Document 93Oj0xRzd56oM64DJEY0KqQgL

THIRD QUARTER REVIEW ORGANIC PRODUCTION AND MATERIAL HANDLING DEPARTMENTS 1965 OBJECTIVES November 9, 1965 I. SAFETY 1. Have no lost time or near-miss accidents and attain a serious injury index of 12, None - Serious injury index 12 2. Conduct a Safety Audit on all expanded production facilities within four months of start-up. Severson to complete audit of Biphenyl Tube by 6/30/65. 3. Complete a minimum of 12 significant safety improvements during the year. a. Aroclor electrical gear upgraded. b. Safety showers installed - HB-40, Santowax R. c. Old hydrogen compressors, and gas meter room dismantled. d. New Muriatic Acid loading dock and piping. e. Eye wash bottles - all control rooms. f. Benzene loading dock upgraded safety-wise by replacing ladder with steps and handrail. g. Gas meters removed Santowax R control area. h. Hazardous Santowax melt pots dismantled. i. Enclosed Santowax R control area. j. New Muriatic Acid Department. k. Eliminated very hazardous Santowax C draw-off required in manufacture of Aroclor 2565 by installation of steam jacketed loading line. Also eliminated handling problems to put material in chlorinators. l. Daily log of pressure condition on three deluge systems at tubular unit. m. Improved OM piping eliminated drum draw-off and reworking operation. n. Eliminated hazardous operation of operating two Biphenyl stills with one receiver in manufacture of Biphenyl F. Piped in Biphenyl F tank. o. Safety showers at HC1 and Aroclor installed. p. New HC1 facilities installed with improved piping and PVC coated grating throughout. q. Aroclor chlorinator sampling facilities improved. r. Reduced use of gas torches in Aroclor - new therminol system installed. s. Level instruments on Aroclor tanks - eliminates measuring sticks and tank openings as tripping hazards. DSW 551659 STLCOPCB4090076 Third Quarter Review -2- November 9, 1965 t. Replaced North wall of Aroclor building. u. New Biphenyl transfer line eliminated hazards in transfer for chlorinator charges. v. New HC1 transfer line replaced an old line which caused HC1 fume problems. A. Safety and Housekeeping inspection to be conducted by Superintendent monthly with responsible foreman and/or supervisor. Housekeeping to improve to Plant Manager's satisfaction. II. QUALITY OPERATIONS 1. Average quality score of 95 minimum to be achieved. Aroclor Biphenyl Chlorine 88.A 103.7 101.1 2. Obtain no more than three justifiable quality complaints, and a complaint index of 2.0 per M pounds production. Complaint Index 3.5 Number of complaints - 11 - 2 justified R.F.T. Index 98.8 3. Obtain no more than eight justifiable service complaints, and a complaint index of A.O per M pounds production. 6 complaints to date - A justified - Carrier error Complaint Index - 3.6 A. Complete Quality Audit on Liquid and Solid Aroclors and develop plan for quality improvement for these products. Nothing done - TSD to initiate Quality Control Board Program 5. Achieve a minimum of two significant product quality improvements. a. Aluminum Aroclor storage tanks. b. Relocate HB-AO draw-off line - Reactor Grade HB-AO. c. Defined operating conditions to allow OM production in normal reactor grade specification. d. Modified Biphenyl tubular unit stripping column operation to allow 10th tray control which minimized production of terphenyls. e. Cleaned up HC1 feed gas to Muriatic Acid Department. Should result in acid improvement before end of 1965. DSV"551660 STLCOPCB4090077 Third Quarter Review -3- November 9, 1965 III. COST IMPROVEMENT 1. Achieve raw material savings of $130,000 from 1964 practice. The yield on the following to be: 1965 Achieved Target Third Dollar lbs/cwt Quarter Savings Benzene Muriatic Acid Cr. (Liq. Arodors) Muriatic Acid Cr. (Sol. Aroclors) Anhydrous HC1 Mercury (826.36) Mercury (827.50) KC1 98.5% Theory 43.0 64.0 116.0 0.021 0.03 141.00 99.7 38.12 64.79 117.65 0.014 0.021 142.79 $ 13,020 -9,448 6,452 0 26,213 43,180 1,380 $ 80,797 All raw materials 3rd Quarter savings $79,700 versus targeted $95,000. 2. Labor utilization to be improved 77,, by increased productivity, and more effective production planning. Product 1964 Usage 3rd Quarter T/D 1965 Usage Hours Savings Biphenyl Santowax R HB-40 Liq. Aroclors Sol. Aroclors HC1 Cl2 - NaOH KOH . 0.078 0.096 0.143 0.073 0.212 0.032 0.045 0.062 0.067 0.090 0.152 0.062 0.206 0.036 0.046 0.062 3,300 410 - 390 2,625 290 - 420 - 175 0 5,640 5,640 = 5.3% equivalent to $20,300 savings 106,309 Organic Production 3rd Quarter 1965 148 M Lbs. Organic Production 3rd Quarter 1964 = 125 M Lbs. 23 M Lbs. = 15.5% Actual Manhours 3/4 1965 = 81,400 Actual Manhours 3/4 1964 = 80,734 DSW 551661 STLCOPCB4090078 Third Quarter Review -4- November 9, 1965 III. 3. Achieve overall plant on-stream time of 93.2%, process downtime maximum of 1.0%, and all other downtime less than 2.3%. Process downtime to be improved by better control of process, and other downtime by scheduling, and better utilization of surge capacity between products. a. On-stream time b. Process downtime c. Other downtime d. Repair downtime 88.8 2.1 4.8 4.3 4. Assist in development and start-up of specific cost reduction items with savings of $330,000. To date $194,000. 5. Improve direct manufacturing costs other than labor at a rate at least proportional to the volume increases. Product 3rd Qtr. 1965 D.C. 1964 D.C. Savings Direct $/cwt. $ Gain, or $ Loss* Biphenyl Santowax HB-40 Liq. Aroclors Sol. Aroclors Muriatic Acid Cl2 - NaOH K0H 0.998 0.525 0.399 0.543 2.135 0.577 0.648 1.890 1.305 0.737 1.355 0.646 2.136 0.452 0.571 1.686 0.307 0.212 0.956 0.103 0.001 0.125 0.077 0.204 $92,500 14,400 41,620 24,570 0 13,160* 13,600* 42,270* Net Gain = $103,560 Dollar Improvement - $ 104 M _ o oy Total Dollars Directs = $1,258 M - \ Volume Increase = 15.5% 6. Achieve 97% on-time shipments - 2.8% DS\N 551662 STLCOPCB4090079 Third Quarter Review -5- November 9, 1965 IV. METHOD AND FACILITIES IMPROVEMENT 1. Complete start-up of PNP Department, obtaining design rate within 60 days with start-up costs of less than 10% of the capital expenditure. OK 2. Complete start-up of Aroclor Expansion, and demonstrate design rate with 60 days of construction completion. Start-up expenses not to exceed 10% of capital expenditure. OK 3. Complete start-up of Muriatic Acid facilities, and achieve 90% absorption efficiency within 30 days of completion. Start-up expenses not to ' exceed 8% of capital expenditure. OK 4. Assist in development of scope and provide liaison for Finished Goods Packaging, and Warehousing Ptojeot.. OK 5. Implement and assist in development of HB-40 project. Project approval to be obtained by 10/15/65. Cannot be justified. 6. Assist and provide liaison for replacement project for Mechanical Rectifiers. Project approval to be obtained by 9/1/65. OK 7. Implement and assist in development of Biphenyl Still Project. Project scope defined by 10/1/65. OK 8. Audif of all reports and records for possible simplification or elimination. Minor improvements only. 9. Develop measurement and controls for "Work to Assist" costs and report on a quarterly basis. No formal program.. V. PERSONNEL IMPROVEMENT 1. Continue F.L.I.T. Operator Training Program for remaining and new operators. Training to be completed by 1/1/66. Training in progress - 24 operators to be trained. 2. Process Function Outlines completed for three manufacturing facilities, and operator training utilizing these outlines to be completed by 1/1/66, Done 3. Develop realistic targets for each operating facility for operators. Performance report to be published monthly. Decided not to publish for operator - supervision only. 4. Develop more objective Position Guides for all supervisory personnel. Moody and Supervisors by 7/1/65. Nothing done - will get 4th Quarter. Conduct at least two supervisory training meetings during the year, Subject to be: a. I.F.O's and P.F.O's - use and training - b. Cost Standards and Reports - Done c. Production Planning d. Start-Up Procedures - new facilities - Done DSW 551663 STLCOPCB4090080