Document 7Rp8E9K00bgpoxzypb2xvad98
R. S. Weis, C&P, B-17202
February 16, 1983
TO: C. J. SLENTZ
s2FROM:
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1982 COST REDUCTION ACCOMPLISHMENTS
Attached are Newark and Newport reports detailing results of cost improvement programs for 1982. Explanations are included for major variance vs. forecast.
PAW/jmg Attachments
R&D COST IMPROVEMENT ACCOMPLISHMENT REPORT QANEWPORT PLANT DATE FEBRUARY ? , 1983 ( A ll value in thousands o f D o lla rs )
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DU P050145870
N 26485.01
QA Liquid NBMSA (Dimethyl QA) ($79M achieved vs. $40M firm
forecast) Also includes unit-consumption reduction of 0.04 lbs.
per lb. of QA. Reduce Methylate ($45M achieved vs. $50M firm and $200M
goal) NaOMe reduced from 29% to 24% excess in line 2. Reduc
tion to 15% excess scheduled for April demonstration. Yield (?102M achieved vs. $50M goal forecast)
Represents a yield increase of 1.1% over 1981. R&D Manpower ($57M achieved vs. $50M firm forecast)
Reductions for one early retirement (wageroll) and one transfer (exempt) were divided equally between CPC and QA. Dowthernffi Reduction ($182M achieved vs. $0M forecast)
Represents savings from in-house component mixing, and for improving solvent recovery. Caustic (Waste Neutralization) (S115M achieved vs. $0M forecast)
Represents savings from improved pH control in waste neutralization. Automation studies are scheduled for March.
DUP050145871
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DU P050145872
N 26485.02
1982 COST REDUCTION ACCOMPLISHMENTS PROGRAM WITH VARIANCES GREATER THAN 20%
CPC
Reduce Kerosene ($42M achieved vs. $100M goal forecast) Kerosene consumption was reduced from 0.9 to 0.7 lb.
per pound of CPC (goal 0.4 lb.) through improved decanter operation and improved BB/BBF phase separations. Loss rate in approaching the historical rate in plant I (0.6 lb./ lb.) . Pigment Losses ($0M achieved vs. $40M firm and $40M goal)
Actual gate losses decreased from 900 to 300 pounds per day. As a percentage of production, losses remained constant (6%). R&D Manpower ($57M achieved vs. $20M firm)
Reduction for one early retirement (wageroll) and one transfer (exempt) were divided equally between CPC and QA. Lower Cost Beta CPC ($0M achieved vs. $60M goal)
The marketing opportunity has diminished for these products.
DU P050145873
R+D COST IMPROVEMENT ACCOMPLISHMENT REPORT
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DUP050145874
N 26485.03
R+D COST IMPROVEMENT ACCOMPLISHMENT REPORT
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DUP050145875
N 26485.04
R+D COST IMPROVEMENT ACCOMPLISHMENT REPORT
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DUP050145876
N 26485.05
R-H) COST IMPROVEMENT ACCOMPLISHMENT REPORT
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DU P050145877
N 26485.06
COST REDUCTION VARIANCE EXPLANATIONS
SM FIRM ------ AUTOAT
INORGANICS
Liquid Alum
48 24 Production lower then forecast.
Eliminate Component
19 0 Program delayed. To be Implemented IIQ83.
Flow Control
65 0 Program delayed. Project Installed 3Q82. Initiated testing during remainder of
1982. Savings anticipated to begin IQ83.
YE-698-D
240 0 Initial trials unsuccessful. Program scope redefined 3Q82. Will batch
strike/finish continuous. One trial successful in 4Q82. Savings to be Implemented during IQ83.
OTHER ORGANICS
Drum Washer Reduce Blending
30 0 Program cancelled. Unable to modify equipment for efficient use.
40 20 Actual production lower than forecast.
Eliminate Clarification
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3 Development work required, delayed plant trials. Full implementation expected by IIQ83.
DUP050145878
N 26485.07