Document 9JqZvOewbM3nqdg9j5xkaE1q

t To From Date Subject R. E. Lehmkuhl G. G. Draper January 28, 1977 a ABERDEEN PLANT GOALS - 1976 CONFIDENTIAL * Attached are the Aberdeen PlantTs actual goals for the year 1976. If you have any questions, please advise. G. G. Draper jf Attachment C: Department Heads * i If n H I' 4. I VAB.0001031373 QUANTITATIVE GOALS Safety 1. Have no additional lost-time injuries. 2. Reduce medical cases by 40%. 3. Institute a Plant Safety and Health Manual Program. 4. Complete OSHA Compliance Action Plan Review. 5. Complete fire training ground and establish a "hands on" fire fighting training program. Program to cover all operations personnel. 6. Establish a first aid training pro gram to provide emergency care training to all operations personnel. Results 1975 2 H P .30 None 4 I h 6/1/76 None Partial * NAME G. G, Draper Aberdeen Plant Objectives 1976 Actual Results 1976 Goal achieved. The plant has operated 373 days without a lost-time injury. 5/1/76 6/1/76 10/1/76 8/1/76 Manuals have been issued to all plant supervisors. To date, the Safety and Health Policy and twelve supporting procedures have been published for inclusion in the manual. Review completed. Fire training facility was completed in July, 1976. Phase I (Classroom) of this program was completed in December, 1976. Field exercises are scheduled to start 2nd Qtr. 1977. r Two first aid training sessions were conducted during 1976 for all plant personnel. The first during March and April and the second during November. The Lead Lab Technicians had a special, intensified first aid refresher training course during February. * . .1.. .. .- f VAB.0001031374 * A. QUANTITATIVE GOALS Safety (Cont.) 7 Establish plant-wide safety suggestion program. Results 1975 None 8. Establish a "Safety Certification" program for operations personnel. None Production 1. Establish a stream factor imporvement program for vinyl reactor department. Program goal to achieve 95% stream 90.6 factor by 12/1/76. (last 4 months) .2 MM pounds (Could depend on market conditions). Cost Control 1. Operate within fixed cost budget for maintenance materials, contract cost salary payroll, operating supplies and unclassified. 118 MM $3,293.5 M Objectives 1976 Actual Results 1976 4/1/76 6/1/76 The Employee Safety Action Request (ESAR) program was established in April. The program processed 68 ESAR's during 1976. Program was delayed due to personnel changes. Currently scheduled for 1st Qtr. 1977. 95% 155 MM Program was defined by 8/13/76 and the portion requiring minimal expenditures implemented in 1976. The stream factor for the 4th Qtr. 1976 averaged 94.3%. 178 MM lbs. $3,067.3 M $2,995.4 M . |l s ^ H- 4-r* VAB.0001 B1375 NAME C - C Draper Cost Control (Cont.) 2. Operate at or below budgeted VCM usage per pound of PVC. 3. Reduce raw material inventory levels. Personnel * 1. Reduce average overtime rate by 15%. Results 1975 1.0425 $1,250.7 M 12.8% (last 6 months) 2. Reduce average absentee rate by 10%. 2.6% 3. Meet Affirmative Action Plan goals for 1976. 4. Eliminate temporary and contract salaried personnel and replace with permanent personnel as required. (Exception: Maintenance Engineer). Objectives 1976 1.0256 $ 925 M 10.8% 2.3% 12/31/76 12/31/76 1.0139 $ 927.6 M Actual Results 1976 The average overtime rate for 1976 was 12.0% The overtime rate was adversely affected by the requirement to bag Oklahoma City resin. The average absenteeism rate for 1976 was 2.7%. A formal absenteeism policy was developed in the 4th Qtr. 1976 and is scheduled for im plementation on 2/1/77.. As a result of manpower reductions, there were few opportunities for meeting Affirmative Action goals. One female employee was promoted to the Buyer position which had historically been fillec by a male. All salaried employees on loan from Ponca City have been replaced by permanent employees with the exception of the maintenance engineer who will complete his CED training program in March, 1977. Two contract personnel have been retained for Capital AFE projects. "I-*'- I >Vll VAB.000: 031376 C a ii Hi C. ft. Drapor A. QUANTITATIVE COALS Cost Control (Cont.) 2. Operate at or below budgeted VCM usage per pound of PVC. 3. Reduce raw material inventory levels Personnel 1. Reduce average overtime rate by 15% 2. Reduce average absentee rate by 10%. 3. Meet Affirmative Action Plan goals for 1976. 4. Eliminate temporary and contract salaried personnel and replace with permanent personnel as required. (Exception: Maintenance Engineer). Results 1975 1.0425 $1,250.7 M 12.8% (last 6 months) 2.6% 6 Objectives 1976 1.0256 $ 925 M 10.8% 2.3% 12/31/76 12/31/76 1.0139 $ 927.6 M Actual Results 1976 The average overtime rate for 1976 was 12.0%. The overtime rate was adversely affected by the requirement to bag Oklahoma City resin. The average absenteeism rate for 1976 was 2.7%. A formal absenteeism policy was developed in the 4th Qtr. 1976 and is scheduled for im plementation on 2/1/77. As a result of manpower reductions, there were few opportunities for meeting Affirmative Action goals. One female employee was promoted to the Buyer position which had historically been fillec by a male. All salaried employees on loan from Ponca City have been replaced by permanent employees with the exception of the maintenance engineer who will complete his CED training program in March, 1977. Two contract personnel have been retained for Capital AFE projects. VAB.0001 031377 A. QUANTITATIVE GOALS Personnel (Cont.) 5. Establish a long range maintenance employee training program. p i 3 None k Labor Relations 1. Reduce grievance activity level by 50%. (Except for dicipline). Energy Conservation 1. Fully implement the energy conserva tion program by April 1, 1976. Partial 2. Reduce energy consumption by an aver age of 10% on a BTU/pound of product basis. (OSHA and EPA additional neec expected). 2625 k NAME G. D Objectives 1976 Actual Results 1976 6/1/76 The following mechanical training programs were conducted in 1976: Duration Mech.SSupv Welding School 3 wks. 3 Pipefitters School wks. Rotating Equip. School days Inst. School 3 days Electronics School 4hrs./wk. (started 10/12 continuing) Planning Sched. School 8 days A long range program detailing needs as well as approach will be developed in 1st Qtr. 1977. 4/1/76 Program was implemented on schedule with the exception of the formal "employee awareness program". This program will be included as part of the 1977 goals. 2350 2189 i I* i h. b- 'iff VAB.00 31031378 Pollution Abatement 1. Obtain a particulate emissions permit . m 2 Complete process design work on EPA- VCM proj ects by 11/1/76 AFE proprojects by 12/1/76. Chemical Exposure 1 Complete de-regulation as follows: A. All areas except large reactors, laboratory and VCM unloading.. t 2 Complete survey of chemical exposure levels by 10/1/76. VCM Residuals 1 Reduce VCM shipment residual levels to 10 ppm maximum on all but 5305 product. 2 Reduce VCM residual levals to 1.0 ppm maximum on all but 5305 product. Quality 1. Reduce number of quality complaints by 30%. NAME G. G. Draper Objectives 1976 Actual Results 1976 9/1/76 11/1/76 12/1/76 Operating permit was granted on 6/16/76. All VCM/EPA projects, with the exception of the incinerator, were designed and AFE's by 11/24/77. The incineration project was deferred to 1977 since the final EPA standard was not published until 10/21/76. 4/1/76 10/1/76 All areas of the plant with the exception of the large reactor area and VCM unloading were deregulated on 4/1/76. Progress in this area was affected by personnel changes. Program was reevaluated in Dec., 1976 and a revised schedule developed. 8/1/76 The average for 707 shipments samples from 4/1/76 to 1/1/77 was 1.12 ppm This excluding 5305 resin. Same as above. 25 A total of 45 quality complaints were filed in 1976. Of these. 14 were found to be not justified after investigation. VAB.0001 331379 A. QUANTITATIVE GOALS Quality (Cont.) 2. Reduce "H" grade resin production. General 1. Complete writing of AFE's on all active 1976 Capital Budget projects by 12/1/76. NAME L Results 1975 i 1.93% 4 b b n * 12/29/75 Objectives 1976 1.50% t 0.70% 12/1/76 * Actual Results 1976 --r|T l'-H ir? ................ T '+*- * VAB.0001031380 NAME G. G. Draper B. STRETCH GOALS Results 1975 Safet 1. Reduce medical cases by 50% * h a 4 30 Production pounds p i 118 MM Labor Relations 1 Negotiate a favorable contract with out a work stoppage by hourly personne1l . < Energy Conservation 1. BTU/lb OSHA consumption 2,625 * i Chemical Exposure 1. Complete de-regulation plans by 8/1/76. m VCM Residuals 1. Achieve <1.0 ppm level by 5/1/76 _r 4 r .1* Objectives 1976 Actual Results 1976 15 15 4 i 165 MM 2,230 178 MM lbs. 4 A new 2 year Labor Contract was successfully negotiated on 3/20^y without a work stoppage. 2,189 BTU/lb. All areas of the plant were de-regulated on 4 4/1/76 with the exception of the large reactor area and the VCM unloading rack. Several ex posure abatement projects were identified and AFE'd for these two areas in 1976. 5/1/76 Average for 707 shipment samples from 4/1/76 to 1/1/77 excluding 5305 resin was 1.12 ppm. VAB.OOOlt f C. SPECIAL PROJECTS TO BE ACCOMPLISHED DURING YEAR (NON-QUANTITATIVE) NAME G. G. Draper f Safety 1. Improve employees and supervisors safety awareness. 2. Upgrade quality of monthly safety meetings. Cost Control t 1. Establish an improved cost review program. * 2. Prepare 1977 fixed cost budget on a ''ordinary and extraordinary" item basis. Chemical Exposure 1. Reduce VCM exposure levels so that area use of gas masks is unnecessary. Personnel 1. Conduct general supervisor training meetings to upgrade quality of supervisory personnel. RESULTS ACHIEVED Progress was made in this area with the institution of the "Employee Safety Suggestion Program" and enrolling of all supervisors in the National Safety Council's Supervisors Safety Home study course. To date 31 supervisors have completed the home study course. Some progress made in this area. However, there is still a lot of room for improvement. Minimum progress made in this area due to higher priority work, re-evaluated for inclusion in 1977 gq^ls. 1977 Budget was prepared on "ordinary and extraordinary" basis. After de-regulation of the plant in April, 1976,/gas\masks have only been required for specific jobs, i.e., hooking up~arfa disconnecting railcars, changing VCM filters, etc. Area use of gas masks are only required in an emergency. Supervisors training meetings were held on a monthly basis in 1976. The meetings lasted approximately 2 1/2 hours each and covered such topics as safety, labor contract, EEO, plant accounting systems, etc. VAB.0001331382 NAME G. G. Draper C. PROJECTS TO BE ACCOMPLISHED DURING YEAR (NON-QUANTITATIVE) RESULTS ACHIEVED Personne1 (Cont.) 2. Complete re-organization plans on functional lines. The Yard and Order Entry functions were placed respectively under the Operations and Administrative Services Departments. This move eliminated one supervisory position. The Mechanical Engineering function was placed under the Plant Superintendent. This function had previously reported to the Plant Manager. The Administrative Services Department was reorganized to eliminate the Plant Controller position. General 1. Upgrade plant facilities in area of stores, shops and laboratory. 2. Upgrade housekeeping standards. 3. Improve scheduling of design and installation of capital projects and improve quality of Capital Budget. 4 / Labor Relations j / 1. Negotiate a favorable labor agreement No production penalty to be sustained in the eventyof a work stoppage. An AFE was submitted and approved in 1976 for relocation of the stores warehouse. This project is scheduled for completion, in 1st Qtr. 1977. The area vacated by the stores warehouse will then be revised for use as Instrument/Electrical shop. Plans for upgrading the Laboratory were finialized in 1976. An expense AFE for this project will be submitted in 1st Qtr. 1977. Good progress was made in housekeeping standards in 1976. A detailed schedule for all 1977 Capital Budget work was completed in 1976. This schedule outlines timing of project from the process design stage through construction. This schedule was utilized in obtaining CED's commitment for engineering support in 1977. A favorable labor agreement was negotiated without a work stoppage on 3/20/76. i. *> i . a t i- p ... j, .' ...j ..v p-H. *' v -M.PS nl r- 11: k* i'-iMWI --Ik* IHf-ivl hii;-W I. . -L- VAB.000 31383