Document 9LO38nRY04KQzk82MqE9r0DXe
Monsanto
FROM ANNISTON, ALABAMA
DATE February 19, 1965
subject 1965 OBJECTIVES - TECHNICAL SERVICES AND ANALYTICAL LABORATORY
REFERENCE
TO J. H. Aldridge A. J. Koenig A. E. Leisy J. R, McClain R. G. Moody H. L. Phillips P. H. Sturman W. F. Taffee J. G. Bryant L. L. Faulkner G. C. Goodwin V. R. Haupt R. A. Haydel W. B. Dunlap K. R. Denman J. C. Price R. H. Taylor E. A. Everage
G. L. Arnett Gene Brown 0. E. Dolin G, E. Jones S. 0. Kemp N. K. Madison Jerry McGaha Gladys Morris Andy Nelson Don Turner M. E. Twigg J. J. Wooster E. G. Wright D. G. Yates
cc: D. B, Hosmer - G. 0. J. A, Mullendore - G. 0.
Attached are the 1965 objectives for the Technical
/kd Attach.
DSW 551664 STLCOPCB4090081
ANNISTON PLANT
TECHNICAL SERVICES DEPARTMENT
1965 OBJECTIVES I. Safe manufacture of quality chemicals at minimum long range cost,
A, Safety
1. Maintain major accident frequency of 0.00
(Department)
2. Attain minor injury rate of 2.50 or less,
(Laboratory & TSD)
5. Conduct monthly safety meetings (except months
of Plant Wide Programs) by TSD members.
' '(Department)
a) Train all personnel in use of Emerson Resuecitator,
b) Train all personnel in use of Scott Air Pak,
4. Engineering to upgrade plant safety.
a) Separate city water from cooling water in:
1) Biphenyl - Aroclor 2) Chlorine 5) Niran
(Price - 12-31-65)
b) Complete program to upgrade high temperature
systems in Biphenyl and Aroclor.
(Haupt - 7/1/65)
c) Investigate protective devices for liquefied
gas storage tanks in plant and take necessary
action.
(Price 4-1-65)
5, Write two newspaper articles pertaining to safety. (Department 12/65)
B, Quality
1. Develop "in-process" charts for all departments.
(Dunlap - Ch.E.-
1/66)
2, Develop a way of measuring savings and benefits
-
from quality control program.
(Dunlap - 9/65)
DSW 551665
STLCOPCB4090082
TSD 1965 Objectives - continued
Page 2
B. Quality - continued
3. Perfect quality audit form and make an audit of Methyl
Parathion.
(Dunlap - 11/65)
4. Simplify scoring and reporting procedures.
(Dunlap - 7/65)
5. Make new PNP batch sheets as combined chart-log
form.
(Dunlap-Taffee-Voss 4/1)
6. Establish a complete quality monitoring system in
one department - process control charts incorporated
into batch data sheets, with adaptive control adjust
ments if feasible - a procedure for evaluating status
of in-process control.
(Dunlap - 1/66)
C. Cost Improvement
1. Attain specific cost improvements of at least $206,000
as detailed in the 1965 Cost Improvement Program. (Department 1/66)
2. Emphasize cost improvements by posting charts for
each product showing target and actual performance. (Engineers)
D. Process Improvements
1. Maintain technical effort on process improvements
of 45%.
(Fuhrmeister - ChE)
2/ Develop process improvement plans for:
Biphenyl
(Haupt 4-1)
Aroclor
(Haupt 8-1)
Chlorine
(Faulkner 4-1)
II. Employ and train manpower for growth of plant and to effect manufacturing
cost improvement.
A. Personnel
1. Hire personnel to fill manning chart.
(Fuhrmeister - 8/1)
DSW 551666
STLCOPCB4090083
TSD 1965 Objectives - continued
Page 3
A. Personnel - continued
2. Develop training program to fulfill department
needs. Program to include training seminars,
educational trips, participation in plant economics
course.
(Fuhrmeister - 3/l)
3. TSD personnel to develop personal objectives for
self-improvement and job objectives. To be
reviewed quarterly.
(Fuhrmeister - 12/65)
4. Establish job specifications foreach job.
(Fuhrmeister - 12/65)
5. Revise job description for Chemical Engineer to
establish separate description for B - D and
Senior level engineers.
(Fuhrmeister ChE *s - 8/1)
B. Function
1. Complete and issue TSD Guidelines.
(Fuhrmeister Engineers)
2. Discuss TSD function with manufacturing groups. (Fuhrmeister - 7/1)
3. Relocate department to improved facilities
and/or develop plan to upgrade existing
facility.
(Fuhrmeister)
4. Develop three ideas to improve effectiveness
of TSD.
(Department)
I
DSW 551667
STLCOPCB4090084
ANNISTON PLANT ANALYTICAL LABORATORY
1965 OBJECTIVES
A. Safety
1. Reduce minor injuries to frequency of 2.50. Maintain serious
injuries frequency of 0.00.
(Department)
2. Eight of monthly safety meetings conducted by an Analyst or
Technician with an average attendance of 85% or better of
total lab personnel.
(Dolin)
B. Personnel
1. Establish job specifications for all laboratory employes. (Dolin - 7/1)
2. Hold four training meetings for laboratory personnel during
year. One meeting to feature guest speaker from Chemistry
Department of Jacksonville State College.
(Dolin - quarterly)
5. Add one experienced Chemist for method development. (Supt.-Dolin-Pers. 8/1)
4. Develop a training program for department. Program to
include visits to other Monsanto locations and technical
meetings by Analysts and Chemists. Chief Chemist to attend
one technical meeting and one managerial training course.
Consideration will be given to attitude surveys and implementing
personal objectives.
(Dolin - 3/I)
C. Facilities
1. Develop long range program to improve laboratory facilities.
Program will include a new building or additional area in
present building.
(Supt. and Dolin - 9/1)
DSW 551668
STLCOPCB4090085
Analytical Laboratory 1965 Objectives
Page 2
D. Function
1. A minimum of three significant new analytical procedures will be
developed and used routinely. (Niran and MEP assay by GLC, Liquid
Aroclor isomer distribution, purity of thio acid by GLC. (Dolin 12-31"65)
2. Twenty percent of current analytical procedures will be reviewed
and upgraded as indicated. (Dolin-Technicians 12-31-65)
3. There will be no delay in scheduled start-ups due to lack of
analytical service.
(Dolin)
4. Develop comprehensive five year program to cover future needs of
department and maintain technical competency. (Supt. and Dolin - 12-1-65)
E. -Cost Improvement and Control
1. Reduce the use and/or cost of two major laboratory supply items,
(acids - Helium).
(Dolin and Technicians - 12-31"65)
2. Institute or improve procedures to effectively measure and control
quantity and quality of laboratory work, supply costs, accuracy
of methods developed, and housekeeping.
(Dolin - 10-1-65)
0S\N 551669
STLCOPCB4090086
THE ULTIMATE TARGET 1. Eliminate waste product and rework 2. Eliminate customer dissatisfaction
3. Promote sales
4. Assure uniformity and conformity to typical product 5. Accumulate process knowledge
6. Continually promote process and product improvement
We will evaluate progress by checking against these goals.
We need strong methods and procedures. - DETECTION - REPORTING - CORRECTIVE ACTION - PROMOTION
Quality is made in the operating departments.
qS\N 551670 STLCOPCB4090087
-2 DETECTION Objectives; Determine key check points in process. Monitor observations at these points to provide instant information on shifting control.
Methods; In-process charts with action limits. Raw material and finished goods charts. Incorporate in-process charts into batch sheets. More sophisticated methods.
Responsibilities;
I Line, Operating
/
J
Design /
the - -
Monitor \
System
\
\
Q.C.
TSD
Use system Maintain system
LAB - Use system
REPORTING Objectives;
In-process control, Intermediates, product For operators, an instant status observation For Management, QC-TSD, the summary required for surveillance and study
OSW 55A671
STLCOPCB4090088
-3REPORTING Objectives: - continued Raw materials For operations, prompt warning For Management, QC-TSD, a summary Overall plant status summarized Monthly review by QC Board QC-TSD routine status reports on quality improvement studies.
Methods: Weekly report on deviations by plant Weekly report on product, raw material, Intermediate deviations by lab Weekly deviations summary by Q.C, Biweekly status reports by QC-TSD on quality improvement studies Monthly on department quality scores by Q.C. QC Board minutes assign responsibility
Responsibility:
.Operating Dept.
1
In-process Weekly Divergence Report|
Quality Control Board
Laboratory
Technical Services
r^-
Raw material
Intermediate Product
Divergence
Report i <y i
Department ------------- ^
Process Improvement Status Report
Quality
Control
T
Weekly Divergency Summary
Monthly Quality Score Summary
Process Improvement Status Summary
&
Minutes assign remedial responsibility
STLCOPCB4090089
-4 -
CORRECTIVE ACTION Objectives:
Prompt remedial action by operators
Production department efforts to eliminate causes
QC-TSD assistance comes in automatically
Quality Control Board assigns responsibility for corrective effort when needed
Establish procedures for preventing bad quality by eliminating quality "traps"
Methods:
Good supervision at all levels
After a check-point has been out 3 weeks, a study is initiated by
QC-TSD, given a job number, recommended action brought to the Board, routine reports of status issued until problem disposed of
Quality Control Board reviews problems, assigns responsibility for action, a report is entered as "unfinished business" in the agenda for that meeting
Carry out quality audits to locate "traps"
Responsibility; Production
OC-TSD
--------------------- y.
3 Weeks
OC BOARD
1 Mo.
oc BOARD
2 Mo.
v r
etc.
PROMOTION
Objective:
Operating people of all levels are involved in continuing and special programs to keep quality demands in mind.
0S\N 551673
STLCOPCB4090090
5PROMOTION Methods: Special committees bring in new ideas and broaden participation Overall promotional program is guided by the Quality Control Board Responsibility: Organization - Quality Control Board Technical work and assistance - Q.C.
SPECIFIC TARGET FOR 1965 1. Establish a complete monitor system in Chlorine Plant, with a full
reporting procedure. 2. Establish practical in-process charts for all operating departments.
3. Simplify scoring and reporting procedures.
4. Establish automatic QC-TSD study when a checkpoint has been abnormal
3 weeks, with regular progress report on status.
5. Make new PNP department batch sheets as combined chart-log form.
6. Carry out a container weight study to determine need for continuous
surveillance. 7. Perfect the Quality Audit form. Make audit of one department.
8. Devise a way of measuring the benefits derived from the plant Quality
Control Program.
DSW 551674
STLCOPCB4090091