Document 7MvXzppJv3MBpELeyER0Ve78a

4f* To T. H. Huffman ftp .J- From: Date: Subject: R. W. Seymour June 27, 1990 ABERDEEN MONTHLY PROGRESS REPORT MAY, 1990 A * V Safety There was one first aid case reported in May. At month's end, Aberdeen plant employees had worked 3988 days (5,298,464 manhours) since the last lost time injury. FY 1990 Kev Statistical Information PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M Caoacitv Utilization Factors May 39.2 92.9 98.4 1.0097 6.1 99.0 5.4 99.8 1.5 81.3 < 4.0> < 82.4> 18.0 Y.T.D. 299.0 88.0 97.1 1.0019 48.6 98.2 39.5 99.6 12.2 88.7 229.2 553.6 Resin Flexible Compound Rigid Compound Plasticizer Operations 103.7 78.8 90.9 63.9 100.9 77.9 82.7 71.5 The latest clean wall test was successful keeping the clean through a ninety batch run of 5305. Resin contamination numbers were good throughout the run. A successful test batch of 5325 was made for Premiere Polymers. Flexible compound inventory dropped about 600M pounds in May with packaged shipments exceeding April by 500M pounds. Line V operated only 3.5 days. PLENEX polymer trials consumed fifty- nine hours on Line I producing new jacket formulations for UL Rigid compound demand remained strong through May. VAB.0001190067 T. H. Huffman 6/27/90 Aberdeen Monthly Progress Report Page 2 - May, 1990 The overall efficiency variance for the month was favorable by $18.0M. The resin and flexible compound groups continue successful off-grade reduction programs with resin off-grade 56% below budget and flexible compound mill scrap 36% below budget. Fixed costs were essentially at budget except for the $83M payroll correction for April. 1. Roy Richards, the Southwire Company's CEO, travelled to Aberdeen on May 24 with other Southwire management personnel to present Vista a plaque for achieving the "Certified Quality Vendor" rating. This award was for performance in Southwire's Vendor Excellence Program for the six-month period November 1, 1989 to April 30, 1990. Vista signed a new one-year Vendor Excellence Quality Agreement with Southwire beginning May 1, 1990. 3. This month 94.9% of the plant's natural teams met and the average number of meetings per natural team was 1.15. 4. R. W. Seymour made an MBVA visit with Eric Strouder to Intex in Corinth, Mississippi. R. W. Seymour Plant Manager VAB.0001190068 DISTRIBUTION Hous ton J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin W. L. McClain J. P. Stokes Austin R. L. Poe X H. J. Hall Oklahoma City LCVCM Plant LCCP Plant H. D. Garrison R. A. Conrad J. Friend LCLAB Plant J. W. Ware X Baltimore Hammond Blane L. R. Bauer J. Pavao C. R. Miller X X Premiere P. L. Foote Aberdeen RWS/DCS (File Copy), TJA, JBA, JEB, JHE, 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 mmmmmmmmmm VAB.0001190069 wmm m mmmrn r SAFETY - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 1 0 1 0 0 Fiscal Fiscal Y.T.D. 1989 12 _6 18 2 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries bv Tvoe Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Injuries Lost Workday Cases Days Lost 0 0 1 0 0 0 1 16 01 30 20 0 1 20 0 1 6 119 2 4 10 1 0 _1 18 3 0 6 4 3 0 Last lost time injury - 7/5/79 Days since - 3988 Employee hours since - 5,298,464 On May 31, 1990, the employees of the Aberdeen plant completed 3988 days with no lost time injury. The Drill Planning Team held four chlorine emergency response drills in May; one for each shift. Following each drill, response training was held for ral chlorine emergency situations. mmmmmrnmf T W VAB.0001190070 Ml mmm SAFETY - Continued Routine dosimetry results for the month were: Chemical VCM Lead Total Particulates Monthly Injury Summarv <____________________________ 80 100.0 16 100.0 6 100.0 _______> pel Ntimhar Percent 0 0.0 0 0.0 0 0.0 Injury Class Description Maintenance Cut, right forearm. VAB.0001190071 MMMMWPPPM T. J. Arbeiter Vista signed a new one-year Vendor Excellence Quality Agreement with Southwire Company, our largest customer at the Aberdeen plant. The agreement covers all 5415 resin sold to Southwire. The agreement clarifies in detail the mutually agreed upon requirements relating to product quality, service and delivery, wire and cable commitment, technical support and exemplary service. This last category takes into account Vista's attitude and commitment towards a long-term partnership with Southwire and our willingness to support Southwire's quality improvement efforts. Our previous quality agreement with Southwire was six months in duration (November 1, 1989 - April 30, 1990). During these six months of our first agreement, Vista achieved a rating of 99.7 out of a possible 108 points. This score earned Vista a "Certified Quality Vendor" rating. A score of 100 points or more earns the highest rating of "Excellent Vendor". As of this time, no one has achieved this highest rating. Southwire's top management, including Roy Richards, Southwire's CEO, travelled to Aberdeen May 25 to present Vista with a plaque in honor of our achieving the "Certified Quality Vendor" rating. Approxi mately 110 Vista employees attended presentations in the plant auditorium and the Vinyl Department control room. R. W. Seymour made one customer MBWA visit during May with Eric Strouder to Intex in Corinth, Mississippi. D. G. Mouldings of Marion, Virginia, visited the plant for a general information exchange and tour. 94.9% of the plant's natural teams met during May. meetings per natural team were 1.15. The average VAB.0001190072 i ' COST VARIANCES - D. C. Skokna Product PVC Flexible Compound Rigid Compound Plasticizer $10.0 73.3 < 36.1) (-2.9,2) $ 18.0 ($163.2) 39.1 78.9 39.6 ($ 5.6) ($153.2) 112.4 42.8 10.4 $ 12.4 PVC - Operations were essentially at budget. Off-grade production was 56% below budget. Flexible Compound - Raw material usage was $22.4M favorable; product mix variance was $45.OM favorable; and the variance due to off-grade was $12.2M favorable. Scrap rates were 36% below budget. Rigid Compound - The unfavorable variance was due to an unfavorable product mix variance of $96.8M offset by a favorable raw material variance of $60.3M. Most of the raw material variance was due to a favorable TiOa variance that was caused by difficulties in accurately gauging the Ti02 hopper. Plasticizer - Raw material consumption was over budget. Price Variances - Resin to Rigid Compound - Resin to Flexible Compound - Natural Gas - Alfol 610R Alcohols - VCM - Other Price Variances Fixed Cost Variances Total 69.5 23.6 20.0 30.9 (188.1) 38.5 ($ 5.6) - Payroll and Benefits - MM&C - Miscellaneous - TI&D - Clearances SM Total ($ 97.5) 34.2 ( 28.4) ( 5.1) 14.4 ($ 82.4) # VAB.0001190073 Continued - The accounting error made in May ($83M of May payroll rates were not accrued) was corrected. M. M. & C. - Activity was below budgeted levels. Miscellaneous: Packaging supplies were $26.8M favorable. Moving, home assistance was $25.OM unfavorable due to John Olson's move. Processing supplies were $10.8M unfavorable. Contract costs - operating were $31.1M unfavorable due to changes related to preparing for a potential work stoppage. Clearances - The $14.4M favorable variance was due to the sale of some surplus equipment. VAB.0001190074 VINYL - J. D. Olson, J. M. Vinoski Safety The Vinyl Department had no first aid or OSHA recordable injuries during the month of Hay. The monthly safety meeting topic was "Lockout and Tagout Procedures". General 1. The latest BUS-80 test was successful. The temporary injection system on D745 kept the reactor clean through ninety batches of 5305 resin. Resin contamination numbers were good throughout the run. 2. A test batch of 5325 resin was made for Premiere Polymers. Specifications for the resin produced were very close to those targeted. Further results are expected next month. The res in raw aterials in the 744 account were valued at $419.9M. - Production, MM Lbs. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4 #8), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime % Reactor Downtime 39.; 1264.! 103.: 934. ( 30.: 92.! 88.: 98.: 98.^ 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). YTD 299.0 1230.5 100.9 7028.0 28.9 88.0 79.4 91.6 97.1 Hours 341 Maintenance downtime (condenser drilling on D744 and D400, reactor cleaning on D700, hydroblasting and drilling on D745, dump valve change on D300, and miscellaneous valve and instrument repairs). 184 VAB.0001190075 VINYL - Continued Drver Reactor limited production. Operational downtime (centrifuge plugs, dryer cleaning, and flameouts). Maintenance downtime (exhauster, centrifuge, baghouse and activator maintenance, and screw conveyor repairs). 49.2 25.8 25.0 J. B. Autrey, J. B. Hegwood Reactors 400 and 744 were shut down during the month for condenser drilling because of cooling control problems. Reactor 745 was shut down during the month for condenser drilling and hydroblasting as part of the contamination control program. The reactor agitator gearbox on during the month because of an The fluid coupling was replaced realigned. reactor 745 was shut down vibration problem, and the gearbox and motor Reactor 700 was shut down during the month for hydroblasting as part of the contamination control program. The chem wash pumps in the old reactor unit were shut down during the month for repairs to their bases. The bases were leveled and grouted in place. The pumps were then realigned and put back in service. There were two Corken VC unloading compressors rebuilt during the month. The 690 compressor had bad rings and a bad bearing on the crank shaft. The 490 compressor was leaking around the packing. There were two major valves changed out in the reactor area during the month. VAB.0001190076 J w* mmm mmmmm COMPOUND - J. E. Nickerson, K. G. Akins A The Compound Department worked without injury during meetings. The General Flexible compound inventories fell from 7.54MM pounds to 6.97MM pounds during the month. Packaged compound shipments were up 500M pounds from April. Line V only operated 3.5 days during this month for inventory control. Line I was down for fifty-nine hours for PLENEX polymer testing and production. This month several new jacket formulations were produced for extrusion onto wire and submittal to UL for testing. Demand for rigid compound remained strong in May. Current orders have the unit on an extremely tight production schedule into July. Operating Comoound Production Days Month Avsc. /Dav Fiscal Y.T.D. Line I 30 Line III 31 Line V 3.5 Total % Prime Capacity Utilization Factor 1884 63 4066 131 180 6130 _51 245 99.0 .788 15937 27648 5019 48604 98.2 .779 Downtime Hours Line I - Product: Changes PLENEX Polymer Testing Miscellaneous Maintenance Quality Problems & Control Dicer Problems & Maintenance 85 59 25 12 12 - Product Changes - Miscellaneous Maintenance - Quality Problems & Control - Dicer Problems & Maintenance Line V - Product Changes - Miscellaneous Maintenance 52 17 13 8 15 15 mm WM VAB.0001190077 COMPOUND - Continued Operating Days Rigid Compound 30.5 % Prime Capacity Utilization Factor 5412 99.8 .909 177 Downtime - Product Changes - Miscellaneous Maintenance - Quality Problems & Control - Scales Maintenance Hours 73 73 42 22 Operating Davs Month Plasticizer 31 % Prime Capacity Utilization Factor 1479 81.3 .639 39493 99.6 .827 Fiscal Y.T.D. 12166 88.7 .715 Maintenance Work - J. B. Autrey, J. B. Hegwood The Line I Banbury was shut down during the month for a seal replacement. The lubrication return lines for the mill were also cleaned during the month because of plugging. The middle compound cooling tower pump was put back in service during the month. The pump had been sent out for reconditioning. The control panel on the #1 dicer was repaired during the month. The ground sensor, contact, and two resistors were changed out on the panel. VAB.0001190078 ENGINEERING - R. E. Polk, S. C. Hillman, M. R. Kane PROJECTS IN DEVELOPMENT - GENERAL EVC Cleanwall Technology The D745 cleanwall trial was successfully run during the month of May in 5305/5265 service. Reactor jacket modifications to cool the vapor space alleviated the wall buildup problems experienced previously with the low molecular weight formulas. Additional testing with 5415 resin will be conducted in early July. Initial testing of an alternative reactor cleaning nozzle has been completed out of the reactor. The need for in-reactor testing is being evaluated. Donnelly Dusting Problem Steve Hillman and John Levardsen visited Donnelly, a flexible compound customer, to assist them in solving a dusting problem at their compound pellet storage silos. A letter was sent to Donnelly with suggestions as to how to resolve the proble Patco Antistat Trials Initial testing of an alternative antistat made by Patco was done on 5415 resin in a rotary dryer. This new antistat has the potential to eliminate fluid bed dusting problems and replace wet calcium stearate in 5385 resin. Q.C. testing at the plant showed no quality problems. Samples will be sent to R&D for evaluation. Additional testing on 5415 resin in the fluid bed dryer and 5385 resin is being planned. Fourth fiscal Quarter Capital Budget The fourth quarter budget was sent to Houston on June 8. AFE's for five of the six projects were submitted with the budget. A VAB.0001190079 8 3 cn tn 3 st 8 8 a m titt HU S Si 3N niNHt is st tcnn Usu E s u) 3 cn cn *8 S c tn o s Z Q (A 5 3* si? 3 3 a~ 3 3 u 3 Ui o cn 3 3 a cn at* s cn 3 2u 3 st E 3cn cn 3 at S a OC ^ UJ O UJ 81 aS I o o 3 53 2 % sS cn cn i*i 3; 3 3 aa3 . a s3 cn cn ^ sa 32 cn 3 cn cn 3 3 iii 3 3 33 cn * I-38 3 3 1 rcn 3 3 5 a_ st cn cn ggSS:s: sa 3 3 Hu I3S3 ha S8IS 8 3 S3^IS38 u 3 cn UJ Of 38 3 8 tn u cn ~ 8 rJ wc W asia 3 cn 8 , i8 aa 8 3 ctnn tt- ut cn cn ui cn 5 5 8 s^s P 3 || _ cn 3 c3n cm8n cn 3cn cca j3g c3n c3n cn m1es cn a 3 gw* EX cn a n k3uaucMnu-C3j^c5-nk5ccScnk5xS cn si 3 3 cn aa lg id bJ SSMMMlZIZoStku! __ S cn 3 *-- a S22i!2,n0 5 cn csn siisi 3i 3 cn 3 5 Illllisssscg^aSdswsSWsisISMl|sCSiHidls|lUdsLlU?si2s*i*i * 3 U UJ u 3 3 3 38 ir> 8 ss 38 cn a S1 cn w cn 2 cn u cn 5 cn m a. S uosi m sa s sa cn a *3 8 22 8 8 2 5 2 8 3 8 a * r8 2 832 s S s 2 10 & aa a Ssgss8cn cn 8 a 8E 8 33 s* 3 5* 3 5 cn cn 3 8 a 8^.. UI cn % * 8 8a 8 32 UJ -- UJ o * 8 M M UI p 3*8 cn -* d s 28 ;2 cn uj eg a 1g 8 3 ex H- 8 32 a 5 | -* 3 8 8 " 3 S u cn X uj Igj cn ys I a23s 1 8 *S* 23 8 28 883 sssiiii 3 3 sli cn 3 3 3 8 5 st 8 t s3 R S 2S sc s2 2 22 uuuaSaaSSS^xxS S2 3 VAB.0001190080 tn 333 ENVIRONMENTAL - F. 6. Jeanson Water All wastewater discharge parameters were met for the month of May. The Mississippi Department of Environmental Quality (MDEQ) conducted an inspection of all wastewater outfalls. No problems were found during this inspection. Waste Waste shipments for the month included: One bulk load of separator oil was shipped to M&M in Gadsden. Alabama. One load of plasticizer filter cake (seventy-seven drums) was shipped to CWM in Emelle, AL. A letter was written describing the plant recommendations for old pond #1 which is a past landfill site. Superfund A visit to Sun Polymers to evaluate pond resin recovery was conducted this month. Conoco and Vista participated in this visit. Sun Polymers is currently recovering two ponds of FVC resin, 40MM pounds, from a B.F. Goodrich plant in Canada. A meeting was set up with the MDEQ in June to review our sites and any remediation plans. Conoco will be involved in this meeting. Several meetings were held with employees and city officials to explain the Superfund sites on our property and an EPA study that was done on these sites. The MDEQ was also notified of findings in the EPA study. Air The modeling study on VCM emissions from the plant was completed in late May and submitted to the MDEQ. If the MDEQ approves the study, they will issue a public notice for our modified air permit application. Thirty days later if there are no objections from the public, the MDEQ permit board will review and hopefully approve the application. Miscellaneous I attended a MISTAP regulation review conference during the month. An environmental training seminar was held for plant operations and engineering personnel. I attended the annual environmental meeting in Austin, TX. A VAB.0001190081 ENERGY CONSERVATION - D. A. Moore A. Unadjusted EUI <4.0%> B. Adjusted EUI <3.9%> C. BTU/Lb. Product 2554.0 D. Total Energy Consumption MMM BTU 132.44 < 7.7%> < 7.9%> 2644.0 1053.20 There were sixteen energy related items completed in May, 1990. Fifteen of these items were steam leak repairs. The remaining one was steam trap repairs. III. Boiler Operation Boiler No. 1 No. 2 No. 3 83.3% 83.0<o 82.9% 83.4% 83.3% 83.0% (1) Boiler number two was operated one day during the month. 11 <ieim mm wmm/m VAB.0001190082 * A IMP J Beall Allen Bodron - Rehire Berlin Genetti - New Hire Anthoney Deanes - New Hire Proaetlo"/Tr"^- Robert "Bud" Stone - promoted from General Mechanic "B" to General Mechanic "A*# Timothy Arbeiter - transferred from Senior Analyst Houston, Tx. to Quality Management Coordinator - None Brian Aftergut To/Trom Leave of Absence None *' fHNMW UNiMB wrnmmmmmmmmm mm m VAB.0001190083 m mm Salaried Employees Hourly Employees Total Employees ABERDEEN, MISSISSIPPI MAY , 1990 mm mmmaimm MONTHLY PERSONNEL EXPORT 79* Minority Employees #, % m Salaried Z 251 Hourly 66 Total 73 New Employees T erminat ions 0 0 Hourly Min. Hired % Min. Hired 0 0 Hourly Min. Term. 0 % Min. Term 0 DEPARTMENTS PAR EMPLOTEES MTM. EMP. %MIN. MEN HIRES YTP TERM. YTP TTffiflflyEE YIP. Warehouse 16 Gen. Plant 13 Maintenance 41 Laboratory 24 Compound 40 Vinyl Plasticizer 5 41 24 5 a a 10 A 5A 26 67 A 30 40 0A 00 00 0 00 00 0 00 Number of Applicants: Month 0 Year To Date APPLICANT BREAKDOWN # Minority A % Minority __0 # Female 0 % Female 0 Hires (Hourly): Month A Year To Date Terminations (Hourly) A Month 0 Year To Date 0 Overall Turnover Projected Annual Turnover __q VAB.0001190084 CO Ul x c_ too i-o 1^3 ir*i i i !** !** 1i 1-0 ! m ni 4 i *! z. i /k-J"ll X t * J 4 -TO I * JL^ | I IOi o - :I i *_ L j t :lo! -z? I **-X I O `O;0 I! 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OMX I XU ll IUJ i II )*-* I UJ t LO !O * I I rrt * i r i > i in i cm * * i in in i CM 1 in i oo i m i cm r i i ! in CM i CM I I 00 1 I i I CD o i in ii in t i in i in in t inin-4 i i( r- co4 i fi * 00 i i I inor*-ni i%>0 ti in K> i I *n* i I I i inin i i 4i I CM i in 1 * i < i i in i o I CM i CD i ro I IM I ^i i CM CM I ii J I CM ii II * 1I i ii in ii i i Ii OI I <l I C4 1 CM I CK I m ro t rn i in i it ti it ii sii in i i i ini i * t 00 i o* i i 4 CinM "o m i IM ro i ro i4 r-4 i M3 t rin- 7i in "i oino if D" r- i CM i i s 00 4 OC CO CO in t in i i o i CM i* i I m i in inJ > Mi I 4--' | I CM I CD CN ro in i ro CM I oo i r*j i ti in 1i in i i tn 4 i i CMm oo in oi o O \ ro i ck CM 1 CO o In i in iI CM I in *I 4 *> I in CM t ^4liw in i m in i ir; to Ul <D CJ CK min ro ^ *^7 i rt ro l^ i 1 1 OO 1 CM 1* 1 ..M 1 rn ^ ic^j f fin f CM ICK 14 I ii tn I CM I* 1^* i I CM I CM f iin 1CM i 1CK IM 10^ iiro i I Ijin ! IC-J 1 I i I 1 I I ( i UJ i i i--i i --* ii *--* i <-L. CO I I I I j i UJ i \i I co I t t 1i Ii Ii I Ul I Ul I Q I Q I rj i r*^ iU i t ! CO I I i a. UJ I c- 00 .` J C i o ro ^ C*J tu CO CO CO *M|W PiPMIMMiiVMli VAB.0001190086 ADMINISTRATIVE SERVICES - J. E. Little There were no safety instances this month. Cflgt Saving? Savings due to competitive bidding were $16,475 for May, and $91,419 for FY1990. Savings due to prompt payment discounts were $2257 for May, and $16,332 for FY1990. Savings due to using excess materials (AFE and work order stores) were $561 for May, and $17,090 for FY1990. Warehouse - Finished Goods Inventory Slow moving and off-grade inventories are still a major concern approximately 35% of total packaged inventories. Strategic Initiatives Darrel Peterson, U.E.&C., conducted VMS overview training May 15-17. Pre-implementation work is progressing well. I met with Price-Waterhouse to discuss activity based cost accounting. Employee Development Mike Swierc and Tommy Cummings attended IPSM May 16 & 17. Tommy Cummings and Amy Vaughn attended Mississippi State Tax Seminar in Tupelo, MS, on May 10. Ruth Morris, Data Processing, was in Aberdeen May 25-28 to make additional revisions to the payroll management system. Meetings 5/02 5/09 5/09 Price-Waterhouse - activity based cost accounting. Gold Bond visit - discussed raw material coordination. Mike Swierc met with Motion Industries concerning quality progra * A VAB.0001190087 T mm VMPNpMM Meetings 5/11 5/16 5/24 5/25 5/31 continued Continued The Stores Team made a presentation to Bob Seymour's Natural Team. Southwire meeting OASIS ~ task review Mike Swierc visited Halstab (Hammond, Ind.) for the supplier recognition presentation. Southwire presentation The Stores Team made a presentation to Engineering. VAB.0001190088 osmi mmmm fPi mum ciuicu pun surriK iiutiis ui tm -SIlNIItl IT PtOHCTI- P991IC HOfTI 1PT/ITC noun PHI 1C 7TD lPf/lTC ileum IISII-90LI IU1l-ttCUfiKi 29,947,36a 442,331 11,271,111 392,181 387,290 9 159,983,172 2,523,919 76,635,359 1,754,999 1,151,411 9 IUUIU COHMU-NU 1,in,219 nuiiu coamo-ricuin 3,912,313 121,111 81,171 9 9 11,712,511 25,199,975 7,648,291 1,254,237 9 9 IN MSIIKS lltll CMPtHI-HU inn comou-ncum mine - ini TOUIK - MCIMII pumcmi TOTAL -utrum n mi- 13,199 MiMii 411,142 9 1,231,989 9 9 6 8 0 0 597,399 9 90 213,869 171,989 384,869 n,in, in 14,151,151 1,259,369 37,970 00 25,946,219 1,735,325 1,113,411 219.723 9 9 9 9 5,255,171 9 9 128,265 1,133.411 1.132.111 1.471.819 226,429,822 96,424,959 8,611,545 B9LI: *UI* IIS1I iiiiim comm tun mnni runieiin mill in W9 IIS1I fUIlKItWHU mu comm runmw mu m MUCM 164 13 24 3 294 CVST0IK1 new COHKHI ClRlIII 19 65 99 0 13 97 27 95 l.iti 291 462 97 11 35 111 15 129 19 9 29 1,477 227 175 TOTH 249 21 37 11 316 1,163 143 325 46 2.379 HCIHH: *111*a.ui Ha mu nniHi cnnhi inn cmmi PUItIClIII Tomut casnmi conn new cinin me comma ............................... 5 19 9 931 72 0 9 0 16 9 9 9 9 00 I1I/9PS 5 14 0 8 36 196 9 0 19 mu 21 117 16 9 161 TT9* mFuuinu comm inn comm runiciw mu in 0 039 101 173 579 4 0 19 70 9 1 9 3 99 213 753 4 1 69 31 1 1 93 191 787 92 4 1,964 A LABORATORY - J. H. Edwards, Jr. A. Safety - There were no safety incidents in the Laboratory during May. The monthly safety meeting topic was the new "Lockout/Tagout Procedure" taught by Bruce Trego. There were five customer contacts during May. 1. Jim Edwards, accompanied by Justyn Miller, visited Gold Bond in Sardis, Mississippi. The target specifications for color in RP-28 WHT 122 were discussed. The call was made on 5/23. 2. D. G. Mouldings made a plant visit and a lab tour was given on 5/11. 3. Representatives from Gold Bond made a plant visit on 5/9 and a lab tour was given. 4. Southwire made a plant visit on 5/25 to present the Certified Quality Vendor award to Vista. A lab tour was given. 5. A representative from Intex visited the plant on 5/29/90 and was given a lab tour. Customer Q.C. km PVC C< PVC Compounders reported high moisture content in a 5415 railcar. Samples of the car were sent to Aberdeen and were confirmed to be high moisture content. The railcar had been loaded from silos filled while the fluid bed dryer was experiencing high moisture problems. The car was returned to Vista. AT&T sent the Aberdeen lab a sample of con tamination from a screen pak running 34862 GRY 546. The contamination sample was iden tified by AT&T as brownish granular material and metal pieces. The sample was sent to R&D Austin for analysis. The metal was determined to be stainless steel. The granular material was mostly chlorine with small amounts of aluminum, silicone and lead. A formal response will be written and sent to AT&T. LABORATORY - Continued Customer O.C. Flexible Technologies reported bad dicing and stringers in 18031 WAT C, lot 10Q13. Boxes with the same lot number in Aberdeen were inspected. Four of the twenty-four boxes on the floor were found to have bad dicing. Seven were down-graded as a precaution. 5/29 & 6/2 Gold Bond returned two railcars of RP-28 on 5/29 and on 6/2. The complaint was that the dry blend was too dark. Quality control records show a definite shift lower in L value for that production run. The reason for that shift is still under investigation. 5/21 Vytron complained that 17462 BLK (lot 59L12) and 17462 NAT (lot 50R15) will not produce acceptable extrusions. A review of produc tion records show high hard particle problems during the production of both lots of material. D. Requests for Corrective Action There were no requests for corrective action during the month of May. E. Product Waivers Customer Product Reason No. Vulcan Plastics 5385-3P Bulk Density Range 1 R/C The following is a summary of residual VCM results on in- process samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of May, 1990. Number of Samples Average RVCM, ppm Reactor Slurries 931 134 Drier 5265 5305 36 0.417 70 0.294 I PRMMMf V vppmm Continued The following Is a summary of the residual VCM analysis of shipment samples for the month of May, 1990. Product Average RVCM. ppm 5265 5305 5385 5395 5415 Dry Blend Debox Pond 39 106 59 11 67 47 12 1 0.101 0.157 0.539 0.116 0.053 0.047 0.336 0.530 Resin Process Capabilities (based on dryer regular s" ) 525 Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Drytlme Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle size, microns 1.50 2.17 -- 8.11 3.17 2.83 1.29 -- 1.07 ----- -- ------- 138 12fi5 0.78 0.60 0.33 2.92 8.67 2.67 1.18 ---0.63 -------- -- 134 5385 2.75 0.67 3.00 2.50 1.56 ----------- 1.45 2.00 -- ----------- 19.4 160 5395 0 0.90 6.67 2.67 0.94 -- 0.84 2.33 4.13 -- 4.6 139 5415 1.40 0.77 4.44 6.33 2.75 0.25 2.54 2.00 2.22 1.52 0.9 174 Hardness Color Hard Particles Heat Stability Contamination Dicing Totals M Lbs. XU 26.0 52.0 -*-- 7.0 -- ---- 85.0 <0.42> <0.84> ------<0.11> -- -- <1.37> M Lbs. XU 7.5 1.4 11.7 - - - 14.8 44.5 <0.12> <0.02> <0.19> ---- <0.24> <015> <0.72> WPMPNMtfp m VAB.0001190092 LABORATORY - Continued Quality Summary Torque Rheometry Color Total 6.3 44.8 51.1 <0.12> <Q.82> <0.94> J. Miscellaneous 1. Software is being written for the Q.C. Supervisor to review, add customers and print out a certificate of analysis for customer shipments. 2. Dave Cox assisted Blane with setting up their G.C. for plasticizer analysis. Methods were tested and samples were sent. 3. The lab re-issued six compound formulas with added BFA due to removing BFA from the 108P plasticizer. 4. Billy Paul Sizemore attended two days of IPSM training. 5. Jim Edwards attended two days of rigid formulations and testing training in Austin. 6. All six natural teams met once during the month. 7. The National Sanitation Foundation (NSF) made its annual inspection this month. They found no violations in production, facilities, quality records or procedures. A mmmmp V VAB.0001190093 m RESIN Ship Date 5/02/90 5/02/90 5/02/90 5/08/90 5/08/90 5/07/90 5/07/90 5/16/90 5/16/90 5/18/90 5/21/90 5/22/90 5/22/90 5/25/90 5/30/90 5/31/90 SAMPLE SHIPMENTS MAY 1990 Product Pond Resin Pond Resin Pond Resin Pond Resin 5385 5385 5265 5265 5305 5385 5385 5385 5385 Pond Resin 5415 5415 5465 Amount 5 lbs. 50 lbs. 50 lbs. 50 lbs. 2 lbs. 200 lbs. 500 lbs. 2 lbs 2 lbs. 100 lbs. 5 lbs. 2X2 lbs. 5 lbs. 50 lbs. 50 lbs. 5 lbs. 50 lbs. Customer W. K. Merriman Inc. V. P. I. American Trading Shawnee Chemical CONNIE NAKAMURA Solem Industries Arlington Mills Procter & Gamble D. G. Moulding KOHKOKU, USA Dayton Extruded Plastics Uniroyal Chemical Co. American Trading KOHKOKU, USA Uniroyal Chemical KOHKOKU, USA COMPOUND Ship Date 5/02/90 5/09/90 5/18/90 5/22/90 Product 18031 WAT CL 48451 BLK 48562 BLK 34643 NAT 419-67B BLK 419-68 BLK Amount 1500 lbs. 50 lbs. Customer Furon/Synflex LOF Tech 50 lbs. 1500 lbs. 1500 lbs. CABLEBOL Times Fiber VAB.0001190094 COMPOUND (Cont.) 5/22/90 38601 BLK 5/23/90 1220-106X NAT 5/24/90 27121 NAT 5/25/90 15072 NAT 18961 NAT 5/30/90 16841 NAT OG 17462 WHT OG 18162 BLK OG 18031 WAT CL OG 5/31/90 38601 NAT PLASTICIZER Ship Date 5/09/90 Product 610P Sample Shipments/May 1990 Page 2 200 lbs. ELECTROCONDUCTORES 4500 lbs. Inovative Plastics 50 lbs. ABC Plastics 100 lbs. 100 lbs. Macklanburg-Duncan 30 lbs. Ron Walker 30 lbs. 30 lbs. 2 X 30 lbs. 200 lbs. ELECTROCONDUCTORES Amount 1 gal. Customer Blane Polymers A VAB.0001190095 NUMBER OF N J DRIES ABERDEEN CHEMICAL PLANT INJURIES d P ' ''1 '' f>I I 1 J`87F M AM J JASON CU'BBF MAMJ JASON QJ'BSF MAMJJASON DJ*9CF MAM TOTAL INJURIES O OSHA RECORDABLE VAB.0001190096 mtqmmmmrnm T oi/ruo PWPMniiiimHN VAB.0001190097