All material to be stored on the floor In two dumps for each batch* Dumps will be numbered and test information slips attached to respective dumps* SGP 0020928 QUALITY PROGRAM 1962 SIGURIM UTAH PAGE TWO IDXL Is Test all kettles for I* C. and setting tino Aa All kettles under 66 T,, C. to be sent to board plant and board plant notified of such high T C* stucco with location of same* Bo Bait treatment will be left to operator's discretion with a maximum of 5 1/2 gallons per kettle for board plant stucco* Should calciner require further instructions in particular situations, the quality depto wl.ll advise on such matters subject to testing raw material# Co Kettle operators to report all findings as to T0 Co, calcining time and other pertinent data# Sheets must also be signed by ealeiner before leaving shift0 20 A log of cycle times will be kept by the Mill Superinfendent This log will be used to help prevent dragging of cycle times When cycles begin lengthening, kettle grates will be changed3 3 At least 2 samples mil be checked per day from each kettle for % purity and % calcination ho Standard testing procedures will be carried out on all plasters being manufactured PERLITE 1a Maintain a standard sample for color comparison in terms of whitenesso 2 Maintain a regular check on raw ore and watch for discrepancies in screen analysis from suppliers) PACKING lo Standard testing aid quality control on all plaster shipments,, 20 Laboratory Depto will pick up orders from general office and pass these on to Hill with formula #'s, retarder and other pertinent data for material required0 3o Mill Superintendent will check each carload to eliminate shipping errors0 L'o Packing report will be signed each day by head bagger, this to be an indication that he has checked the count of material shipped and verified it as correct I ail Superintendent will check all ears for count and correctness and sign packing report to this effect* BOARD. PLAI'fT le Maintain paper control programto reduce waste of #1 paper A Close inspection of paper or? arrival to insure proper claims against carrier SGP 0020929 QUALITY PROGRAM 1962 SIGURD, UTAH PAGE THREE 2~ Standard testing of paper and stucco to Ensure unifora materials for manufacture of board* Aa Control records from new control equipment at wet end will be forwarded to plant manager for his review and filed by the laboratory* 3a Continue preventive maintenance program to reduce delays* Machine shut downs contribute to wet wastes kiln gaps and formation problems. Wherever possible planned delays will be taken to avoid such problems* Ivo Maintain program for reduction of waste in board plant operation* So Continue use of pallet tags at stacker Tags to be signed by each inspector and at least four bundles per lift checked each end with penetrometer* Results to be recorded on pallet tags and Board Plant Control Sheet* 60 Any questionable board at stacker will be blue tagged by inspector* If board is obviously defective it can be placed into the dunnage pile immediately* If the quality is only slightly questionable* however, it may be held for re inspection by Quality Supervisor and Board Plant Superintendent* 7* Warehouse will be checked daily for warehouse damage5 board will be date stamped and removed from warehouse ultimately when found to be damaged* Record will be kept of this and a goal of 50$ reduction for 1962 set* 8* All loaders mil be required to sign loading diagrams for material placed on cars by then. Warehouse foremen mil check loads, count, correctness of procedure, etc*, and sign diagram in appropriate space* 9* Full coverage of loading operation will be expected of warehouse foreman on each shaft and they will also make out a report on loading and shipping each day the department operates Any damaged board will be removed before covering and banding 10* Further check of loading operation will be carried out by Quality Supervisor 11, Pictures mil be taken wherever requested or deemed necessary to verify shipping condition and especially with regard to pool cars including plaster and joint system products* 12* Loading dunnage to be sprayed blue without exception before placing on car* 13a With the installation of the new warehouse it is hoped we can give 1 day service on mixed carloads. The Board Plant and Mill will have to exchange information on this matter to insure a 1 day service on mixed carloads, Trds mil be the responsibility of the order expeditors 21* The new warehouse will also mean a 2 shift loading operation which will a.nsure X0G,i supervision on loading crews This supervision must be exercised to the fullest to eliminate shipping errors and damaged material on care* SGP 0020930 QUALITY PROGRAM I?62 SIGURD* UTAH PAGE FOUR QUALITY - PLAHT GENERAL I Quality meetings to be held once per month with all salaried personnel and include as many hourly personnel as practicable 0 Meeting to cover complaints received during month and particularly acute complaint areas so that these may be cleaned up and re-occurrence prevented* 2a Ho3.d quality meetings with all operating crews each quarter* L'tth the aid of graphs and diagrams the quality picture will be outlined for hourly personnel and areas which shew poor quality or personal errors will be emphasised with a view to eliminating such problemso 3<> 'Whenever applicable quality and shipping complaints will be posted on the bulletin board with samples or pictures if available* U Posting of monthly complaint surraiary on all bulletin boards comparing 1962 to 1961 complaint occurrence and cost picture* 5o Quality Supervisor will review program monthly with plant manager at quality meetingso 6 Personal contacts by foremen with hourly personnel to explain the importance of high quality standards to our customers and applicators0 T Order expeditor will be re-located in the general office to improve communications between order service and billing department* 80 Each complaint will be reviewed by Plant Manager with department concerned and Quality Supervisor after formal investigation by quality department* All other standard testing and laboratory work will be carried out as normal} the reason this is not included here is because it would entail too much detail* SGP 0020931 QUALITY REPORT Sigurd 1961 Hie complaint experience at the Sigurd Plant has been somewhat better in 1961 than the previous yearj however., we still found ourselves confronted with sizeable complaints on material shipped in I960* These complaints are shown against the 1961 record since they were entered in that year* Hotably among these was the series of complaints on high shoulder board shipped into the Denver IMarket* Curiously enough vie continued to get occassional %igh shoulder" complaints whenever requested to ship board into Denver$ this we found rather singular since the problem was eliminated in the early part of 1961 and no complaints of high shoulder were received frcaa any other area* This series of complaints in the Denver Market alone cost over U,000, the major portion of the material being shipped in i960a The second complaint of this nature concerned acoustical plaster which was unaccountably streaked or discolored after application and drying. Since the walls were already painted $ this proved to be an expensive job entailing almost $900 to correct the situation,. Another large complaint, the magnitude of which we were quite unaware of until confronted with the adjustment report, was a cracked board complaint from the Salt Lake City Sales District, The complaint report indicated that the problem, was not serious at all, but the final adjustment amounted to O978s>00o While adding to our overall cost, this is reported here on the basis of a i960 complaint. In analyzing our complaint picture for 1961 we feel there are several major areas for improvement: !a SHIPPING ERRORS Though not the most costly of complaint reasons, the figure established in this area has, nevertheless, been quite expensive At the start of 1962 a two-shift operation began in the board plant warehouse and we aim to increase the efficiency and accuracy of our shipping department with individual supervisor's designated to the task of correct loading procedures on each shift. Compared to I960 complaints on shipping, errors were reduced by some 0700 2 CRACKED Aim BROKEN BOARD We continued to receive this type of complaint in the first half of 1961, but after installing special support arms with rubber pads at the wet-end transfer, this complaint area was virtually eliminated 3* IJSCI-iLLATiEOUS This accounted fox' the largest proportion of our complaint costs and is probably the most difficult one to combat. The biggest complaint in this group was one of brittle board in the early part of the year After reducing the weight of our board while still maintaining the quality, brittle board complaints were drastically reduced as to be almost negligible SGP 0020932 PAGE Iv.t! QJALITY PEPORT SIGURD 1961 In order Csf occurrence rather than severity, we must necessarily record a 'lack of talc on board" complaint next. In the latter part of the year this, too, has lessened appreciably0 Other complaints in this category include damp board, nail pops, complaints on shifted loads, high shoulder board, butt ends not finished properly, soft core, tom visqueen covers and for lath, a lack of end clips and poor suction . Many of these we have already eliminated and the others are being worked on fastidiously Noticeably there were no complaints on poor bond or clean peelers in X96I| we feel this was a big improvement over the previous year when a total of 11 complaints cost over $7,000 in this area. Core splits and blisters were more apparent in 1961, but we feel this problem can be solved -with the blending operation of the front end loader and the new stucco system currently being installed Plaster quality has shown very great Improvement, the major part of this coming from a complaint on acoustical plaster mentioned previously in this report and listed under IGscellaneous* The Keenes Department too has an excellent record with only one adjusted complaint which involved a shortage of 10 bags of material* Although the actual occurrence rate of complaints greatly increased in 1961, the number of adjustments dropped considerably involving a total savings of $10,658*71 in complaint costs. We feel that we can do even better than this in the year 1962 SGP 0020933 3QSBD PRODUCTS Pool' bond -r;laar. p&elexs Core splits ** core blisters Cracked > broken Edge taper Edge formation Split ply paper - end splits Off clitoansiona Surface imperfections 1U.seeX'lene ous PIASTER PRODUCTS Setting Kiss Working Properties Broken Bags Cracking Misce Il&ns ous Kaenes Cement Shipping Error's (all divisions) Jolms-lfenville Complaints Tcmz* I960 Complaints adjusted m l?6l < 21 30 -V 5 11 10 1 66 11 1 1 9 2 58 31 ViV9tX Cmaplaints I960 '**i-~/'> d5-. i - 0 - 12 1163,61 27 2.689c 0? 6 118202 6 88033 3 1508,15 P3 * 12 3956o66 2 W** O / *r'* U>* 3 36-03.61 X 3.9 <,20 29 1366,17 6 1062o65 3,1 $36922*99 2615-98 #17536097 1C1 #283.95,68 SGP 0020934 SGP 0020935 vx;hn:to:vy oltt xtoinhial aavingG note in 'Mia foilouirg areas; DIRECT u\dCR - Bffo3;'ug mro mis tbrextgho-rh the plant. to GtrsaisXins crews, to lining thorn in lino Tilth current bosiisssa levels 6 Soto wmeoesr-as-j' job:; Tiers- elind noted. oat fee the soot port, 'this trissniriu vmo done witho&i furthe;? capital oxperxiLtnrQK * The tmi result of strorni&iniDg the hoard warehouse orom was & $22}0CGo savings in afreet labor for ihs entire plant IJl^ibi^IhBG'-' Additional savings in ovsrtims xsr-s mde* Particularly In the board nanafneiorirg and beard warehouse de-nartnsntS; resulting in m |3;?OCO. plant savings* social sssmTrs^ cqispt mimics Ac & airsst result of strsailtinlng tea erers as sutltesd above*. m additional tjbs00D* cavings was coda in Social Sseirrity costs and Ocspsnsatioa Instsrarassr, ^PPLIFS hW KXiWpmiTM The eliateiim of the 2nd, shift stripping opsrstiox: in the quarry? tbr changing of tbs shot pattern and the use of a loser ect exploaire? the purchase of poks-^palXsts in barload lots for the Joint System department, seeing approzitsately f)60S flight en. ssaoral true!: load nlugrputey the elimination of eoo'TVkgcted poly chcebo ins board leading srxd rnebasl ;isag of bracing lesbar and sic:,l ot;ccxpiugr ;iJ. onorrAncs to a total saxingy for the ctarA of f3-b,OoO SGP 0020936 PLAIT UvPSEAB Peenoed ucC.c^'ise charred to Beohauicc.1 ovo^- he. r topoiher with savings on salaried overtias payments s earlnys on repair roderial a?sd repair labory snd lane? depreciation costs, cdfcat losses on other overhead it-sm and resulted in net ga-ringc ol $2400 ftn? the pltxyrfj. This total savings was reduced by tha wag increase ia the ssw Union Contrast; by higier costs is rapsir satsrials used in the Grinding* Oalelivlag and Board Manufacturing dsparbi&ants; by higher fuel andelectriaiil power costa is all departments, and by higher costs in daiorial handling, but still amounted to sa overall springs of $x$s.COD The gaii end locals listed aboro, ere brought oat in detail in the attached reports end the loose# e;q~ssrier3-2cL while substantial*, point out areas whers \re oast work toward furth? luffs?cpsreiasnt la 1962 o SGP 0020937 i O ;;-,j - * :. '- ti r i~CS4< `' c* 'o A.*i\ *1 iA fi"\ ! AN ? cp H N 5n- 8 o vS? un an SM O VnUN O *J\ no .*a, O S 8 P2. nQsOH1\ j,Hr;<JsS O \D fcwsc*. CO*v 04*CO<'>CO~ <* <- ch O-N<X9>,PSa >>-.". o<-: S'- On-.S3 p* CO vO O t -i rCV-Si '- ~-s| \0 H -cX>n' `<S5Na-\UoNiicsCoOo OJ 'O *; On <M ,f0-S-\i'c-tQMsoOCiv\ <**~t H<n. CO. AN un Cf'O" r! .\C.$JN>\ 4 OO-NNCN o NO SH g C-3 TA O On C'N tr\ o'3 VT6; vO Cm VO "' ;'V o iCO On V\ S-- '" f-O fA rH O'1- c~ 00 tr-H 1U "I On O X3 S3 AS C-- Cs CO lA-'J d` ^S* ij .. a >2 H SSJ ;-4 O KV CO - ^;.> JA NO S'N UN W.1 1A r O s 4H C4 O Cxi rS <w O AN'.A sS . >> C?N -ot tH i~i OWO CnJ i--{ "X ,H CfN H 4""4 vSD 'NO NO Xi CO xt . ";' CS S-A CC ^ V CO fA C% '>* ON ct Otjs.'n NO P"S UN F"i fSi NO r- Or~ni -.P 2 .. C4 S.NS-. U*\'..C"P`, U\ i.ns.- vO& r~*J>.AZs cooV -- O O'! ?a . h co.7-1 <M o. .-f H o-N CAJN x*. 'CC--n> NO4- !30?-. UN CJ nO UN -M On Un *~i S*" * <h2 NOn rO~sn co co A- HI ^<iii UNO \0 CO A<1 :- VA mO 5kin~ j~j o co <nn on on ,,-* ct _x? ^f* t>- r- r*l ON CO JSf' C-.J vO CNo!.v"4^ Oi? CNOi O^n--O1fflO'O- O aortOt; o O r-i Xtt. Sfl 3\OOnOOslNC-J CHO N?O"CCrHS5 CHr4VCHNJ ffiH~A; 'WOs Osnn'ON C' OOn 1OAn CO c-0 6r. Cs Os to On-C 5-1 8 t`- cAW O UN 0,< nO H On r~ CO t/\ .JS Jg CK m O CM CO 04 ON6 CN CO NO CO Cns CX AJ i -3>{ SS r 43 NA ON <H -H ^Ct fA SNi S'- W3AH O'. *N ea vs a ... sn - tst f.;. .- 4*. os~He j<-H2 A'OHHOAOC ON JS- -it s-j SH HsH ri r*S OUNCO -cSnO r*i 04 00 r-S>-'*0 HpH s H CA ?N4 co cn-OCO CO -^1 SO aHCNi fANO ON*tA i*Sj n S>.. ON tu jH c \-5nOOn Xt\ go O <XI SM On O XAUMAnO r-i CnInO -CJ A*'<5 3 <\ 5i -S tfi *7i 4 - % 6\ *> *?j jiH !h CN h 'O sCHV! UN nO Oi-ni U--N{ UN CN l~I On O ) UN CNj CNa fA OO On H fJ H .H CO A^ j*. H sH K> unloctes t o 't e ls o f Ttepartraents 21 a*>i 22 so rs oao vSs S 45 .p Xwi ,.,,1 no &MC r*!C-! D HR! pa.j~4 < C3 C, *r* SGP 0020938 Wi "0 I .;.! ! 't .WV<0MC>mG-A->COQA VAQii5r`.4\\ f-fit pMis. Ms Mn Css. >- mvO vD CO Vi. 1A H CO si *cy CM CK! 0s 4D !* 0\ m\A CO i 'SI a, n ft *. 0 O S"t V V cv *- tv r, w-i oc. v"5 6% . . co ;-} CJ Os iA> Os AV * *, IA (H me; 1A; j .cl'O f- ..cj V, rv.pJO 50 Os 5oSOS S'! 'V mftpsis Ja S-- O'. ;m c-4 53 3 .1 i' m ; gefe. COOSS i-S4JviaiKJ 'CH K+3 *U *>HH Si r-i jg <~4 U d"> 0 k 2f OMH -P -P 1A t- O *V\ -- vO M tA Os H -O vO <O5 fcoo swft H cv r-i so Os > CM p"i *=3l m3 3 US VO, jo Os >- I ?*- H CA 'A .* " J o .PJ..SJ jOO ie?cfs"ntc<oso> eOcv*hH*o-do-shQH, Kc~- C 3 .8 sO w ?*5 e ;3jv S3 : r-> 3 c s ? 05 A CO. t C- m8<*Su-\T{i 4i&>x>:* S if.. :"i 8 I j..;' V f *i*- <O*s4sVO> i\; WsC .J O CM CW . 3 f TO SGP 0020939 i mm tmo |h i-H ?- 04as CV1 1 so-sH 4. siro\ meo-iw <nsO WCM ,, ! ,, 3 ,, 3 s0H\ o= H<) $ 0 it. so SM -7 SN P7 CO V. 3s rc Pi- H "rrst Cl L*i f0e & t$ 4) CO ,O0i O R OS >4 <oe Xfi u& ^s4is 3 Mri f-i .s . o4 csVi M ci g <5 O f-ji O O rf\ IQ Tt4 ? X 5 t/I a? v*t 3m t~i >a Ti 44 v. -a .op d r*4 ^ iii s; O s-fo3t # - t f SS3i r-i $ -3 li g SGP 0020941 U\ P$fak> t>o a* @ r*i O a, f* ft 9t9>9 O H <srsi ari -pri-. .J1S >I to u. * 8* ceo &&* ma $ oif! SGP 0020942 11 AX/:'.,. SALARIES * Fj.?mt laboratory Usehc-ilcal 0* ih QcTi'-l-s Plant Plant Offleft HOBKLX* AiitO `firviOlH? HL&?xb Laboratory rfechaniosl 0* H* Gen*!* riant Sttbsndling Plant Office cmr-RTI'^.s Salaried BoisSIt wctio; SOC. SEC* TAXES comp, mmwcE REPAIR UBCft HP PA IK ft^EIAL 87a & SOPFGIES STATIC'IPH7 PCS'PAQ FUEL ELECTRIC KS3ER TPTAR KCW? TBISORAPF 3UFPFR DDFXl COmKlBBTIGB DUES Sr SuBSCKIFPIOHS TRATEL CHAFGIEG 73GATIOB stuns? i V5TO 102a2 33678 663X1 3002 X0886 131^7 30333 3196 1*20 2313 33.68 5?22 7718 6793 6X93 17308 m6f 'em til 853 2X3S 5628 1X963 3636. ??8 xSe ISli 216X1 386$ C X!A) O.SkXfTYT' -STLJ>J. OX*.,<Zl,f ?m.L 00UTR01IABJ7 f|63X36 11 s'xs., 1963.1*->; r-.-'T-'V- . -. '. .4`"J7iac (XvBi op ( Pops) 11933 8070 67613 iao?3 8396 18039 13550 jShjB 1333 132 6x5 83a? 61X3 7273 2905 2E-02 BIOS 72X1 2722 ilm 639 ZZ9? 6im 10895 3310 32 100 128 3970 ' 13X52 173 ' XT':3-^L-iV:'- i'.JfiSXip* 5203260 6 ( 6850) 2172 ( 1379?) 0336 605 / 1201} ( 99) 3a 9X3 288 1793 ( 109) C 596) m c in) 1393 yli.C-6 3.053 2m. i m) m C 167) 60 1008 m 7ts6 T-iS C U) C 1029) .X.J11L 6 8676 I:ro0Tctsd X XnnisX i ( lj?6) 23^9 (15001) 58a 09 C 13105 ( 108) 56B 887 31k W&l { m) ( iu2) IjSo { 121 j 1520 X02SO 1160 2183 ( 275) ( 1821 Ti 'HSh 019 616 ( lil C 1663) ~LJ&L $ 9583 SGP 0020943 Plf^nt Office - Pairrice " !i - Ovsrtiiro ' r - Hourly stationery foe tc io Telephone telegraph Pub-Total Gi.ii ,, 11 on .?r..\T-T T uhfuiG C^Pc.GSi G.c VO 1953 >.u;a f 62696 : '~o21~ 2 6:. :62 1440 2863 3640 610 ?,.? f v. 30 9? 3408 3436 1132 1262 1370 6112 o-j34 11368 ^3821. 3364 2 Gaan 4j2gg_____ S to900 I960 3 32992 268 5 614 4311 1345 12670 3 78200 a) w19~61~ .39 144 2969 1629 11c 7 3 36.ll (1) Eleven month costs, projected to an annual basis- Thousands of .ollsrs LEGFKr Salaries Overtime Hourly SGP 0020944 SGP 0020945 y ii-o O.JCR U?-.CJiV .'.^'5 "ROVR.RvG lS;}hi-e 1GRGCG V 2,. S3 :-; AZ?& ;: 12 rouXW-5 Lower Poord leiglits: 3Q2u?l# :- l^!3?/&5u<, >: 12 iRiiilLfR V:-3'i re-aru <1 G-id.ReL'o g OggLs: ,013 >: 325 Oparels l>ulk LiGoetowo SpR-LeiR 6.??3 '""\" VSsOO/k-on XO^OGO luRieo/year 1 I69w 1X3 >3 Cl 09 13S10,C0 300 lor. Kook SlorogG Biro GG,3,GiL;Jl 2'.GS O' . . O'OEiO :.:.V.J.,. ' ' GROGS, msksXL Sv&l&ligc&r & Air GctcoJIi* Calefoin-k 'tfeba'tdvti>? Bllsjiadbc oas s&r* or g^shifls,, Cs?jw RedosLioig cvi Basra jfeoMnes Org rrr. or l-knifla, Oil3 3RV1 OR 2**Shlftf> f. Deistall Br.lk PIrxIsS.or Syslsiiis Oreo: 1 ooir00cw. Or 0:RrO: u::r` ;CiIAl OBJIG'- . .-v S aB3I200 r>0i' <,00 313,00 32000,00 rvAr'-A' **:?*> GA^i-RUS V/\J IoOOOhOO XlOQOoGG 10000,09 ?3og,oo eOOCIGO (> 800280.00 SGP 0020946 BRUNSWICK PLANT GOJT RSPORT 1961 ELEVEN NONTHS VS ELEVEN NOIITHS l?6l I960 SGP 0020947 G03T ITPLRl jhl) 3ffClICK PMF The following is The cost arsalysio a-id variations for the first eleven months of 2960 versus 1961 together with comments covering various itm as shown on attached table* Direct Labor k Genewi labor increase of 3w uas granted July 1961, which affected 102,9511 hours through Ijovoraber IJel* amounting to 31is.s3VS20.., All Departments showed gains in varying amounts which allowed the labor inero.iso to bo ohsaii'.ed and shew a. savings of )1635 706*15 o Crushing rn;d_Grindirf Drrroct labor savings amounted to jiyJ0.9A?^. k reduction in labor costs of 73S&?cJ.O is noted in these departments* Volume; increased, by 2k059$ in crushing mi 21*72/1 in grinding* *ial caning o nri Tubing 'direct labor savings. amounted to -,5666.,,26,- Through a. volume increase of ItLthf in calcining, increase in total dollar amount, of $i,036,.,89 was ruccessfolly offset* In tubing vm suffered a volume loss of l,.2v^c xbirraf pan. of 1561 :re reirscodad 'labor charges to tubing which has now been oor rect&O.;, 7.1:and Loading iir-K:-, Xch-.-r saw/vra of TlwlTlfGu is shown in ?T7L* Total labor for ',V. is iofn-row-vt is Gig her in 19 61 by .J6158..73 wit a volume increase i !: 1 the gran, shown in unit cost* SGP 0020948 drvt labor In; s of Lf,,6&.lf/p is shown... ?ds is rsfleetad In a i.-- f'.c/en.re or 1 08b, aiif !- -d Loci' feed; op f.rvf, ; ;fi:r crri rr:s or .vf'lfii is sha-m.c Volume on this item is- ;:-52id if, iff iuranr comparison period, allowing a total dollar :.ncr:-iism c,i i?7io86 to be absorbed for the r aia shovru dear : are L utu "b.ce i'. tuber reduction of ;36$,120.,!?5 vras effected A production ' nor -aso <f ip,= 05A eas Huene 'which enabled us to absorb the hourly -.rjyi d 3% and show above rainG incut aw.i 1; claim j, -. .3 fr-r savin; > of ci3y861u?0 is shown- A volsana Inertias'-- of f3,,6}f is noted for this deparlaont,. focr i and I.am Louden;; lirec* labor sari-ps of clitfSfOoOu was effected through a department -A.!.so oriro case of 2(f43fL Actual dollar Xsbor costs increased diarirf tie rompaccum p<rf ou in the amount of Itflro.fS- of which 33j0.3*r,36 ''o'; f?e no Vs-boT i?crease pranisd in July Ifo'U free L.Ln: n-"A.,o v f-f.ff' A if is reflected due to frurujaaed volume in all ['rr- - - \ tf e rfiff epets-t:. on ons rcarenb in the board plant u i , 1-cl rf.on 1,ulcer ,uducud the owrvii; ovcrninc account,. SGP 0020949 vOoxflor- S;; v -A.;.5' . 2 ;-V;/S;.- o.J. oo2.;.c OVO : IkC'.s.;. 9oo: w-j.'ly -i-: :- 'of OrorpCiVOViion 2o:o. i-.v :y SI;.. 9nf f/ 3 io -': if ocf.sf So :n> ' r nil a-: r-a'.<?!so? , 2;Ai;0^ Gf vav of 2>3.,,B9G2l2 is b:vi,' 2nGrss:. o i>ioxrori.lon mb aosness of tb o Gboib ;v.o> v:ifi ooS: about lop .b-oSe? o >/ pair ivx.;;:ial!- i-bxirr.-? f:1 Slf.j.ibb .21 :2o ,;r2'2ci;2ecr Tns lc-::-~. cf Gi;2,iD0..of> in oyushius 2a Uc-aati by repairs, t-o tie rock Sied io i9S.y, TIiu :'iOGi."in'criei Toiaao incrv vvi---. lx 5.j."J fapoi tosm-s 2s r:bpcn.s:i 20o (sv tpft 3 oolops noted.. x..O'. 209 Cot:: S (Pafc Sivzc Rorrivr ;y',co2c^0. 2,.0;: 239-23 ?;-'> Rr` j'.ounp.npa rcr Kilo 29 233023- dup-obuoa ,u 2os.;o cf y`3^->9?7 ?9 i:-; x^S2L-;.y3-.;o.---Gri'xiinr 3.03$. of 3211,,8o iu to.?'isoiad 2/; pxx'o'o'xx 0.2 Si.vof.xau;! painf for painting. `.Srucry i.r r\u p 2r>aa -if .iL;v22..ol 3.? rr 3.'. robed io. yuix-hasoo of oshf-. .x:>:S-y e:.-'-;., aprUip befits ary re-tayy abodes aud bahts borahouoa bud s.-obity; o.oro of off., 98939; io rasleotri in dtmnaye runs oi 3 92(9 f-2.c ,;.pv$''o (but :ui 2923. bos err Jo.o-d:o>FOc Daring i960 only iffV'.'-f : or -f do: ruro :>>;; vo,; due to availability of dunnage SpU: . ;.'.v : ."O' vebiri , -roOcO" SGP 0020950 :U,j/ ; U IP: l' C ;C; )-'* V.'i. . in rolicihoe. '' { ' . :' -n ( i bl. 615 /1. ii aecountad bar oon to not showing . v roc i bri db 'pint, op li&O,. plus inGpecois in oil price t; j ;. . VJ loos in . aievnirr is don to plica s.oo -once o.C .bouiwr b;rl- a;! - .3 7 !' to $2o?0. daviibo : '"VO:: ln si '= .-U3?Vn 0 is itif.nuiiei.. roculhiip from basinnsn iueisasen .a sib i-;. : v iorsn'cs except ir-birr, 1 tubing lose of $*.21 c/|.8 is 'the vm : '; vi` no c,3;' nsbir.g o-provs llll;. iai sro-Iinr ;b.h .'17.?, 51 is rcociricd which isauXbs iron volume irc/nasos "i y>, 5 nop , ic-,5 a in ;:oarc. & noth and iBldS in board and Lanh .slC? pi 150 .56 is reyloci-id in increased volmae.- sst ' Q'i. ml ;-.c.j ; is an-sc ociitilv has sale bearing on incroanad overload : pa -sea dir Vr - ,v-:iod we ebon increased n;:ponditurns c_C 5l6.912, 6i| c.[c .a, - SO V . i .0i~.,;0:.. ,'vp,. : h ... o' ; -V pr I L. ' voia simm os "milois :d. in -ga imoabeo ,, 'bb. dm iidilional .hoi ap rvii-ad, :h: lycb eb 162? "o . iiiniM': -vid job fl j iliirrtiana SGP 0020951 R3pair Labor and Repair* Material Is down by $$1,380.* 52 due to reduction in force and revised work wsek of mechanics* Teleph5 one<rC ea*C^V a*&a**e;ifc> Up $2,28lo6ii due to increased collect calls from customers and salesmen * Supplies Up $5,1X8 ,$?1 due largely to dunnage Materials made* Group Insurance Up 3ii,9U8.00* Rant Up &2,156,,3U. Services Purchased Up $L3,6UU.13 Depreciation Up $3,185.76. G sneral Comaents During l$6l a number of job classifications were eleminatedi one paper hanger helper and one utility man was removed from each wallboard shift and `the 2nd. shift crushing and rock handling craw was discontinued. Manpower nos-ds are? constantly reviewed in order to control labor usage. SGP 0020952 SGP 0020953 GOST SATLim PLAW 1962 Jjyi3QABD .HACK 7 It" SPEED INCREASES It the start of 1961, the established machine speeds for the throe major products were* 3/6" Lath 3/8" Board l/2n Board -> - 17? F.P4.M0 175 F.P.M. lliO F0P,,M,, it the elo3 of 1961, these machine speeds were* 3/8 Ml 3/8" Board l/2,f Board ~ 183 F.P.M. 180 F.P.M. 1U0 F.P.pr, fi-.e top limit on the spaed of the machine is 183 F.P.M. The 1961 33qx*.rienee indicates good control of weights and other quality aspects of boat'd p.roducts produced at the above speeds., Consequently It appes-ri? reasonable to bring 'the machine speeds to a level somewhat oeyond current xperience. This would be executed in two steps* (a; Studies by Ehrssm Mfg. Company during 1961 revealed the fact that the speed of W/B machine can be increased to,a maximum of 220 F.P.M. sy electrical modifications. The cost of labor and material to accomo- iatn trees-'.', changes is approximately $3*5>OOc. change* and modifications to complimentary equipment attached to or servicing the board machine will cost an additional $5, *>00. (b) At the cuxTont. lath spaed of 183 F.p,j-i0 the Cce Lath stacker is jtaxrYorr.g at speeds which have affected its reliability. SGP 0020954 S6P 0020955 .Fiatt c.iyiu;:; ofK..:Jh> j;foduo;ff hyprovvr hrs been rMe'.vcd for the lease and rnstailatioa of an Acciv:-ay rf ocorss Control equipment* 5y means of this equipment s 7c:;\y tight control can be maintained on board neiyht variations niin t.h? final result vcpaeted of loner ever all urights* Savings are ban.--.: on 3.o;-;or fraj.glit costa annually of $15 <.000*00 and oc^.orlai savings annually of 0'i0.1G00oG0o 1KVBST hl7H -- $18,310,- DO SAVINGS -- $>23* 000* 00 per year, bargt; siyi^^r of joj-r Tha practicability of barge uiilo-iding of bsy&rhaue&er paper at the plant has beer generally accepted;, Engineering stuc-las indicate that ?, 3.,:.lege type traveling hoist can be purchased and installed iannsiliat --ly East of hue present paper storage building at a cost no-1 to suned t53pC00ol0o Ibo savings feat rauld be enjoyed by this acrangerrmt are twofold: (a) An allowance of ':;2,25> per1 ton from the C G* W5 ? 15.3 Lae.,- barge Iine_, in consideration for utilising their barges ccr this type movement and (b) a net savings of dldO par ton in freight rrr.es of barge over rail movementtSo Savings Arc. be sad on l:?6l Weyerhaeuser paper usage of It-700 tons* I.iVtST.FFlT -- blR,;GOOL,00 GLLGS = $$7,395*00 per yuaty In add!ft or to the Capital Investment Savings herein enumerated there is a cent toning opportunity for savings in various areas of rarhiae o',:;fv;tV" ..:,. In cwluaiion. of the ip6l performance relative to these it so sera? indicat "du SGP 0020956 ags u he 'JET BOARD & GRINDING WASTE n --!--n.i. . ....nnmAas November to data I960 performance indicated an experience of \,,$8%s tilth a forecast- at that time of reducing this figure to 1%C November to date 1961 results indicate an actual experience for the period of 0,87$o 5, MACHINE DELAYS The forecast last year of accomplishing major redactions in this category were wall intentioned but the results indicated an un qualified failure to meet Uses goals Service requirements have >i bearing on this matter but are not necessarily the basic cause? R&per breaks have been a factor however. More stringent effort will Ise directed in this area to realise a respectable improvement during 19&o 6,, MACHINE SPEEDS Major machine speed increases were accomplished during the Uth quarter of I960 with moderate spaed increases successfully accom plished during 1961. Any additional speed increases can be accomplished only with electrical and mechanical modifications to the machine outlined under Item #1 of this report? 7. '3GARD WEIGHTS A weight reduction and weight variation control program was instituted late is. I960? The initial phase of this objective has been successfully accomplished with furthsr refinements expected in 1962 as outlined in Item. 02 of this session of the report* SGP 0020957 ray fi* SALEABLE PERFECTS Indications are that Saleable Perfects to Kiln Production were improved from a 92% in I960 to 97o8Iip in 1961, A good part of the I960 performance does represent a portion of start-up ex perience and outside bo ax'd storage losses0 Our initial objective for 1962 has been set at 98 >,00/5 Saleable to Kiln Productions SGP 0020958 Ii>IDEX Page iJo. TITLE 1 - Comparative Board and Lath Shipments 2 - Comparative Plaster Shipments 3 - Comparative Paper Shipments 4 - Comparative Board Complaint Costs 5 - Comparative Plaster Complaint Costs 6 . - Comparative Paper Complaint Costs 7 - Comparative Calcining Rates p - Comparative 3/8" Board Production Rates 9 - Comparative l/2" Board Production Rates 10 - Comparative 3/8,f Lath Production Rates 11 Comparative Paper Production Rates 12 - Comparative Machine Efficiency Ratings 13 - Comparative Crushed Rock Costs 14 - Comparative Stucco Conversion Costs 15 - Comparative Plaster Loading Costs 16 - Comparative Board Manufacturing Costs 17 - Comparative Board Loading Costs 18 Comparative Safety Graphs SGP 0020959 1 pl. ait Acme Akron Blue Raoids Brunswick Fort Dodge Grand Raoids Hew Orleans Sigurd BOARD ArlD LaTH SHIPMEi'JTS 1957 Ai4i I UAL SHIPMENTS - MSF 1958 1959 1960 1961 165,952 198,177 228,143 182,143 169,974 82,762 87,810 95,706 98,622 100,983 - - - - 21,046 - - 8,975 152,172 210,441 169,266 178,225 189,906 154,854 163,444 114,776 124,923 129,397 101,119 113,211 - - - 7,709 27,163 81,446 96,649 118,438 115,115 112,889 Total Company 614,202 685,784 770,565 811,734 919,151 t t J l-< SGP 0020960 PLAiJT Acme Akron Blue Rapids Brunswick Fort Dodge Grand E.apids Hew Orleans Sigurd PLASTER SHIPMENTS ANNUAL SHIPMENTS - TONS 1957 1958: 1959 1960 1961 34,837 50,108 57,426 - 62,414 37,746 27,968 27,424 47,564 44,841 60,515 37,688 32,276 33,472 52,707 53,179 951 58,837 37,633 - 34,977 23,629 51,460 33,700 32,006 60,001 26,929 29,941 14,957 41,630 36,280 37,623 50,518 24,559 607 25,567 Total Company 270,499 250,308 271,756 257,666 231,741 SGP 0020961 'I') 3 KJ PLANT Pryor Paper Pryor Felt PAPER SHIPMENTS ANNUAL SHIPMENTS. 1957 1958 1959 33,690 35,387 39,455 21,501 22,948 25,842 TONS 1960 35,408 24,331 1961 40,747 26,703 Thorold Paper Thorold Newsprint 36,250 33,205 45,938 30,486 50,547 30,531 36,958 35,409 27,946 36,141 SGP 0020962 BOARD COMPLAINT COSTS PLANT Acme Akron Blue Rapids Brunswick Fort Dodge Grand Rapids New Orleans Sigurd COST PER V000,000 sq. FT 1939 1960 "1961 $ 28.34/ / $ 22.84 *i> 19.73 $ 47.70 $ 19.76 & 27.20 $ $- $290,15 $- $ 21.87 $ 9.78 ' $ 74.81 vj> 30.99 $ 26.73 ^ $130.97 $ 69.20 $ 44.08 ^ $ $- $ 21.77 $ 54.05 $120.61 $ 94.22 TOTAL COMPANY $ 63.18 $ 43.42 $ 37,89 SGP 0020963 5 O 51 PLASTER COMPLAINT COSTS PLANT COST PER 1000 TONS 1959 A: i960 KA 1961 -3 Acme $ 61.21 $157,26 $322.05 Akron $ 11.16 $ 8.59 $ 31.74 Blue Rapids $ $ $168.85 ^ Brunswick $ $ 14.34 $ 26.74 Fort Dodge $ 40.45 $ 40,18 $ 34.73 Grand Rapids 5 22.80 $ 60.34 $ 13.75 Mew Orleans Sigurd $$ 7.02 $$203.11 $184.25 $57.07 TOTAL COMPANY $ 28.00 $ 65.79 SGP 0020964 6 plant Fryor Thorold PAPEL COMPLAINT COSTS COST PER 1000 TONS SHIPPED 1960 $ 325.08 1961 $ 301.90 $ 164,74 $ 634.84 Total Paper $ 243.19 $ 444.27 J 3 SGP 0020965 ' ~j:> it .cme A.zron Blue kapids Brunswick Fort Bodge Grand I.apids ilew Orleans Sigurd rt r - r* r -r r-t\' C* x J -U i rSJ i. j i --IjO 1s *--f 1 1952 5.35 3.53 3.57 6.22 7.85 6.32 TOiTS xT'Xji.v j1ETTLB . 1953 1959 1960 6.26 6.30 6.42 8.54 3.87 8.92 3.49 - 3.45 7.43 3.58 7.76 6.23 6.27 6.10 7.84 7.85 7.63 --- 6.46 6.55 6.63 1961 6.33 r , 8.67 5.39 '/ 3.03 6.35 / 7.63 7.42 6.48 i SGP 0020966 8 PLANT Acme Akron Blue Ranids Brunswick Fort Dodge Grand Rapids New Orleans Sigurd 3/8" BOARD PRODUCTION RATES KILN PRODUCTION PER GROSS MACHINE HOUR 1957 1958 1959 I960 1961 28,716 31,178 33,361 34,581 34,992 13,879 15,338 15,700 16,028 16,080 - - - - 10,224 - - 17,393 34,637 39,990 29,611 29,753 31,354 33,797 35,692 17,963 19,926 20,450 21,361 21,997 - - - - 22,450 16,684 17,782 18,106 18,746 19,742 SGP 0020967 PLPiJT Acme Akron 31ue Rapids Brunswick Fort Dodge Grand Lapids New Orleans Sigurd 1/2" BOAKD PRODUCTION RATES KILN PRODUCTION PER GROSS MACHINE HOUR 1957 1958 1959 1960 1961 23,836 26,050 28,430 29,001 29,524 9,797 11,218 11,376 11,876 11,831 - - - - 8,596 - - 20,530 28,548 32,203 24,350 24,920 26,304 26,207 26,951 13,724 15,178 15,720 16,536 16,559 - - - - 16,740 13,899 14,537 14,698 15,697 16,555 SGP 0020968 10 PLANT Acme Akron Blue I.apids Brunswick Fort Dodge Grand Rapids New Orleans Sigurd 3/8'* LATH PRODUCTION KATES KILN PRODUCTION PER GROSS MACHINE HOUR 1957 1958 1959 I960 1961 20,778 23,449 22,267 21,265 23,131 14,912 16,419 17,137 17,570 17,129 - - - - 8,103 - - 16,292 29,376 39,095 31,485 30,939 29,914 33,923 39,057 20,115 21,151 21,480 23,461 23,186 - 16,191 - 17.055 - 17,771 - 18,464 19,222 SGP 0020969 PLANT Pryor Paper Pryor Felt PAPER PRODUCTION RATES TONS PER DAY 1957 1958 1959 1960 91.8 101.9 106.1 110.2 72.2 73.9 80.6 81.6 1961 120.6 82.4 Thorold Paper #1 Thorold Paper #2 Thorold Paper #3 79.1 85.5 108.8 81.0 91.2 111.4 83.6 95.2 113.4 84.2 92.5 115.6 85.0 92.0 115.4 SGP 0020970 12 MACHINE EFFICIENCY RATINGS PLANT 1959 1960 Acme 89.90% 90.01% Akron 89.30% 92.43% Blue Rapids -- Brunswick - 82.30% Fort Dodge 87.77% 89.13% Grand Rapids 87.54% 83.34% Hew Orleans -- Sigurd 90.04% 90.25% Total Gypsum 87.86% 88.17% 1961 92.55% 92.76% 82.22% 91.51% 91.92% 91.07% 89.22% 90.00% 91.42% Pryor 85.65% 89.68% SGP 0020971 FLAWT Acme Akron Blue Rapids Fort Dodge Grand Rapids Sigurd TOTAL LOCK COSTS DlIJiC? COST PER TON 1958 $ .748 $ 3.093 $ 1.413 $ .997 $ 1.361 $ .913 1959 $ .645 $ 2.958 $ 1.384 $ .958 $ 1.501 <1" .820 I960 $ .735 $ 2.872 $ 1.544 $ .912 & 1.690 $ .799 1961 $ .705 $ 3.100 $ 1.088 $ .737 $ 1.347 $ .754 SGP 0020972 14 3 PLANT STUCCO CONVEkSIOUCOSTS , . DIKECT COST FEk TON 1958 1959 1960 1961 Acme $ .869 $ .887 $ 1.026 $ 1.180 Akron Blue kapids $ 2.014 1.551 $ 1.931 1.521 $ 2.058 $ 2.331 $ 1.531 '$ - 1.184 Brunswick - $ 2.127 $ 1.215 $ 1.175 Fort Dodge <t 1.173 $ 1.345 $ 1.304 $ 1.354 Grand kapids r4f> 2.004 2.127 $ 2.270 $ 2.227 New Orleans Sigurd $$ 1.163 $- d*-P 1.269 $ ' / - .. d> ,; 1>342 'A 1.488 1.323 A SGP 0020973 PLAiJT Acme Akron Blue Rapids Brunswick Fort Dodge Grand Rapids Rew Orleans Sigurd PLASTER LOAD 1 AG COSTS DIRECT COST PET- TOR 1958 1959 1960 1961 $ 2.742 $ 2.314 $ 2.726 $ 2.847 $ 1.971 $ 1.959 $ 2.212 $ 2.016 $ 2.411 2.160 $ 2.385 $ 2.396 $- $13,092 $ 2.443 $ 1.733 $ 1.642 $ 1.874 $ 1.835 $ 1.979 $ 1.765 $ 1.719 $ 2.460 $ 2.031 $$ 1.460 - $ 1.734 S 8.194 ! $ ':1%736V#' 1.536 SGP 0020974 16 .i BOARD MfUIUFACTllRING. COSTSr ; PLANT DIRECT COST PER MSP 1958 1959 1960 1961 Acme $ 2.760 $ 2.776 $ 2.815 $ 2.854 Akron $ 4.935 $ 5.509 $. 5.800 $ 5.873 * Blue Rapids '$ - $ '"mi $ 5.729 Brunswick 4> ~ 3 6.891 $ 3.996 $ 3.244 Port Dodge 4> 3.036 $ 3.436 3 3.191 $ 3.017 Grand Rapids 4.650 $ 4.844 $ 5.425 $ 5.349 New Orleans Sigurd $.$ 4.028 $$ 4.234 .$ mu-- /. 3 5.122 $ -iVodb^% 4.047 SGP 0020975 L ost t m i: t'K ta v t t i :j l l - Total Plants f t u _______ V>AJ is/,!____ ___ &<rlt , tS6t 1SU SSU hst! Ul i' PLAUT Acme Akron Blue Rapids Brunswick Fort Dodge Grand Rapids Mew Orleans Sigurd BOARD LOAD IMG COSTS DIRECT COST PEI; HSF 1958 1959 1960 1961 $ 1.584 r4-> 1*823 $4&> - $ 1.832 r* 1.179 <& 2.034 $ 1.790 $ 2*141 .$ $ 2.664 d* 1.920 $ 1.424 $?*P 2.109 $ 1.966 $ 1.785 $ 1.844 $ ** -. $ 1.851 $ 1.852 & 1.564 rf* 1.707 $ 1.890 $ 1.730 S 1.918 $ 1.611 $- $ 2.143 . $ 2.122 ;4 2.193 SGP 0020977 PLANT MANAGERS* MRFTING JAN. 22-21+ 1962 CLOSING REMARKS I, personally, am convinced that the most important factor In obtaining luallty Is people. Whether or not a plant puts out a quality product depends almost entirely upon the desire of all of the people Involved, all the way ?rom Mr. Malcolm Meyer to the cleanup man in the plant. If the desire Is P?eat enough, means will be found to correct faulty equipment, faulty materials >ad processing - or whatever else may be the cause of poor quality. (Bf all ;he people involved, it seems to me that the most important ones are those who actually make the products. They must be provided with the proper equipment ind materials and, above all, a desire to make an outstanding product. This nsans leadership extending all the way to the top but Is particularly important it the plant manager and quality supervisor level. A strong quality department at the plant level is vital. On this phase, C again strongly urge that the plant quality department be adequately staffed so that the quality supervisor has tine to work on and solve In-plant quality problems, and to make frequent market surveys and studies without seriously iffecting the normal plant control process. This requires that the quality supervisor be backed up by a plant chemist or chief tester - or whatever you dent to call him - who Is capable of looking after all of the routine quality problems in the plant. As a prime example of this, I refer to the former setup where Dale Greve ras quality supervisor at Brunswick and Walter Wagner was plant chemist. Phi a set up worked extremely well and should be the pattern for all plants. In my opinion. I say this, all the while realizing that quality supervisors of the caliber of Dale do not come along every day. To accomplish our task, we need to consider all of the basic processing, such as control of grind, kettle calcination, tube milling,mixing, feeding and processing, etc. To that end, the Laboratory will provide as much assis tance as possible. It Is recognized that in wallboard manufacture, the quality of the paper ts very Important; and Messrs. Burkhart, Kart, and Haworth are working very lard on these problems. Much has been accomplished but much more must be ione, especially in the area of finish of the i.vei.'-y paper. In order to have a target for 1962, I would like to suggest the following 30&18 3 1. Reduction in total overall complaint adjustments of 20$ or about $15,000 including policy. SGP 0020978 C.;iIGLUSIGN imt 1 2 3 1962 COST SAVINGS 50HMARX DESCRIPTION imnsrrajT W/B Machine Speeds 29,000.00 height Control 18,330.00 Barge Paper Shipments $8,000.00 TOTALS (0-0$, 330.00 SAVIICS $ U7,000.00 23,000.00 $7,20$.00 3127,30$.00 SGP 0020979 PREMIUM BASED ON $100.00 PAYROLL ACME "Retro-Standard Actual AKRON lie iro-Standard Actual BLUE RAPIDS Retro-Standard Actual FORT DODGE Retro-Standard Actual GRAND RAPIDS Re tro-litandard Actual PRYOR lie6ro-3tandard Actual SIGURD Retro-Standard Actual TOTAL PLANTS lie ir o-standard Total i3S6 *2.91 1.81 3*29 2.00 2.15 1.05 1.07 0.95 1.47 1.24 2.98 2.07 2.77 2.28 2.29 1.61 1221 $2.84 1.63 3-53 2.66 2.17 1.14 1.10 0.41 1.40 1.17 2.24 1.07 1.38 0.90 2.14 1.40 1958 $2.22 1.04 3.08 2.49 2.09 0.00 0.56 0.00 1.40 1.39 2.13 2.03 1.48 1.05 1.83 1.23 1959 $1.71 2.90 2.14 0.80 1.40 1.61 1.38 1.68 1.05 1960 1961 $1.73 $1.70 2.45 2.06 2.11 1.41 0.79 0.70 1.40 1.54 1.99 2.09 1.11 0.90 1.53 1.41 Retro-Standard Rate based on 20% Manual Rates / 80# experience. Experience of 3 years determine rating, i.e. 1958, 1959 and I960 establish 1962 retro* 1959 Plant breakdown will not be completed until 3/1/1962. 1958, $0.00 Actual Blue Rapids and Fort Dodge due to return of reserves carried over when Bestwall established own premium* Grand Rapids $1*40 is minimum* 9# increase in manual rates efractive 1961* SGP 0020980 56 64 T| O?hO> 3a , h1 S & SI'S EdO ED 9 Pd H nO fit O' rl H *4 d* p fe > O rl O < CJ 55 c cd fT* a A 0 C^I >9 00 ru A PA O CM A CM A rH HI X> d LA H =0 CM P- O' A 0' CM dd s: S3 A 0 rH 0 d --I 0 rM A -=* OA A -d- A p- O OO'' O' O A o 9 P* H Ca U> 0 i-H rp' cr 6A rH <*\ 3 p~ CD H 03 ("I A $ P- A %A M O NTH O F N O VEM BER 1 9 6 1 - A C T U A L - V S - S TA M D A H i> t 0 *C> CO H O' CO o _ OvO 9 vOOxO CM <9 CO d AvO A 9 dH O rH OA A H t-- X) H O' O O d LA <5 H P-- XA'O H O H CM d 03 O CM O 8ACO P'0 P-A H CO CM rH rHsO AH CM p-_=r-=r a a P P- P- CO H A CM rA C'-CM o XArH iah V P- CM 03 d f-t 0 TJ P 03 O OO oe sD rl H CM A Ao AsO rl rl OO oe OH r-l i--I p- r-- pvO \0%o 99 9 P- O O' r--1 CM rH O9 O* A'O rH rH vpO-vpD- 99 Hd AAAA O 9 99 IP-rH AO rH CM H CM 2 P ,00 4o3 U3 h s0: 3o3 oa AA O CM P- O aa o o_q-mAOXt XA LA CM (CM 9 AH CM O' XA 9 vOvO CM u\ XA H CM rA XAXA C--CM XAJLA 99 9 9 rH P-H o d AH LA A AA P'o ACO A A 9 A -L AA P-CM O #9 9 Ad 9 OCO 30 AA AAAA CM P-P-CM 9 999 XArH AA 9 dCM CM rH` O 9 <9 CO -9 CM O o CM rH O e CM &0 CJ rl u a p 0 p o si 03 II oj <1 si p -3 bO a o -3 64 43 43 P P0 2*80 -4 be 63 cO H O 43 64 P < $ 43 0 P 43 O CO C4 33 s d p A0 rH O 1L <H 43 CL, p 0 M =8 9 8 o 43 M P 63 Q 0o -3*4 a 43 P 0 .4 a x cO 64 a0 a*--,i o 64 43 < e 03 4p3 so O O ft, 3 Si O 64 M o 0 9 CM Hi 64 43 43 P QP 0 03 O >4 i=> a M CO SGP 0020981 tbO S3 H 43 ca L4 64 P O 0 S3 M 43 <.0 P H C^0|P0 4CO3 0 A rl 6h O C3 CQ *2 0 CO o 2 60 < o W 03 0 05 2 W 35 1 ACTUAL U P -"P C 'S AND DIVIDENDS ALL P LA ITS - TIP-FOLD ^XCEPT'-' D (PRO VINCIAL RATING) 19561957 19581959 X F U F F t'L