Document 7MYe9r3YMe494Yx5pJ7D5Ow3B

T. H. Huffman I lUVIft* Date: SutM. D. C. Skokna May 25, 1990 ABERDEEN MONTHLY PROGRESS REPORT APRIL, 1990 There were five first aid and one recordable Injuries reported during April. The recordable case involved a Compound Operator who suffered a back sprain while charging the Line I blender. The annual insurance inspection was done on 4/24 and 4/25. At month's end, the Aberdeen plant's employees have worked 3952 days (5,250,925 manhours) since the last lost time injury. PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M April 40.0 93.2 98.1 0.99889 6.4 98.8 5.8 99.7 1.7 87.3 < 0.7> 173.8 87.5 Y.T.D. 259.8 87.3 96.9 1.0008 42.5 98.1 34.2 99.6 10.7 88.1 < 8.2> 309.7 535.3 * Resin Flexible Compound Rigid Compound Plasticizer 109.4 81.6 98.6 77.1 100.5 77.7 81.5 72.6 A revised clean wall Injection system was tested on D745. A very slow buildup of contaminants occurred and the test was discon tinued. Based on our experience and EVC recommendations, a revised injection method with reactor vapor space cooling will be tested during May. In the flexible compound unit, demand dropped slightly. Line V operated 18.5 days. PLENEX polymer trials were run on Line I for sixty-two hours. As part of the PLENEX polymers development, the Banbury rotors were modified co accept cooling water. PED con ducted a test run on Line V for rigid pellets. VAB.0001190098 5/25/90 Abtrdetn Monthly Progress Report - April, 1990 r Favorable raw material efficiencies in the resin and flexible compound units due primarily to lower than budgeted production of off-grade products, and favorable product mix variances in the resin and flexible compound units caused this month's overall favorable variance. These favorable variances were partially offset by an unfavorable product mix variance in the rigid compound unit. Off-grade production in the resin unit was fifty percent less than budget; and in the flexible compound unit, mill scrap was thirty-two percent below budget. Fixed costs were favorable due to payroll being below budget and a favorable M. M. & C. variance due to less than budget activity. However, April's payroll costs were understated by $83M due to an error which will be corrected in May's fixed costs. OMP 1. One hundred percent of the plant's natural teams met during April. 2. Prestolite (a flexible compound customer) performed an audit of our quality systems. We received a score of 77.8%, an improvement from last year's score of 69.7%. This put us into Prestolite's "Conforming Supplier" category. 3. Hi-Tech (a resin customer recently purchased by Southwire) visited the plant for a general informa tion exchange and tour. 4. The Newsletter Team published its first issue with an emphasis on people-related stories. Doug Skokna Plant Superintendent rah \ i VAB.0001190099 Houston J. D. Bums R. 7. Ferrell I T. H. Huffman C. J. Matson D. F. Harman Austin HflinmonH Blane Premiere R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin W. L. McClain J. P. Stokes R. L. Poe X H. J. Hall H. D. Garrison R. A. Conrad J. Friend J. V. Ware X L. R. Bauer X J. Pavao X C. R. Miller P. L. Foote RWS/DCS (File Copy), JEB, JME, SCH, MRK, JEL, DAM, RBN, JEN, JDO, REP, BLT X X X X X X X X X X X X X X X X A * VAB.0001190100 SAFETY - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Adi il Fiscal > Fiscal YJ.D. 1989 5 12 10 1 Jk ' 6 16 13 132 000 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 00 35 39 01 00 6 2 3 6 1 0 Cuts and Abrasions Eye Injuries Burns Bruises S trains/Sprains Stings Other Totals 35 3 0 10 13 4 12 2 112 02 0 -2 6 16 Jl 13 Lost Workday Cases Days Lost 03 0 84 2 42 Last lost time injury - 7/5/79 Days since - 3952 Employee hours since - 5,250,925 On April 30, 1990, the employees of the Aberdeen plant completed 3952 days with no lost time Injury. Topics for the plant safety meetings during the month included First Aid Training and Contractor Safety. An insurance inspection was held on April 24 and 25. Malcolm McMullen from Houston accompanied the representatives of the insurance company on the inspection. 1 a HMHM mmmm W P8M8 VAB.0001190101 A SAFETY - Continued Routine dosimetry results for the month wore: Chemical VCM Lead Total Particulates Percent 79 100.0 20 100.0 8 100.0 0 0 0 Percent 0.0 0.0 0.0 Department- FA RWC FA FA FA Compound Compound Maintenance Compound Maintenance Contusion to lower right leg. Muscle strain to lower back. Cut to right index finger. Laceration to right middle finger. First degree burn to lower back. FA Maintenance Cut to right forearm. A Compound Department employee pulled a back muscle picking up a fiftypound bag while charging a blender on Line I. VAB.0001190102 April marked the first roith in which all plant natural teams met. The facilitator team continues to teach team techniques to each natural team as the teams work through their Initial projects. Several teams are meeting more than, once per month with .the ratio of the number of team meetings to the total number of teams being 1.13. The Newsletter Team began during the month with the first issue using the team approach published in early May. The format was changed to include more people-related stories. The team is com posed of employees from many areas of the plant. R. V. Seymour made three customer MBWA visits in April. Visits were to Southwlre in Carrollton, GA (4/5/90) with Mark Eramo; Nibco in Greensboro, GA (4/18/90) with Nick Forsa; and Gold Bond in Charlotte, NC (4/19/90) with Nick Forsa. All these visits were very positive. The discussion was focused on projects we have done and are doing in the plant to improve reliability of our operation and the quality of our products. VAB.0001190103 D. C. Skoknt -i PVC Flexible Compound Rigid Compound Plasticizer $101.2 19.9 ( 48.3) $ 87.5 $100.4 124.8 107.7 $371.0 $201.6 144.7 59.4 $458.5 PVC - Raw material consumption was $103.8M favorable, the product mix was $31.2M favorable, partially offset by an unfavorable $78.1M variance due to producing less than budgeted amounts of off-grade resin. Note: Off-grade resin production in April was 0.01855 lbs./lb. versus the budget of 0.03719 lbs./lb. - a 50% reduction! Raw material use was $19.8M unfavorable, product mix was $29.3M favorable, and off-grade was $7.6M favorable. Millscrap production was 0.0098 lbs./lb. versus the 0.0145 budget - a 32% reduction! - The overall variance was essentially all due to the product mix. Favorable raw material efficiencies of $15.0M were the primary reason for the overall variance. - Resin to Rigid Compound - Resin to Flexible Compound - Natural Gas - Alfol 610* Alcohols 610P to Flexible Compound - VCM - Other Price Variances Total 102.0 70.8 64.6 33.7 24.6 15.2 $371.0 Payrolland Benefits - MM&C - Miscellaneous - TI&D - Clearances Total $119.9 53.1 ( 4.3) 5.1 O $173.8 Continued 1 A?* $3M error was made (wc did not accrue one week of operating payroll) and a $37.1M favorable benefits variance were the reasons for the variance. The error will be corrected in May. Lower than budgeted activity caused the favorable variance. : Major variances in this category were: * $47.1M unfavorable, The physicals budgeted for the second quarter cleared in April. $26.OM favorable. favorable the lab-vinvl team see savings from the VAB.0001190105 A VINYL - J. D. Olson, J. M. Vlnoskl Safety The Vinyl Department had no first aid or OSHA recordable injuries during the month of April. The monthly safety meeting topic was "Heart Attacks and Safety Attitudes". 1. A revised BUS-80 injection system was tested on D74S during the April 5305 resin run. A very slow buildup of contami nants occurred and the test was discontinued. Process engineering is investigating BUS-80 charge amounts and reactor vapor space cooling, and future tests are planned for May. 2. A test of a resin wetcake dewatering agent was conducted on 5305 resin this month. Initial results are good with a twenty percent overall reduction in centrifuge wetcake moisture content. Properties of the dried resin were normal. More complete test results are expected next month. The resin raw aterials in the 744 account were valued at $300.2M. - Production, MM Lbs. - Daily Rate, M Lbs./C.D. Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime % April 40.0 1333.3 109.4 935.0 31.2 93.2 94.0 93.4 98.1 YTD 259.7 1225.0 100.5 6094.0 28.7 87.3 78.1 90.7 96.9 Operational downtime (recovery scheduling conflicts, New Module rinse/charge water conflicts, waiting for Q.C. data before charging, 0-ring leaks, no place to dump, rinsing chem wash tanks). Hours 319.2 Maintenance downtime (D745 reactor hydroblasting and condenser drilling, D400 condenser drilling, 0745 agitator seal flush line repair, miscellaneous valve and instrument repairs). 172.5 VAB.0001190106 VINYL - Continued Reactor Halted production. Operational downtime (centrifuge plugs dryer cleaning, and flaaeouts). Haintenance downtime (screw feeder repair, baghouse maintenance, screener repair, centrifuge repairs, shear pin replacement). * <r*f 68.5 17.3 14.2 - J. B. Autrey, J. B. Hegwood Reactors D300 and D400 were shut down for condenser inspection because of cooling control problems. A normal amount of soft residue was found on the shell side of both condensers. The condenser tubes on reactor D400 were drilled during this time. Number 1 Bird centrifuge was shut down during the month for repairs. The bushings and bearings were replaced and the scroll was sent out for balancing. The centrifuge was rebuilt and put back in service. Representatives from the Bird manufacturer are scheduled to arrive at the plant next month to discuss our continuing problems with these centrifuges. The boots on #7 Bird hopper were replaced due to their deteriorated condition. The fluid bed dryer was shut down during the month for repairs to the fluid bed scrubber. The demister pads in the scrubber were changed out because of pluggage. Reactor 0745 was shut down during the month for condenser drilling and hydroblasting as part of the contamination control program. The west blower on the 282 transfer system was changed out during the month because of a bearing failure. There were six major valves changed out in the reactor area during the month. ** CQMPOtnm - j. e. Nickerson, K. 6. Akins The Compound Department suffered three injuries in April. A restricted workday case was incurred when an Operator strained a back muscle while charging a blender. There were also two first aid cases in April. One Mill Operator received a small cut to her finger and another Mill Operator tripped on a step and skinned his knee. The topic of the safety meeting was "First Aid Training". Flexible compound demand eased slightly in April. Inventories rose from 6.86MM pounds to 7.27MM pounds during the month. Line V only operated 18.5 days this month due to pelletizer maintenance and lower orders. Line I dedicated sixty-two hours for PLENEX polymer testing and modifications to facilitate PLENEX polymer production. This month the Banbury rotors were modified to accept cooling water and work continued to modify the PLC logic to accept operator input for parameters particular to PLENEX production. PED conducted a test run on Line V to optimize twin screw configurations for rigid compound production. Demand for rigid compound remained strong in April despite lower tolled volume. Production rates were limited during the month by mechanical problems with scales. Extra precautions were taken in finished product testing as well as equipment testing to minimize impact on the customer. The scale problems were eventually traced to a fatigued support beam that has since been replaced. Operating Month Avg./Dav Line I 30 Line III 30 Line V 18.5 Total % Prime Capacity Utilization Factor 2053 68 3666 122 656 6375 225 98.8 .816 Downtime Hours 14053 23582 4839 42474 98.1 .777 - Product Changes - PLENEX Polymer Testing - Quality Problems & Control - Dicer Problems & Maintenance - Miscellaneous Maintenance 98 62 19 5 22 VAB.0001190108 COMPOUND - Continued - Product Changes - Miscellaneous Maintenance - Quality Problems & Control Hours 91 17 10 - Product Changes * Quality Problems & Control - Miscellaneous Maintenance - Startup/Shutdown - We lex Maintenance Operating Month Rigid Compound 30 % Prime Capacity Utilization Factor 5812 99.7 .986 48 38 14 9 9 194 34081 99.6 .815 - Product Changes - Quality Problems 6i Control - Miscellaneous Maintenance - Scales Maintenance 60 58 30 17 Operating Davs Month Avg. /Dav Plasticizer 30 % Prime Capacity Utilization Factor 1663 87.3 .771 10687 88.1 .726 J. B. Autrey, J. B. Hegwood - The Line V Welex was shut down for repairs to its gate during the month. The gate was removedt rebuilt and realigned because of a sticking problem. VAB.0001190109 COMPOPHD - Continued - continued The vacuun j removed for xs on plasticizer reactor R-l and R-2 were cleaning because of a calcium carbonate but ldup. * The compound cooling tower was shut down foi to coupling"ha ft with during the month. The The shaft shaft was ^rinrrther^,,TMWaS Perfor"d * the -internee The Topaz unit in the compound c down for repairs during the month. board was The sy system VAB.0001190110 macTmnaiTHQ . r. e. Polk, S. C. Hillman, M. R. Kano * Problems with low molecular weight resin due to wall scale contamination recurred with the April trial o BUS-80 application in 745 using the closed reactor addition system. Based on recommendations by EVC, modifications have been made to 745 reactor jacket to allow cooling to the reactor vapor space all the time. The cooler surface is supposed to improve resistance to wall scale. The BUS-80 application began again on May 9. Testing is being planned to evaluate alternative nozzles for better washing of the reactor walls as another way to address 5305/5265 contamination. Plant testing of a Nalco dewatering agent on 5305 has been completed. Initial testing indicates a ten to fifteen percent reduction in wetcalce moisture can be achieved. Nalco representa tives are preparing a report on test results. A meeting was held at the plant to review 5305 RVGM reduction options for this winter and longer. Results were presented from testing conducted through last winter by FED and plant engineering to determine ways to meet American Mirrex Corporations * s 250 ppb VCM requirement. The Business Area, Marketing, PED, R&D, plant engineering and operations were represented. One action step is to have a project in the 4FQ90 capital budget to prepare for the coming winter. Low calcium resin was shipped to Klockner and American Mirrex for trial runs in film applications. American Mirrex was satisfied with the results and Klockner has reported that the resin is adequate for their thin film application. Orders for more trial shipments are anticipated. A design was completed to add a small amount of cooling water to the reactor condenser thereby forcing steam stripping to continue for a longer period of time. RVCM levels are expected to be reduced by 40%. VAB.0001190111 *1 oc i Ui a s! 13 8 A a a? 8 U. cn 51 33 cn at 25 cn i cn 8 si >-*i* E*** C3 IS S I u. 5 *"* um 3 ST 8 cn 8 s! cn QB 3E CO p- cn 3 1s! sl|s8C s iii 3 3 82 8 ccnn Ii UJ & I tI cn M- St cn 8 cn A 8 8* uj 8 3 cn cV i-- cn cn isiilii CS cn IS S S C UI UJ cn cr s si ss3 . cn I s ~ ssU> H % I ;3 cn A 38 B mm cn uj cn ss si si cn w S cn iU u a M3 3 ccnn UJ A .I cn cn 8a!SS33 3388 UJ si a* 11 si X*1|3= !(> S m x3 8 8 m 8mm 8 M|npl 2= -- -- si " G3 5 25 Eu 8si 3 *338 8a 8 a2 at a s sss3ss sliiaisisisiisiSllisiliicn S cn 0cn1 "*1 8 9 r * 8I--5S: 2 5 cn cn * 8an SmT 3 A cn A 13 n! * c! srcsgcc s e ww'tS-fet-*--1* A-- A-- A-- *-- - A-- **--"* A 82S------ p-3 83CiCS88S^i-ijj 3 AA3A S 'mimiN M'S ` lKM T * - MM19I3 is g S& II IfII X i i I | 3 mm JJj s \ III 1 wiX A s! Ias - m m a B i Sm nB Sr Vm lCilnSl ^ slssils iia88aa8 e -* " B * -* 8 8 s 2" tSsias _J A A UJ a s ssSliSS *T Is *xiX $m =}*M S 3 II II a i & S ill ii ssI aUJ I 3 c c ^ a A cw St IS C & ^ JC 3 3 Ri as VAB.0001190112 #w HTHI* fHp F. 6. Jeanson Vater All wastewater discharge parameters were met for the month of April. * V The Mississippi Department of Environmental Quality (MDEQ) collected samples from our wastewater and storm water outfalls during March. Results from this audit were favorable. We were in full compliance. I attended a water toxics course in preparation for applying for an updated NPDES permit which has to be submitted this summer. Waste Waste shipments for the month included: - One bulk load of floor sweepings to Chemical Waste Management in Lake Charles, LA. Worked on finding customers for vacuum/vent dust and pits #1 and #2. Plasticizer filter cake was reapproved at CWM in Emelle, AL. f a Permitting for the VCSM project and minor source status has reached another roadblock. The MDEQ is requiring us to redo modeling of VCM air emissions from the plant. The modeling study done in 1988 was unaccept able to them. A contractor was commissioned to redo the modeling with all the new UFA requirements. Emissions data was submitted to the contractor. In addition, building wake effects will have to be used on this modeling. A survey was completed measuring all buildings and vessels in the plant and the data was given to the contractor. i The contractor expects to have the modeling complete in mid-May. Once this is submitted to the State, they will issue a public notice. Thirty days later if there are no severe objections from the public, the State will review our permit. Hopefully, we will have a new operating permit as a minor source and a construction permit for VCSM by the end of June. A meeting was held with Conoco to further discuss the five sites and cost allocation. Conoco Initiated a contractor to propose a plan for a thorough investigation of the sites. meeting was also held with Sun Polymers to discuss pond #2 reclaii 11 visit their plant in Canada where they are currently reclaiming r BFG in May. There are 20MM pounds of PVC resin in pond #2. We mmrnmmmmtmmmm VAB.0001190113 Continued A 4 I visited HiTech Cable (Southwire) In StarkvlUe, MS, a resin custoner, to help then apply for an air perait with the State. !p' We sold $11M worth of used equipment to Louisiana Chemical Equipment Company. Environmental projects and costs for 1988 and 1989 were calculated as well as an estimate for future environmental projects and the last five year environmental costs. A day of environmental training for plant operations and engineering personnel was set up for Hay 18, 1990. I visited Evans Cooperage in New Orleans, Louisiana drums. The plant is in need of another drum recycli current recycler have gone up dramatically. Evans recycles empty since costs from the VAB.0001190114 Apr-90 HASTE BEBUCTIQK IHSEX SHEET MULL EUUMM 'TITIt IMIE MTB* HHr'nBbfQB flNBSs 8ECTCLE1/88LI 8A8IE 3 H0KTH 90 YT8 1989FY ti.m 52.401 102.531 85.831 70.811 94.341 195.5a: 94.941 109.511 i. Qffsit*. Haiardous Hastts 49.341 100.091 100.4BX a. Land Ban Hastos b. Haiardous Solids c. Non-Haiardous Trtatid as Hazardoss 80.891 89.401 35.851 34.341 88.101 104.481 244.741 111.191 93.77X 11. Rocyclod Haiardous Hasttf 71.541 45.501 103.511 III. Offfit*.* Nun-Hazardous Hast* a. Rtc*vcltd b. Noo-tecv clcd 54.441 49.231 95.371 88.821 50.571 99.941 45.741 98.391 95.031 IV. VinarabU B*y- -Products V. Total Haste Hatar 109.101 101.491 111.301 185.921 .i 111.291 T. ' 95.011 VI. Air 1 Hator a. SAM - Air b. SAM - Hator c. Hos-SAM - Air d. Hos-SAM - HaUr 41.081 73.321 91.901 74.501 355.491 28.221 85.471 81.701 798.181 34.051 h 103.041 88.051 I .. 592.121 98.301 87.241 Apr-90 HASTE SESBCTIOK 1HSE1 SHEET OVERALL EICUJBIA6 TOTAL HASTE HATER* 88H-8ESYCLEI HASTE RECTQJEO/SQLI HASTE Offsite. Kazardeut iattn * a. Land Ban Hattas b. Hazardaut Solids c. Haa-Hazardout Trtattd at Hazardout 19B8FY 7648138 3150255 4497B83 19S9FY B056439 3044204 5012236 90 YTO 3817953 1297508 2520445 3 RaatH 1638973 433260 1205712 321409 329304 187116 41481 2412 79068 239930 6006 B946S 233833 510 40517 146090 510 18480 22491 II. Racvciad Hazardout Hasttt III. Qfftita. Hoa-Hazardout Hast* a. Racvciad b. Haa-Rtevdad * 653226 * 688080 248863 122178 2429430 2357718 978334 345919 247201 21B2229 247500 o 2110218 143699 834635 57404 288515 IV. Vanarafcla Bv-Prnduett * 3597456 4076656 2127884 1026131 V, Total Hast* Hatar 4424987560 4271245861 2864282394 1225351498 VI. Air 1 Hatar a. SARA - Air b. SARA - Hatar c. Hoa-SARA - Air d. Hoa-SARA - Hatar 646617 604682 275756 103265 73316 55 264206 309040 65694 333 264290 274364 34841 257 55398 185260 14664 51 19493 69056 j i ^ - `.'I r VAB.0001190116 April. 1990 to A. Unadjusted UI <0.6%> B. Adjusted EUI <0.7%> C. BTU/Lb. Product 2451.0 D. Total Energy Consumption MMM BTU 132.00 < 7.9%> < 8.2%> 2649.0 917.89 A. There were five energy related items completed in April, 1990. Three of these items were steam leak repairs. The remaining two were steam trap repairs. No. 1 No. 2 No. 3 83.5% (1) 82.9% 83.4% 83.3% 83.0% (1) Boiler number two was not operated during the month. h VAB.0001190117 None Gordon Ostrovski - Promoted to Storekeeper nAN from StorvkMpcr "B". Robert D. Roberts - Transferred to Electrician MBH from General Mechanic "A". Donald Whatley Compound U Promoted to Compound Operator from Charles Holcomb * Promoted to General Mechanic General Mechanic *m. from Freddie Franks - Promoted to General Mechanic "A" from General Mechanic "B". Daniel E. Johnson - Promoted to Mechanical Engineer-- Aberdeen from Construction Engineer-GBD. None None None VAB.0001190118 * Vu?: ap-; *3 p t: IV StUritd hploym Hourly Kaployaas Total Eaployaaa 76* 172 248 Varthornsa 16 Qan. Plant 13 ttm 41 Laboratory 24 40 Vinyl 33 Plastitisar 5 16 il 33 2 m l M Hubor of Applicant*: J I' Month Tsar To Data APFLZCAHT BB1AKD0HM: # Minority % Minority # Faaala % Faaala Includes 1 Co-Op. K1PQKI MtBodtjr Idioms # t % gf] h fd 6 66 82 38Z Total 72 29Z Hourly Mia. Hlrad % Mia. Hlrad Hourly Kla. Tara % Xla. Tara ,-A*1 * ,. xf .Nv tfc. a kh *' i `l,,1a. 1 i- .r Hiraa (Hourly) To Data Month (Hourly) Taar To Data Ovorall Turaovar _jQ Prolaatad Animal Turnoaar \-K. t* - i:W-i^! r * sTrj i AWi- r ''ji : ! . *fc(Sf&J: :-"p i ? cij'ViL h s 1 if`V '>' aK-I S" I -I t T " ^ IP HU mrnmmmmmmmmmmmmmmm VAB.0001190119 m KPWT 'UAL HOWS ANALYSIS REPORT I t /DISTS. Aon list rhs, jfc, jvu, kpaathent heads, file 2/8? THRU 4/29/90 4 v -fc -7 3 m k o H *W'. Hf ^ +. - COOMO 4-- w ;V 1 1 'A * i- ,i . ri. j?;- 1U-'- U, 1 * T pi* %. 'i: VAB.OOOl 190120 IS U IS Itn N ' "^7 + I -i h.-' <* C - i. DEPARTMENTAL HOURS ANALYSIS REPORT DISTRIMTION LIST RHS, JFC, JVU, DEPARTMENT HEADS, F1L 4/ 2/9$ THRU 4/29/9$ CM rI i is -1 *I h isu j I ititt*o I CM I ICI O CoT\\ i-4 $4 , *\ tIt OTO> I I i -.j *MPM ^mrnmmmrnm si VI it r i l; T VAB.0001190121 - * * J. E. Little Safety There were no safety instances this month. Judy Frossard presented a video and literature on tornado safety. Ginny Balk presented first aid training for heart attacks. Savings due to competitive bidding were $2589 for April, and $74,944 for FY1990. Savings due to prompt payment discounts were $1258 for April, and $14,075 for FY1990. Savings due to using excess materials (AFE and work order stores) were $2223 for April, and $16,529 for FY1990. Slow moving and off-grade inventories are a continual concern. Slowmoving compounds increased 34% to 1429M pounds. Also, vent dust has increased to 140M pounds. We are still working with Fred Williams regarding disposition of material. Preparation for MMS conversion to VMS is in progress. Sharon Palmer is working on inventory cross-references to equipment. Lane Johnson and Gerald Burzynski were in Aberdeen 4/18/90 to discuss project tasks. Representatives from Price Waterhouse were in Aberdeen April 24-26 to review/collect data for activity-based cost accounting. Meetings 4/02 Pre-meeting on Prestolite audit. 4/Q5 4/09 Post-meeting on OASIS presentation (Houston - 3/27 and 3/28) ; attendees Fred Williams, Ted Nickerson, Linda Michels, Amy Bagwell, and Jack Little. VMS - Hardware plan. 4/11 Mike Swierc and Charles Worlow met with Bill Arket from Union Camp to discuss optimal box require ments . VAB.0001190122 Continued Meetings - continued 4/16 Mike Svierc met with Lynn Weed of ECC America, a calcium carbonate supplier. 4/17 Activity based cost accounting meeting. 4/18 Prestolite audit. 4/20 VMS meeting update with Bob Seymour and Doug Skokna on implementation plan. 4/23 Meeting with Administrative Services personnel to discuss the environmental policy. We had four "Shadowing" participants visit our department during April. i VAB.0001190123 LABORATORY - j. H. Edwards, Jr. * pi A. Safety - There was one safety incident in the Laboratory for April. A wasp somehow got under Eddie Smith's shirt sleeve stinging him which resulted In a. first aid case. The monthly safety meeting topic was first aid treatment for heart attacks taught by Ginny Belk. B. Customer Contacts - There were four customer contacts during April. 1. ElPaso, a PVC division of Group Dekko, made a plant visit and tour of the lab. 2. Jim Edwards, accompanied by Eric Stouder and Eric Ingram, visited Twitchell in Dothan, Alabama. The performance of 5385 was discussed. A plant tour was also given. 3. HiTech made two plant visits. Larry Miley, an engineer with HiTech, made a plant visit April 17 to learn about the storage and containment of plasticizers. On April 27, people from Southwire and HiTech made a plant visit and tour of the lab. A Syntron contamination analyzer was presented to HiTech during this visit. 4. A quality audit was conducted by Prestolite. Jim Edwards, Richard Williams and Billy Paul Sizemore participated in answering questions and presenting lab procedures. 4/23 4/25 High moisture content was found in a 5415 truck shipment. Samples were received from Athol and confirmed to be 1.71 and 1.62 percent moisture (0.3% maximum specification). The fluid bed dryer had made some high moisture content 5415 at the time of this shipment. A team Is being formed to solve the problem of "special handling" silos which should help prevent known quality problem resin from being shipped to sensitive customers. AT&T reported finding fiber contam ination in lot 30S03 of 34862 BGE 10 compound. This was the same type of contamination found in lot 39K04 which they complained about in February. VAB.0001190124 TAifliUTOtY - Continued continued The source of the fiber contamination was determined to be from our geylord boxes and the method used by AT&T to dump the boxes into their system. Beth Vista and AT&T have action steps to resolve this problem now that the contamination source is known. 4/25 The customer rejected the railcar of 5385 because of the high number of glassies larger than the 40 mesh. 5385 made in 700 and 745 has a high glassy count and the vinyl plant usually is able to segregate this material from normal 5385. This segregation is not possible when the plant is required to make four products at the same time (like when 5395 is made). Also, the rotary dryers are not equipped with 44 mesh screens to classify out the larger glassies. 4/30 4/30 The customer reported finding "sand" in the RP-151 WHT 145 dry blend loaded in railcars. Tpd Nickerson visited the plant and samples of this "sand-like" materiel are in Austin being tested. Test results should be available the week of 5/14/90. No "sand" was found in the retain samples. The Investi gation continues. Customer reports cold spots In the melt which usually disappear when the extruder temperature is Increased. The compound, 48451 BIX lot 30S21, has stability problems at the increased temperature. Alan Butler visited Donnelly and samples of rejected windows made from the suspect lot were brought to the plant. Donnelly reports that the next lot, 30T08, processed better but it is not known why. The Investigation continues. Alan Butler has scheduled a trip to Aberdeen on 5/15/90. mmm MfpMMMM m VAB.0001190125 laboratory . Continued There were no requests for corrective action during the month of April. Cus tomer Blane Dayton Product 5395 RP-151 WHT 145 Reason Bulk Density Color No. 1 R/C 1 R/C A The following is a summary of residual VGM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of April, 1990. Number of Samples Average RVGMf ppm Reactor Slurrigg 933 132 ________Drier 5265 5305 33 0.345 54 0.367 The following is a summary of the residual VGM analysis of shipment samples for the month of April, 1990. 5265 5305 5385 5395 5415 Dry Blend Debox Pond Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color 51 57 58 5 51 57 4 0.101 o.m 0.709 0.083 0.028 0.083 0.304 7 1.226 (based on dryer "regulars") 5265 2101 5385 5395 5415 2.13 2.33 ---- 3.947 6.33 3.00 0.89 1.40 0.73 3.08 8.00 3.17 1.64 0.59 3.08 2.50 0.16 1.73 4.56 6.33 1.52 0.81 3.42 6.67 VAB.0001190126 LABORATORY - Continued (based on dryer "regulars") - cont. ms % on Pan (vs. 2%, max.) % thru 140 Mesh Drytime Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle site, microns 1.43 -- 0.72 -- -- -- -- 133 5305 0.67 -- 0.55 -- -- -- -- 135 338$ 1.43 ---- 2.31 2.33 ----- 31.2 158 1392 1.14 -- 1.50 2.33 2.61 -- 0 145 5415 2.92 0.42 6.17 2.00 2.34 1.58 2.6 170 Hardness Color Hard Particles Contamination Dicing Totals M Lbs. Ill 26.0 -- ----- -- 26.0 <0.405> -- -- -- <0.40> M Lbs. (%) 15.8 50.9 49.8 14.2 JLk*l 130.7 <0.24> <0.78> <0.77> <0.22> <0.22> <2.01> Torque Rheome try Color Total 3.3 <0.06> 7.9 <Q.14> 11.2 <0.20> 1. The raw netrials specifications book was brought up to date. 2. The Hunter colorimeter required two visits from the service nan to repair a memory loss problem in the colorimeter. The problem did not affect the measured color results. 3. Three Aberdeen High School seniors visited Vista in April to learn about the use of computers as part of the Shadow Program. 4. All six natural teams met once during the month. Half of them have picked problems to solve and the other half are close to choosing a project. SAMPLE SHIPMENTS APRIL 1990 RESIN Ship Date 4/05/90 4/10/90 4/11/90 4/11/90 4/11/90 4/12/90 4/12/90 4/12/90 4/17/90 4/20/90 4/23/90 Product 5265 5305 5385 5415 5305 5385 5305 5385 5415 5415 5395 5415 5415 5385 5265 5305(Clean Wall) 5265 Amount 50 lbs. 50 lbs. 50 lbs. 50 lbs. 5 lbs. 5 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 2250 lbs 2X50 lbs, 150 lbs. 1000 lbs. 200 lbs. 50 lbs. 100 lbs. Customer CHISSO PETROCHEMICAL CORP. CANADIAN GENERAL TOWER Leon Plastics Inc. Dupont Polymer Products Twitchell Company Vista - Austin RID Holm Industries LaGrange Molded Products VCE - BELGIUM CHISSO PETROCHEMICAL CORP. Kappus Plastics Co., Inc. COMPOUND Ship Date 4/04/90 4/20/90 4/24/90 Product 38525 BLK 38525 BGE 10 150-6A NAT 160-6C NAT Amount 250 lbs. 500 lbs. 50 lbs. 60 lbs. Customer Marine Industrial Superior Cable Corp. Vista - Austin # VAB.0001190128 ABERDEEN CHEMICAL PLANT INJURIES 40 jrmw MAM J JASON UW M AM J JASON UTWBF M AM J J ASON MOP U A a tom. MAMS turn nfmnrwnir 4 1. .1-. % .-i 4- J i 1 L/: VAB.0001190129 ABERDEEN ENERGY CONSUMPTION si/nue VAB.0001190130 A