Document 4JpB3QZG0YR7KbGV6Z3yapr1j

CSCAMtl A PLANT INC. INTEROFFICE MEMORANDUM To: Mr. R. E. Davis From: E. A. Primeau PVC Monthly Report September, 1972 Dots; Copies: October 5, 1972 SUMMARY Prime production for September was 5, 015M lbs. versus a budget of 4, 929M lbs, and a September 20 forecast of 5, 100M lbs. Off-grade, tailings and sweeps amounted to 77M lbs. which represents 1,5% of total production versus a budget of 5.2%. A total of 577 charges were made, an average of 19 per day. The variance generated by PVC for September is ($4, 365) unfavorabl The variance resulted from: 1. PVC Bulk {$5,332) 2. PVC Packaging 967 The forecast variance on September 20 was $16, 500 favorable. The items affecting the variance are as follows: Forecast Actual Raw Material Process Costs Volume Machine Hours $8, 100 8,200 ( 2, 400) ($8, 388) 537 4,919 { 2, 400) Analysis of Variance Raw materials were unfavorable because of the low production of off-grade resin (77M ibs. vs. 270M lbs. budgeted) resulting in less by-product credit. Process costs were at budgeted level being $500 favorable. Mr. R. E. Davis PVC 2- - October 5, L972 The volume variance of $4. 9M was due to production of 86M lbs. of prime resin above budget. Machine hour variance of ($2,400) unfavorable is due to the 30-day month. October production is projected to be 5, 300 M lbs. and variance is expected to be $3, 000 favorable. DISCUSSION During September, eight resin types were produced. Two types, 1230-P and 2200, accounted for 70. 6% of the prime production. Average number of charges per day was 19. The 1230P production was 1, 929 M lbs, produced in 208 batches. Average yield was 642 lbs./hr. versus a budget of 579 lbs./hr. Only minor contamination problems occurred during the month resulting in the production of no off-grade resin. The Quality Control Laboratories continued their controL analyses using inherent viscosity as part of the product unification program. The initial problems with technique were resolved and the results are within normal analytical precision. The request for the replacement stainless steel reactor, agitator and drive was approved and the equipment ordered. Expected delivery date is January 15, 197 3, and installation by mid-February 197 3. The ALpine mill operated 159 hours on overtime this month to produce fashion-grade resin. All but two of the 11 reactors were solvent cleaned this month. Shutdowns every two to three days were necessary on the Artisan unit to keep it operable. However, sufficient clean soLvent was produced to continue the cleaning program. After reviewing the pilot plant studies made by Artisan, it was recommended to make a plant test run using M-pyrol (N-methyl pyrrolidone). The recommendation was approved and 6000 gallons of M-pyrol was ordered and received on September 28. Test runs using M-pyrol have been scheduled during October. A program to test EDTA in the 1230-F charges to reduce reactor fouling was started the last week of September. Initial results show a marked reduction in fouling. This work will continue in October. AP00047564 STATISTICS September Actual Budget Year to Date Actual Budget Prime Product Ho mop o lyme r Copolymer Subtotal 5, 015 0 5, 015 4, 269 660 4, 929 54, 498 6,429 60, 927 51, 970 8, 030 60, 000 Off-grade Homopolymer CopoLyme r Tails Sweeps Subtotal 0 0 59 18 77 - - 270 840 504 1, 065 98 2, 507 - - 3, 291 Total Production 5, 092 5, 199 63, 434 63, 291 Off-grade, % of total prod. Bulk Production, % Prime VCM Efficiency, % Reactor Availability, % Production, #/gal. yr. Off-Grade Analysis 1.5 60. 0 92. 0 92. 6 1,279 Type 0 5.2 - 94. 8 88. 5 1, 258 4. 0 53. 0 94. 0 88. 7 1, 277 5. 2 - 94. 8 88. 5 1, 258 Lot No, 0 Quantity 0 Reasc 0 Product Sequence rth Line Batches South Line Batches 2200 1225 2200 8217 2200 3185 1225 2200 37 35 78 10 31 10 26 49 276 1230 2160 1225 2250 1230 2225 1230 63 14 35 20 20 24 125 301 AP00047565 Statistics - September Page 2 Downtime Analysis Cleaning Reactors Schedule Charges Behind on Recovery Hold to Drop Plugged Drop Valves Change Types Slow Drying Hydraulic Motor Maint. Miscellaneous Production Summary Type 1185 1200 1225 1230P 1250 2160 2185 2200 2225 2250 3185 6150 8217 Floor Sweeps Septe mber Hours % 640 157 145 105 20 14 31 25 86 1, 223 8. 1 2.0 1.8 1. 3 0. 3 0.2 0. 4 0. 3 1. 1 15.4 Year to Date Hours % 7, 021 2, 455 1, 456 383 290 660 452 259 1, 572 14, 548 7. 3 2. 6 L. 5 0. 4 0. 3 0. 7 0. 5 0. 3 1. 6 15.1 August 0 0 759 2, 752 0 0 0 1, 014 216 550 0 0 0 Septe mber 0 0 878 1, 945 0 107 0 1, 635 191 155 72 0 91 18 5, 092 Year to Date 48 2, 173 9. 599 18, 328 1, 241 1, 181 1, 209 14, 726 1, 631 5, 458 996 6, 429 317 98 63, 434 AP00047566 7? aaa AP00047567