Document DZGMwk7zngynyarRvKDmRd04

T. H. Huffman From: Date: Subject: D. C. Skokna August 27, 1990 ABERDEEN MONTHLY PROGRESS REPORT AGGHST, 1990 There was one first aid case reported in July. The plant received a Five Standard Star rating from the International Loss Control Institute as a result of the June audit. This is the highest rating that is available on a baseline audit. On 7/5/90, the plant employees reached eleven years since the last lost time injury. At month's end, the plant completed 4044 days (5,381,143 manhours) since the last lost time injury. FY 1990 Key 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 Operations July 40.4 90.7 98.3 0.99805 5.8 96.6 5.7 98.7 1.1 79.1 < 1.9> 33.4 40.0 Y.T.D. 376.9 88.6 97.4 1.0010 60.2 98.1 44.4 99.4 14.7 86.5 < 7.1> 248.6 634.0 Operation in the resin unit was very smooth. Tie-ins for the cleanwall project were completed in the Old Module. An additional six railcars of low calcium 5305 were produced for Klockner. Production was relatively low and finished inventories rose in the flexible compound unit. Line V operated ten days. PLENEX polymers development used fifty-five hours of Line I run time. Costs Variable costs were favorable primarily due to low VCM usage and a favorable product mix in the flexible compound unit, partially offset by an unfavorable product mix variance in the rigid compound unit. VAB.0001190005 T. H. Huffman 8/27/90 Aberdeen Monthly Progress Report - July, 1990 Page 2 <2M 1. All of the plant's natural teams met during July. 2. Bob Seymour visited Northern Electric. D. C. Skokna Plant Superintendent rah +P ****mmmmmm VAB.0001190006 DISTRIBUTION Houston J. D. Burns X ENTIRE REPORT R. T. Ferrell X T. H. Huffman X C. J. Matson X D. F. Harman X H. R. Flammer X R. R. Smith B. J. Bean X X R. H. Gerlach X R. D. Gamblin X W. L. McClain X J. P. Stokes X Austin R. L. Poe X H. J. Hall X LCVCM Plant LCCP Plant LCLAB Plant H. D. Garrison R. A. Conrad J. Friend J. W. Ware X X X X Baltimore Hammond L. R. Bauer J. Pavao X X Blane Premiere Aberdeen C. R. Miller P. L. Foote RWS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, MRK, DAB, DAM, RBN, JEN, JDO, REP, BLT X X VAB.0001190007 mm SAFETY - B. L. Trego First Aid OSHA Recordable Total Injuries July Fiscal Y.T.D. 1990 Fiscal Y.T.D. 1989 Number of Restricted Workday Cases Number of Lost Workday Cases Injuries bv Department 0 0 3 0 3 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Non-Occupational Injuries Lost Workday Cases Days Lost Safety Record Last lost time injury - 7/5/79 Days since - 4,044 Employee hours since - 5,381,143 On July 31, 1990, the employees of the Aberdeen plant completed 4044 days with no lost time injury. The major topics for July safety meetings were CPR and Off-the-Job Safety. VAB.0001190008 SAFETY - Continued The Vista Plant received a Five Standard Star Rating from the International Loss Control Institute as a result of its June safety audit. This is the highest rating the plant could receive with a baseline audit. Routine dosimetry results for the month were: <_________________________ Wunber Percent VCM Lead Total Particulates 78 100.0 11 100.0 4 100.0 Fvmber 0 0 0 Percent 0.0 0.0 0.0 Monthly Iniurv Summary First Aid Department Maintenance Abrasions to abdomen and right forearm * VAB.0001190009 QUALITY T. J. Arbeiter 100% of the plant's natural teams met during the month of July. Bob Seymour made an MBWA visit to Northern Electric, Bay Springs, MS. He was accompanied by Mark Washington. The Plant Manager's Natural Team began planning the third annual Quality Appreciation Day to be held during September. The Plant Manager's Natural Team communication survey results are in. Our employees have told us the most important communication items are (in order): 1. Benefit Changes 2. Training and Education Available to Employees 3. Promotions, Advancements, Successful Bids 4. Customer Communications Regarding Product Quality or Service 5. Aberdeen Q-Scorecard Their favored methods for receiving this information are (in order): 1. Bulletin Board 2. Newsletter 3. Calendar of Events 4. Safety Sign 5. Employee Meetings The Plant Manager's Natural Team is now working on ways to measure the effectiveness of communication. The Vinyl Operations Supervisor's Natural Team has set a goal for reducing pond resin. The plant averaged 200M pounds per month pond resin for the first nine months of FY90. The new goal for FY91 is 100M pounds per month. Achievement of this goal could increase cash flow by $200,000 per year! The Aberdeen plant Q-Scorecard as of July 31 was 10.65. Cost control, waste minimization, and safety continue as our highest scoring line items. Our improvement areas are natural team scores, Cpk calculation and linkage. VAB.0001190010 COST VARIANCES - D. C. Skokna Variable Costs Product July. 1990 Variance. $M Total PVC Flexible Compound Rigid Compound PVC - Total $59.9 74.1 < 93.6> < 0.4> $40.0 <$394.2> < 87.2> < 104.0> 3.6 <$581.8> <$334.3> < 13.1> < 197.6> < 3.2> <$541.8> Favorable VCM usage and a favorable product mix were partially offset by variance due to off-grade. Off-grade production was <0.0165> pounds per pound versus a standard off-grade production of <0.03719> - 56% below budget. However, lower than budget off-grade production results in a net negative efficiency variance because debox resin is credited at 28.5C pounds versus its standard production cost of 21.3C per pound. In July, we were "penalized" $71.5M due to this system quirk. Year-to-date the net negative efficiency variance due to reducing off-grade production by 33% is $253M. Flexible Most of the variance is due to product mix. Most of the variance is due to product mix Plasticizer - S0.4M Unfavorable Price - VCM - Resin to Rigid Compound - Resin to Flexible Compound - Fhthalic Anhydride - Calcium Stearate - Ti02 - Alfol Alcohols - Natural Gas - All Other Prices Variances Total M <$434.8> < 110.8> < 84.4> < 22.3> < 18.0> 11.2 24.4 28.1 24.8 <$581.8> K VAB.0001190011 PMMp COST VARIANCES - Continued Fixed^Cost Variances - $33.3M Favorable - Payroll andBenefits - MM&C - Miscellaneous - TI&D - Clearances Total <$ 5.6> 72.0 < 25.6> < 5.0> < 2.5> $33.3 Payroll and Benefits This category was essentially at budget. M. M. & C. Low activity and delay of scheduled resin unit turnarounds caused this category to be favorable. Miscellaneous - Moving, Home Assistance - $24.2M Unfavorable. - Operating Supplies - $15.2M unfavorable ($13M was mischarged and should be in Processing Supplies.) - Packaging Supplies - $31.0M Favorable. VAB.0001190012 VINYL - J. D. Olson, J. M. Vlnoskl The Vinyl Department had no first aid or OSHA recordable injuries during the month of July. The monthly safety meeting topic was "First Aid and C.P.R". General 1. Work continued on the BUS-80 injection system with tie-ins completed in the Old Module during the month. Early dismantling of the chem wash system began with the removal of the backflush filters which will be used on another project. 2. Another six railcars of decalcified 5305 resin were shipped to Klockner. Calcium levels were three to four ppm, slightly higher than previous shipments. Causes for this rise will be determined prior to the August shipments. 3. The resin raw materials in the 744 account were valued at $298.0M. - 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 u 40.4 1303.2 102.2 935.0 30.2 90.7 95.8 97.1 98.3 YTD 376.9 1239.8 97.2 8833.0 29.1 88.6 82.0 92.8 97.4 Hours 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). 423.5 Maintenance downtime (PVA ram valve repair on D744, cooling water line repair on D500, Old Module VCM charge pump seal replacement, installation of BUS-80 charge nozzle on D700, condenser drilling on D742 and D743, condenser drilling and hydroblasting on D745). 269.5 * VAB.0001190013 VINYL - Continued Drver Downtime Reactor limited production. Operational downtime (centrifuge plugs, dryer cleaning, and flameouts). Maintenance downtime (activator and centrifuge maintenance, screw conveyor repairs). % of Total Downtime 23.4 56.8 19.8 Key Maintenance Work - J. B. Autrey, J. B. Hegwood Reactors 742, 743 and 745 were shut down during the month for condenser drilling because of cooling control problems. Number five dryer was shut down during the month for repairs to one of its Trunion rollers. The Trunion roller was re placed and the dryer was put back in service. Reactors 700 and 745 were shut down during the month for installation of new nozzles for the new BUS-80 system, during which time the annual safety disk replacement was performed on reactor 700. Number five centrifuge was shut down during the month for repairs. The thrust bearing cap failed, allowing the scroll to wear against the top flange plate. The Bird was removed and replaced with a spare. The damaged Bird is being repaired for a spare. Number five Bird centrifuge was shut down during the month for motor and starter replacement. The motor starter went to ground and burned out. The motor had to be replaced because of bad bearings and windings. There was one major valve changed out in the reactor area during the month. VAB.0001190014 mw COMPOUND - J. E. Nickerson, K. G. Akins Safety The Compound Department worked without injury in July. The topic of the monthly safety meetings was "Off-the-Job Safety". General Further formulation testing for PLENEX polymers consumed fiftyfive hours on Line I. Line V operated just ten days in July to control inventories. Flexible compound inventories rose 338M pounds in July. Rigid compound rates were up 1MM pounds over June. Screener maintenance and rescreening a railcar of product were responsible for fifty-seven hours of downtime. Lower plasticizer rates in June reduced the amount of 610P avail able for shipment and internal usage. Due to processing problems and an attempt to maximize 610P shipments, inventories of byproduct intermediate grew significantly over the past two months. There- , in July, much more production time than normal was devoted to VRP/RAE production. Consequently, plasticizer rates were reduced. Only .88MM pounds of prime plasticizers were produced during July. It is expected most of VRP/RAE will be recovered by the middle of August. Operating Compound Production - Davs Line I 30 Line III 30 Line V 10 Total % Prime Capacity Utilization Factor Downtime Line X Production (M Lbs.) Month Fiscal Y.T.D- 1832 3647 _31 5798 96.6 .747 61 122 32 215 19701 34784 5756 60241 98 .771 Hours - Product Changes - PLENEX Polymer Testing - Miscellaneous Maintenance - Quality Problems & Control Line III - Product Changes li - Miscellaneous Maintenance 109 55 19 11 99 16 VAB.0001190015 * COMPOyyp - Continued Product Changes Miscellaneous Maintenance Startup/Shutdown Werner & Pfleiderer Maintenance 68 14 13 9 Operating Month Fiscal Y.T.D. Rigid Compound 31.0 % Prime Capacity Utilization Factor 5653 98.7 .946 182 44360 99.4 .835 Downtime Hfi.urs - Product Changes - Screener Maintenance & Product Rescreening - Miscellaneous Maintenance - Quality Problems & Control 61 57 33 33 Operating __Bays____ Month Production (M Lbs.) Fiscal Y.T.D. Plasticizer 31.0 % Prime Capacity Utilization Factor 1118 79.1 .470 36 14718 86.5 .684 Key Maintenance Work - J. B. Autrey, J. B. Hegwood Plasticizer reactors R-l, R-2, R-3 and R-4 were shut down during the month for cleaning of their vacuum jets. The vacuum jets were cleaned because of an ive calcium carbonate builduo. Plasticizer reactors R-3 and R-4 were shut down for repairs to their agitator shafts during the month. The shaft key that holds the agitator blades on is continually failing. Some modifications were made to the key to alleviate the problem. Line I and Line III were shut down during the month for repairs to their rotary steam joints. The rotary steam joints were replaced in both cases. VAB.0001190016 ENGINEERING - R. E. Folk, S. C. Hillman, N. R. Kane PROJECTS GENERAL 5305 Decalcified Resin The design and estimate have been completed for permanent ion exchange systems in each reactor module. The AFE for this project is being prepared. Cleanwall Technology The AFE has been approved and construction is being expedited. Startup of the system and operator training are expected to be completed in August. Production Model Building Production model building for OASIS continues. Debbie Tollison attended meetings in Houston to resolve issues about these models. Work is beginning on building customer specific models. The First Fiscal Quarter 1991 Capital Budget was submitted to Houston on August 20. AFEs for all first quarter projects were included. The IRR for the total budget is 18%. New Hire Joe Ganc from Penn State will begin as a process engineer in early September. VAB.0001190017 ENGINEERING R.E. POLK, S.C. HILLMAN, N.R.- g g 8 <n NHIIII 5? g g Ug % g g M INIII IIII UItIIIl IIIIMIIIIIIIIIIIII s g g ^g cton cn $ cn g i g & C s Xa 115 g UJ d M8 3 ill* g 3 8 3 S cn s (J Q S 5d 8 sfcfe tso* 8|C ;l| * g S ;;i * s g 8 g gs BS s cn 3g g jX 8888 Uu p*c* xi 8i IUm4p 8 ;g 8aa fig S ss a.!* g n" *g X tf S -1 -1b! 8 5s s JZ a SE gg g il|s g8 cn g 8ms X pBNB cn 8 a* cn cn cn cn cn 08 jg re cn cn cn to cn *i8S8~~a~ig5iS = 3u 8 to! cn m ggggg^gg^^SCggSSgg x3 9 to* g 3 g *s8iSs||Iggagg^slS|st | g 8 8 3 8 8 to tai g co co ^ 3 cn 3 5Ba XK Si s8 iixiiiSEE 8*n cn g SS 3 cn *s 8 cn cn * SCsO in uIi io u g UJ g i 8g 33 d - 3 g g g 8 g s! 5 i cn g g dg 8g 3si S fc toi P 88 8 S Sgg a S81 s s; a * pcmXpp S iisl 8: 28 sli NSOO N510 H520 L530 PLAWT HATER SYSTEM NEST IHCINERATOR REPLACEMENT NISCELLAREOUS CAPITAL PROJECTS < I15H FURNITURE UNO OFFICE EQUIPMENT ENGINEER!!* IS IN PN08NESS.PROJECT COMPLETION IS PLANNER FOR iM-1991. DELIVERY OF THE INCINERATOR IS PLANNER FOR2/91.PROJECTCONPLETION IS PLANNED FOR 5/91 ENGINEERIN6 IS IN PR06RESS ON 32 PROJECTS. EQUIPMENT IS ON ORDER. VAB.0001190018 * ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were met for the month of July. A bioassay test was set up for the first week in August. Waste Waste shipments for the month included: > One bulk load of floor sweep was shipped to CWM in Lake Charles, LA. A federal appeals court ruled Alabama's law banning hazardous waste shipments to CWM's Emelle landfill is an unconstitutional restriction of interstate commerce. We still cannot ship hazardous waste to Alabama until final appeals have been made. This ruling Would apparently mean the end of a similar law passed by the Louisiana legislature. An evaluation was made of sending hazardous waste to an alternate site in Ohio and Oklahoma. Suoerfund An order was received from the State this month to do a remedial investi gation of our Superfund sites. The order requires a submittal of a remedial investigation plan to the State within thirty days of the effective date of the order (7/17/90). Conoco has DuPont Environmental Remediation Services (DERS) preparing this plan. DERS expects to have the final issue the first part of August. A meeting will be set up in August with the State to review the remedial investigation (RI) plan. Arrangements for Vista to pay a portion of the RI plan were negotiated. DERS was also commissioned to write up comments on the original report issued by NUS. These comments were completed, reviewed by Conoco and Vista, and will be sent out early in August. Air A construction permit was received from the State for the VCSM project which includes a vinyl production increase of 40MM pounds. Our new max imum production when the VCSM project is compete is 500MM pounds. Additional modeling will also be completed. Scott Environmental will do two additional dispersion model 'test cases with lower overall plant VCM emissions. These cases will be completed in August. VAB.0001190019 mmmm mm ENVIRONMENTAL - Continued Miscellaneous I attended a third, third landban seminar held by the CMA. The 1991 waste hauling budget was completed this month. The semi-annual SFCC plan survey was completed. I VAB.0001190020 July. 1990 Fiscal Y.T.D. A. Unadjusted EUI <1.5%> B. Adjusted EUI <1.9%> C. BTU/Lb. Product 2498.0 D. Total Energy Consumption MMM BTU 132.43 < 6.9%> < 7.1%> 2625.0 1314.36 A. Maintenance There were eleven energy related items completed in July, 1990. Ten of these items were steam leak repairs. The remaining one was steam trap repairs. Baling Combustion July. 90 No. 1 No. 2 No. 3 (1) 83.2% 82.9% 83.4% 83.3% 83.0% Boiler number one was not operated during the month. VAB.0001190021 J . Beall Donald Barclay - transferred from Supply and Transportation-Houston to Director of Administrative Services-Aberdeen Jack Little - transferred from Director of Administrative Services--Aberdeen to Director of Administrative ro i nay i me Don Whatley - from Compound Operator back to Utility (Jerry Jenkins came back to Compound Dept.) Larry Frye - bid from P-1 Operator to Maintenance Helper. None Bobby Ward - terminated. None VAB.0001190022 Aberdeen, Mississippi Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations DEPARTMENTS Warehouse en. Plant Maintenance Laboratory Compound Vinyl Plasticizer PAR 16 13 41 24 40 33 5 80 * 171 251 JULY, 1990_______________ MONTHLY PERSONNEL REPORT Minority Employees //, Z Salaried Hourly Total a 65 72 1QZ 38Z 29Z 0 1 EMPLOYEES MIN. EMP 16 24 p 33 Hourly Min. Hired Z Min. Hired Hourly Min. Term. Z Min. Term. 0 0 0 0 Z MIN. HIRES YTD TERM YTD TURNOVER YTD a . xi o n0 a0 a0 0 a0 Q Number of Applicants: Month 0 Year to Date APPLICANT BREAKDOWN J'f Minority0 Z Minority // Female 0 Z Female 0 0 0 This total includes 2 Co-op students and 2 Summer Process Engineers. Hires (Hourly): Month 0 Year to Date 0 Terminations (Hourly): Month l Tear to Date___1 Overall Turnover .6Z Projected Annual Turnover 1Z VAB.0001190023 i J PARTHENTAL HOURS ANALYSIS REPORT Btribuuqn l is t rus, jfc , jvu, department HEADS, FILE 7 / 2/9D THRU 7/29/9$ O1 i 19 t 91 9 1 i <D 1 9 I O 1 9 *| 00CM 00f*N* 1 j NO in i i 00 00 1 1 00 CM 1 1 9 CM | NO ro CM CM ronO 1 CM i l I | i0n0 CM \ in i o CM CM * I1 to in ro ro 00 ro CM ro ro U CD CO CJ CO oOo\\ H Ul V I I * <r UJoZ CO CO o cn UoiUo) Ul coco N CO CO 2> CO CD o UJ s CO CO r- J .V CO t I OI CM I t f I in 00 in to in t 'O ro I I NO cm in ii in in to OI o ii * i ro i m to i o 1 l On 1 9 J 9 1 O 1 00 i 9 l i to 1 9 1 9 1 1 9 mi m I i 9 1 CM 1 to 1 9 1 9 1 1 9 9) 9t a in i 9 1 O a CM 1 1o 9 1 ro i On j 9 t o tin InO CO CO 00 4 ON oo CM CM j in ii o in* ii i i CNI I CM I 00 \ CM I * It in in I1 CM tn ro iii iii tn i -o ii ^ i GO I 00 *l CM I CM I CM I I moo * ro * tiii in iitii 9 1 9 1 in i in 1 in i in in * 1 1 in4 1 1 CM i CM 1 CM a CM ro 1 nO 1 On i 1 CM a ro CM 1 On a 00 l N 1 i n* CM \ i a CM 1 a I IItI o I 1CM I CM I I I iii ii cm \ I o oI CO I # in n J in ii CO CM 1 in ^ !i NO CM I CM I I I I Ul I I I iiiiitii I I I i 1 I I t I i HIM IS a 1 in a a i CD 1 ro i a E ? 1 NO i i iro |4 IPO in r-i 11 9 1 i 1t 1 I 9 9 4r 1 |1 CM I 1 9 a a 1 1 On 1 1 N" 1 1 1 i CM a \ f (in 1 CM |4 1 tin CM CM oo 00 in Oh CM in m in o in CM CM CD cm CM On ro in o* in CM ro aa 1 i 1 i a a in a 1 ro a i i ia 1 a CM i in i CM a i iin ro in a 1 a a 1 i1i ma1 i NO 1 CO a a CM 1 fs- 1 CO i On a 1 a CO 1 i CM a NO 1 i 1 in i in i a ifaia iin ICM 1CM iro a iro ICM CO ui CO s t Ui ai tits I I CD I IM UJ U g I I 3 *i s! otno 4 4 CO COCO CO 5 Zl M VAB.0001190024 M*  i Z 10 003 1 0 -40C 1 --ro i oo <E O 1 NO OZ 1 CM <r i II I IO I o 00 t I -o I 00 *o CM n i ro \ ro no M io o io I NO t 0 I CM fi l uinni l i o* ro ro nO in ro ro irIO I CM CJ r- i -o i oo m in CM ii ro- iii rcom* On n ro m ro i ro i * CM ro i I i1<00r I iro i \i i i i iu ii tl zr-- 1 kt U<C 1i11 OminO4 ifi1 ro4 i1if ^5* ro4 *r 11 l oCM ro oo CM CM o NO ro i CM Os i i CM CM I i nr 100 t4 iro Ii i i cn m in ro ino>o ii o ro CK ro Cl ro in NO in oo 0 I ro i 4i tft LU UJ w u~ accn*o >* 0 UJ -On <CO)S <c oetv o crco M* cn i *3 <* --00 QCSttCM -i ttOiCd LU i CD i cn ro i m i i i CJ* ro O in CM !> i cn n <K cn ro cn irno i in I CM \* ro I I CM i ^ I I ti CO i CM rO O CM CM On ro CM inuli cn in 4 OO 1 1 1 1 in Is" m |N i0 i in i i r-w i i * o tE ro **1 O 1 CM 1 1 1 in rS<J 1 1 1 o Os 1 1 1 in CM V in CM in LU cn cn 1 i i CM 1 CM 1 c- t 1 nO i ro ro I CM CM i ro CM \1 ^ l 1 Os i in i ro i CM 1 1 NO 1 in 1 ro i *- i ro i NO 1 ro CD ro 1 1 4- 1 On 1 ro i r- t CM i Os 1 0 ro Uoicncn I t I cn Q cn CJ in cm in t in in in in i CM in in CM tn in I* i in oo ro in i ro m On Os oo i i CM 00 ro i I H I >H o C\ 0\ o i in i 4 i c*- i j -i CD i in oo o i in 00 CM i ro in i i in oo CM ro m in i fc 1 1 t 1 i 1 i i uio 1 o to MQC | 4 H-Z i *r occn 11 0000 1--QC 1 CM tnz 1 ^ in CM 1 1 o i i 0 in 1 1 o o l 1 in fN- 1 l O 1 1 O o 1 1 in^ - | i <z> in 1 t in o in ro NO 1 in 1 00 1 ro 1 ro 1 in i i i i i NO rw oo oo CM 1 1 nO 1 CM 1 ro 1 1 l l l Os ro 0 l 1 1 1 i CM in 0K CM 1 1 1 1 1 On OO 1 1 1 1 1 in On On 1 1 1 1 1 ro CM NO 1 1 1 1 1 in in CM NO ti ii ii f LU 1 ! 3C j Hi I UI I I -- I $ ii at i !$i& cn 3i Ui 0 cn i in i in i <i i CM CM I in i in i i0 in i 0 ro i 0 in i i * i i 0 t0 i0 CM i 0 ro i i i * * * in CM 4 i i 0 04 *O irnw i i i i i i i trynf i Ui QC i i D_u1 LU i LU r-si a Z i CJ i t i cn i UJ i i LU a nO ro 4 CM n* ro in 4 CM in CM CM 00 CM in ro CM CM omo 444 in * CM On 0in tn o u- cn tn tn ****** <* VAB.0001190025 ADMINISTRATIVE SERVICES - D. A. Barclay Safety There were no safety instances for the month of July. Cost Savings Savings due to competitive bidding were $5,243 for July. Savings due to prompt payment discounts were $1,768 for July. Training New OASIS coding was taught to all personnel. * VAB.0001190026 * i vV >,. ..J'uv-iL UIIHN CIMCAL FL1IT SII!f!K AlALTSiS JUT 1999 H0IT1 POBLIC 1PT/ITC KICI/TOLL-SI1P1KITS I! PKOMCTS........................................................... UItSSIilI-PIIiCUUfill 21,724296,,694159 1,414219,,151919 174,(119 Hlunniuiui ccoommmm--nitcuuou 919,949 1,115297,,5(1919 99 119 B9SIIISS 12,699 9 9 liineu ccookwpomhi--piaiucia6U 2,615969,,417919 1,946,1599 99 TT0OLLLLI8IK6 -- PMAClIA6KB 99 09 92565,,729969 Fusncmi 269,169 9 212,926 total 29,267,912 11,997,741 1,276,929 ro PV1LIC IFT/ITC............................. nci/rou 2K2,,(1S(4I,,1$1(25 924,,912165,,215191 2,111,4(09 2114,,222772,,294429 119,,499152,,217219 99 69,972 9 9 229,,951946,,219999 9,229(11,,57919) 99 99 99 7,113694,,859695 1,5(4,441 2,275,019 1,682,839 2(4,114,542 119,294,894 11,118,685 -SIIPIUTS I! WM- BILK: IIiKLnSUil11CIBMLI MCt0jNo8PLI0T9tIB FU5T1CIX1I TOtlL JOLT FKrBuUiIGSSiiiDITIBICcuIoIciInlotmTmTDitn TOTAL TTD fiction: nITPILSLoII1XnSIITILcIKCoiCmmt0JImOP0L9TItD TOTAL JOLT mlmKuISimuTH iuccocitmnotmm!TBmt TOTAL TT9 iailcax cisronx PICIIF CCAOXHI1OIII 16211990 19991 419258 299 29 65 1,42163222136 26117219 1,862 299 CP9SICT100HP8B CCAOIMI1OIII 2593 7166 9 99 28 191 5164445949 867 TOFC COITAIIII Al/OPS 09 90 9 9 09 5 91 9 60 15 22316799 712292823 95 9 991 99 6529 21 273 935 5 1 124 TOTAL 223119852 285 2,34116973268 2,959 TOTAL 1211293 0 144 1,9219295724 1,338 VAB.OOOl190027 *. LABORATORY - J. M. Edwards, Jr. A. Safety - There were no safety incidents in the Laboratory during July. The monthly safety meeting topic was "Off-the-Job Safety Training" taught by Jerald Uptain. B. Customer Contacts - There were two customer contacts during July. Richard Williams accompanied Eric Ingram and Ken Walker to Flexible Technologies in Abbeville, South Carolina. They successfully trialed two cadmium-free compound formulations without having to make significant changes to their equipment. Jim Edwards and Richard Williams accompanied Mark Eramo to Hi-Tech Cable in Starkville to follow up on a quality complaint. They pointed out two occurrences this year when they saw I.R. values on the finished wires drop to an uncomfortable level. Austin and Aberdeen are working to regain Hi-Tech's confidence in our resin and Q.C. C. Customer 0. C. Problem Reports 7/03 Exxon. Houston. TX Exxon reported that a tank car (NATX 78222) shipment of 610P plasticizer was very cloudy. The plant made three process changes and the lab started checking in-process samples for clarity to prevent recurrences. 7/11 Vvtron Corporation. Loudon. TX Vytron reported stronger than normal odor from 17462 NAT 50516 causing workers to get ill. It is suspected that high alcohol con centration in VRP plasticizer caused the unusually strong odor. In-process alcohol content testing of all plasticizer batches was started to prevent recurrences. 7/18 Exxon. Argo. Illinois Exxon reported high suspended solids content in a bulk truck of 610P plasticizer. Another process change was made to prevent recurrences and a decision was made to put temporary dedicated supervision in the plasticizer plant and retrain the operating 7/24 Pniroval. Inc.. Mishawaka. IN Uniroyal reported seeing wet clumps in the top of a 5385 truck shipment. The truck was returned. Condensation from warm resin had collected at the top of the compartment and dripped down on the resin causing the clumps. VAB.0001190028 mm m LABORATORY - Continued 0. Requests for Corrective Action There were no requests for corrective action during the month of July. E. Product Waivers Customer Dayton Extruded Plastics RP-151 WHT 145 Reason Color No. 1 R/C Exxon F. RVCM Summary 610P Clarity 1 H/T RVCM of In*Process Samples The following is a summary of residual VCM on in samples. None of the daily exceeded 400 ppm RVCM during the month of July, 1990. Number of Samples Average RVCM, ppm RVCM of Shipment Sai?p|p-f Reactor Slurries 930 137 5265 24 0.227 5305 65 0.221 The following is a summary of the residual VCM analys is of shipment samples for the month of July, 1990. Product Number of Samples 5265 5305 5385 5395 5415 Dry Blend Debox Pond 27 87 74 8 50 58 4 0 0.088 0.090 0.201 0.060 0.048 0.042 1.657 mm VJMM mmmm mm VAB.0001190029 LABORATORY - Continued 6. Resin Process Capabilities (based on dryer "regulars") mi S2J25 5385 5395 Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Drytime Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle size, microns 1.67 0.92 ---------- ---- 4.93 2.22 1.67 0.96 -- 0.52 -- ---------- ---- ---- -- 140 1.20 2.33 1.22 1.83 4.17 2.67 0.70 -- 0.63 -- ------ --------- 138 1.31 0.85 2.47 2.50 0.96 ----------- ---- 1.40 1.67 -- -- 12.6 161 1.03 1.19 13.67 5.67 0.95 -- 0.72 1.67 2.02 --------------- 0 145 H. Flexible Compound Quality Summary 5415 1.14 1.04 4.56 6.33 2.67 0.17 3.56 1.67 3.87 1.81 0 172 Adjustments j.Is l 111 Hardness Color Hard Particles Contamination Dicing Cross Contamination Streamers 5.0 <0.09> 5.0 <0.09> ! Rigid Compound Quality Swrnnarv Rejections M J,bs 40.9 7.1 26.4 15.6 11.2 5.4 106.6 <0.72> <0.13> <0.47> <0.28> <0.20> <0.10> <1.89> Torque Rheometry Color Color & 40 Mesh Total J. Miscellaneous M ,_ (11Rejections Lbs 12.7 4.7 34.5 51.9 <0.23> <0.08> <0.62> <0.93> 1. The old Instron tensile tester, donated to Mississippi State University, was installed and calibrated. Dave Cox and Bobby Jenkins trained three teachers on its use and how to maintain it. i VAB.0001190030 mm w m HMip LABORATORY - Continued J. Miscellaneous - continued 2. A database file (in Symphony) was started to store incoming raw material analyses. This is part of the new process of checking raw material shipment certificates of analysis against Vista specifications before unloading. 3. Jim Edwards attended an all-week seminar in flexible compound technology in Austin R&D. All lab personnel were certified in "Basic Life Support" by the American Heart Association Cardiopulmonary Resuscita tion and Emergency Cardiac Care. This was a four-hour course taught by Ginny Belk. 5 All six laboratory natural teams met once during the month of July. h VAB.0001190031 mm T RESIN Ship Date 7/10/90 7/10/90 7/13/90 7/16/90 7/20/90 7/20/90 SAMPLE SHIPMENTS JULY 1990 Product 5265 5305 5385 5415 5465 5265 5305 5385 5305 Amount 300 lbs. t 50 lbs. 50 lbs. 50 lbs. 50 lbs. 5 lbs. 5 lbs 5 lbs 2 lbs. Customer ETS H1SHAM ZABIAN E. I. DuPont Rintec Corporation Capitol Wire & Cable Azrock Industries NATIONAL PLASTIC AND BUILDING MATERIAL INDUSTRIES COMPOUND Ship Date 7/06/90 7/09/90 7/11/90 7/25/90 7/30/90 Product 461-119A WHT 461-119B BLK 34642 NAT 461-120A WAT CL 461-120B WAT CL 27251 BLK 18031 WAT CL Amount Customer 1500 lbs. 1500 lbs. Central Plastics, Inc. 100 lbs. CONDUCEN 1300 lbs. 1500 lbs. Flexible Technologies 100 lbs. Philatron International 100 lbs. Fiberchem Inc. DRYBLEND Ship Date 7/24/90 7/27/90 7/31/90 m Product RP-151 WHT 145 RP-151 WHT 145 378-143 BLU 170 Amount 2X2 lbs. 2X2 lbs. 100 lbs. Customer Dayton Extruded Plastics Dayton Extruded Plastics Pyramid Plastics VAB.0001190032 PLASTICIZER Ship Date 7/20/90 Product VRP Sample Shipments/July 1990 Page 2 Amount 1 gal. Customer Plasticolor Inc. VAB.0001190033 NUMBER OF NJURIES ABERDEEN CHEMICAL PLANT INJURIES (Twefco Month Running Totota) TOTAL INJURIES O OSHA RECORDABLE VAB.0001190034 *mm & h ABERDEEN ENERGY CONSUMPTION P BTU/LB j mmmmmmmmu* en/me T VAB.0001190035