Document J3Bypb3MOKKgJ6wegvQaZeL0v
T. H. Huffman
From: Date
Subject:
D. C. Skokna October 22, 1990
ABERDKEM MKHRHLY PROGRESS REPORT SEPTEMBER, 1990
There were no injuries reported during September. For FY1990, the plant experienced five recordable injuries (the safest year since we became Vista). As of 9/30, the plant's employees have com pleted 4,105 days (5,473,212 manhours) since the last lost time inj ury.
September
Y.T.D.
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
41.5 87.7 96.9 1.00092
5.4 96.3
5.5 99.8
1.8
87.4
< 5.8>
<351.4> < 40.9>
457.4 88.4 97.4
1.0005 71.3 97.9 60.9 99.4 18.0 85.7
< 6.9>
<105.9> 680.5
Operations
The Cleanwall Project started up successfully. Quality remains good.
The Low Molecular Weight Resin Expansion Project started up by
making a batch of 5305 in D-600. Reactors 300, 400, 500, 741 and
742 were shut down for annual rupture disc changeout, hydroblast
ing and dye-penetrant testing.
im
*
,
September's production set a new thirty-day month record. The fourth quarter resin production (120.9MM pounds) set a new quarterly record, and the FY1990 production is an all time record.
Flexible compound demand was below average and inventories in creased by 0.3MM pounds. PLENEX polymers development used thirtythree hours of Line I's time. In FY1990, production of millscrap was reduced from 2.0% of production to 1.2% (the current rate is under 1%). This accomplishment was the result of a natural team proj ect.
VAB.0001189942
T. H. Hoffun 10/22/90 Aberdeen Monthly Progress Report - September, 1990 Page 2
#r
> TIL-
W
Rigid compound business was good all month, Several serious quality problems were reported at major accounts, Teams have been formed to investigate.
Cot
Variable costs were $41M unfavorable due to an unfavorable product mix in the Compound Department partially offset by good raw material efficiencies in the resin and plasticizer units.
Fixed costs were $351M unfavorable due primarily to a $258M write off of the Line III Expansion Project that was cancelled in 1984, and a $43M unfavorable benefits clearance.
mi
All of the plant's natural teams met during the month.
Twenty-two teams were recognized for project successes at the third annual Quality Appreciation Day held on September 24 in the plant's auditorium. The results of these teams' efforts will improve the quality of our products, productivity and the environment.
The Area II Maintenance Natural Team made its pre sentation to Management. They justified the pur chase of a portable steam cleaner. This investment will be recovered in under six months by reduced outside cleaning costs.
The Area I Maintenance Natural Team made its pre sentation to Management. This team recommended changes to the placement and attachment of reactor manway covers to improve the safety of opening and closing the manways.
Lou Makakanja, Nibco Inc.'s, Quality Engineer, visited the plant to explain Nibco's product quality data requirements and increased our under standing of Nibco's quality needs.
Preliminary results show Aberdeen's Q-Scorecard at
10.8.
VAB.0001189943
r
9k
T. H. Hoffman 10/22/90 Aberdeen Monthly Progress Report - September, 1990 Page 3
QMP - Contlimed
Flexible compound off-grade was reduced form 2% to 1.2% of production.
m Prime resin improved from 95.6% in FY89 to 97.4%. We received a 5 Star Rating from AT&T (flexible compound
customer) - their highest. Reactor seal repairs were reduced from twenty-two in FY89
to seven in FY90. m The graininess problem at Klockner (5305 resin) was solved. The contamination problem at Southwire (5415 resin) was
solved. Southwire is our largest customer.
Floor sweep, a hazardous waste, was reduced 26,000 pounds a Waste oil, also a hazardous waste, was reduced 279,000 pounds a VCM emissions were reduced 3629 pounds - a 5.5% reduction. Resin dust was reduced 175,000 pounds - a A water recycle project in plasticizer reduced water use by
Paper and aluminum cans are being recycled.
D. C. Skokna Plant Superintendent rah
* mm mm
VAB.0001189944
DISTRIBUTION
(
ENTIRE REPORT
Houston
J. D. Burns
X
R. T. Ferrell
X
T. H. Huffman
X
C. J. Hatson
X
D. F. Harman
X
H. R. Flammer
X
R. R. Smith
X
B. J. Bean
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
H. D. Garrison
X
LCVCM Plant
R. A. Conrad
X
LCCP Plant
J. Friend
X
LCLAB Plant
J. W. Ware
X
ft* 11 iimt
L. R. Bauer
X
J. Pavao
X
Blane
C. R. Miller
X
Aberdeen
P. L. Foote
RWS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, MRK, DAB, DAM, RBN, JEN, JDO. REP. BLT
X
VAB.0001189945
mmtm
SAfljLTf - B. L. Trego
First Aid OSHA Recordable
Total Injuries
+
Number of Restricted Workday Cases Number of Lost Workday Cases
0 0 0
0 0
Fiscal
15
20
3 0
Fiscal
Y.T.P. 1989
/
3 0
Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehous e Office
Totals
Injuries bv Type
Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other
Totals
02
04 0 14 01 01 0 __2 0 24
076
012 04 6 024
014 030
0 JL
0 24
Lost Workday Cases Days Lost
Safety Record
Last lost time injury - 7/5/79
Days since -
4,105
Employee hours since - 5,473,212
On September 30, 1990, the employees of the Aberdeen plant completed 4105 days with no lost time injury.
The main topics for safety meetings during September were "Infection Control" and "Lift Truck Training".
A
mmmrnrn
VAB.0001189946
m
SAFETY - Continued
The plant had only five OSHA recordable Injuries in FY1990. This makes it the safest year since becoming Vista.
Routine dosimetry results for the month were:
Chemical
VCM Lead Total Particulates
Monthly Inlurv Summary
No injuries were reported.
74 100.0
0
4 100.0
0
6 100.0 0
Percent
0 0
0
VAB.0001189947
All of the plant's natural teams met during the month of September. Some of our team highlights for the month were:
Area II Maintenance Natural Team made their pre sentation to Management justifying the purchase of a portable steam cleaner. The steam cleaner will pay for itself In less than six months by reducing outside cleaning costs. The steam cleaner will also save money by extending the life of expensive equipment.
The Area I Maintenance Natural Team made their pre sentation to Management justifying modifications to the placement and attachment of reactor manway covers. The team explained how rotating the exist ing hinges, adding a second set of hinges (D700, 745), adding safety chains, and increasing the size of jacking bolts can save a life and reduce the amount of time required to open and close a reactor.
The plant held its third annual Quality Appreciation day on September 24 in the plant auditorium. Twenty-two Manager's Quality Awards were presented recognizing teams for the completion of their projects (up from eight in FY89). The teams receiving awards were:
Project Engineering Natural Team
Millscrap Team
Lab C-Shift Natural Team
Team (2)
al Team
Team I&E Natural Team
Team
Team
Scheduler/Planner Natural Team
Lab/Vinyl Team
Team
Recovery System 1
or Blinding Team Team
Team
Team
Team
Purchasing Team
Team
The projects completed by these teams will have a positive impact on the quality of our products, the productivity of our employees, the safety of our workplace and the quality of our environment.
VAB.0001189948
Continued In addition to the above listed teams, Mike Kane, Senior Process Engineer, and former Quality Management Coordinator, was presented a Manager's Quality Award recognizing him for his contributions to the improvement of the quality systems at our plant. Lou Makakanja, Quality Engineer, withNibco, Inc., visited the plant on September 10. Our visit with Mr. Makakanja centered on Nibco's requirements for statistical data on product quality parameters. Lou was very helpful in increasing our understanding of Nibco's The Aberdeen Plant's final Q-Score for FY90 stands at 10.8, pending approval.
VAB.0001189949
COST VABTAMCMR - D. C. Skokna
Variable Costs
Product
September Efficiency
PVC Flexible Compound Rigid Compound Plasticizer
PVC
Total
$ 63.5 < 50.3> < 76.3>
<$ 40.9>
<$485.0>
< 24.0>
< 101.4>
21.8
<$588.6>
<$421.5> < 74.3> < 177.7> - 44.0 <$629.5>
The favorable efficiency variance is due primarily to below budget VCM usage and a favorable product mix.
Flexible Compound
The unfavorable efficiency variance is due to an unfavorable product mix.
Above budget use of Ti02 (due to prior month's tank gauging problems - Y.T.D. Ti02 variance is $52.5M favorable), anda an unfavorable product mix caused this month's unfavorable efficiency variance.
Plasticizer
Consumption of alcohols was under budget.
- VCM - Resin to Rigid Compound * Resin to Flexible Compound - Phthallc Anhydride - Plasticizers - Natural Gas - Alfol* 610 Alcohol - Electricity - Other Price Variances
Total
SM
<$614.0> < 100.4> < 75.4> < 20.4>
13.9 32.2 33.3 88.2 -54,1 <$588.6>
j
VAB.0001189950
Cont limed
Fixed Cost Variances
- Payroll andBenefits - MM&C - Miscellaneous - TI&D - Clearances
Variance - SM
<$ 37.7> < 0.2> < 319.1> 4.7 < Q.9>
Total <$351.4>
The variance was due to an unfavorable $43.2M benefits clearance.
r
H. M. & C.
Was at budget.
Miscellaneous
- Warehouse G/L - $258.3M Unfavorable due to the write-off of the Line III expansion project that was cancelled in 1984.
- Outside Professional Services - $25.4M unfavorable due to VMS charges (U.E.&C.).
- Wastehauling - $33.5M unfavorable.
VAB.0001189951
VlnYL - J. D. Olson, J. X. Vinoskl
The Vinyl Department had no first aid or OSHA. recordable injuries during September. This completes an injury-free fiscal year for the department.
The monthly safety eeting topic was "Lift-Truck Training and Licensing."
General
1. The BUS-80 cleanwall system was started up this month. The system is performing well and quality remains good.
2. The low molecular weight resin system on D600 was started up and is functioning well.
3. Fiscal 1990 was a record production year for the Aberdeen Vinyl Department with 457.4 million pounds of resin produced. Also, production in September set a new thirty-day mark at 41.5 million pounds.
4. The resin raw materials in the 744 account were valued at $308.9M.
Sent.
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
%
41.5 1383.3
108.4 936.0
31.2 87.7 89.8 91.7 96.9
Ppyptlmg
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).
457.4 1252.9
98.2 10672.0
29.2 88.4 83.2 93.1 97.4
Hours
462.0
Maintenance downtime (reactor cleaning and valve repair on D742, seal change on D500, reactor cleaning, jacket welding, and gear box repairs on D741, Old Module VCM line repairs, hydroblasting and condenser drilling and wiring upgrade on D300, D400 and D500).
425.5
1
w mm
VAB.0001189952
Im
VINYL - Continued
Dryer Downtime Reactor limited production.
\ gf-Iatftl Pyyntrinw
40.7
Operational downtime (centrifuge plugs, dryer cleaning, and flameouts).
35.8
Maintenance downtime (activator and centrifuge maintenance, star valve repairs, maintenance on dryer centrate lines, repairs on activator air header, #8 Bird motor repair, and screener repairs).
23.5
Kev Maintenance Work - J. B. Autrey, S. A. Truitt
Reactors 300, 400, 500, 741 and 742 were shut down for annual rupture disc changing, hydroblasting and dye-penetration check. The junction box for each for of these reactors was replaced for upgrade and upkeep.
The gearbox on reactor 741 was pulled and the spare was put under 741. The gearbox was removed from 600 and the old gearbox from 741 was placed under 600. The gearbox under 600 had severe pitting and wear on the bullgear. It will be re built for a spare.
D500 reactor seal was changed due to wear after nineteen months in service. It has been rebuilt for a spare.
Number four Bird was taken out of service due to worn bushings. The spare was installed in its place. The Bird was rebuilt and is the current spare.
The motors on #8 Bird and #4 Bird were replaced due to bad windings and bearings.
Seven major valves were changed out in the reactor area during the month.
'""N
VAB.0001189953
COMPOUND - J. E. Nickerson, K. G. Akins
Safety
The Compound Department had no first aid cases or OSHA recordable injuries in September.
The topic of the monthly safety meeting was "Forklift Training" conducted by the Safety Department.
Flexible compound inventories rose to 7.72MM pounds in September. The failure of a roll mill motor and a coupling was responsible for sixty-two hours of downtime on Line III. PL&ftSX polymers produc tion consumed thirty-three hours of production time on Line I.
Demand for rigid compounds remained steady in September. Several serious, and perhaps unrelated, quality problems have been reported at major accounts. Teams have been formed to investigate specific problems.
Plasticizer production continued to increase in September. During the month, 1.78MM pounds of plasticizers were produced. This was the highest production for fiscal year 1990.
Operating
Contoound Production
Days
Month
Avg./Dav
Line I
30
Line III
29
Line V
14
Total
% Prime
Capacity Utilization Factor
1733
58
3173
109
474
34
5380
201
96.3
.670
Fiscal Y.T.D.
23186 41106
6988 71280
97.9 .758
Hdurs
- Product Changes - PLENEX Polymer Testing - Quality Problems & Control - Miscellaneous Maintenance - Dicer Problems and Maintenance
mLine
- Product Changes - Roll Mill Maintenance - Quality Problems & Control - Miscellaneous Maintenance
67 33
22
9 4
71 62 14 11
VAB.0001189954
mmmrn
mmm
T
COMPODHD - Continued
Line V
- Product Changes - Quality Problems & Control - Miscellaneous Maintenance - Startup/Shutdown
44 26 15
11
Operating Devs____ Month
Ri^id Compound
50.0
% Prime
Capacity Utilization Factor
5470 99.8 .926
182
Downtime
Hours
- Product Changes Miscellaneous Maintenance - Quality Problems & Control - Welex Motor Replacement
58 40 17 16
Operating __Devs
Month
Avtt. /Dav
Plasticizer
30.0
% Prime
Capacity Utilization Factor
1781 87.4 .827
59
60923 99.4 .851
JLD. 18001
85.7 .672
Kev
- J. B. Autrey, S. A. Truitt
The vacuum
calcium carbonate
Line I's #1 and #2 dicers were brought down according to the preventive maintenance schedule.
Preventive maintenance was done on the crane.
The motor on Line III front mill roll was replaced because of bad windings.
VAB.0001189955
W
mmmmmifmmmmmmmm
m
tP
Iv'M >
R. E. Polk, S. C. Hillman, M. R. Kan
The modifications which allow the batch water stripper water to be pumped to the cooling towers have been completed. The system is working well. The batch water stripper stream has been period ically high in VCM causing a potential spike at the inlSt to the wastewater treatment system. TC regulations require that the VCM concentration at the wastewater system thist be less than 200 ppb.
A HAZOP was performed on this project. shortly.
' "i
A report will be issued
Production Model Building
Production model building for OASIS is essentially complete. A few customer specific models remain to be completed.
Evaluation of the contsmlnatlon related dry blend problems con
tinues. There appear to be two separate and distinct problems. One
is related to the surface pits found on extruded profiles. The pits
are believed to be formed by small pieces of line scale which do not
dissolve in the PVC melt. The other problem is related to gross
contamination of the dry blend. The contamination problem is a
periodic one. The most recent occurrences caused a customer's ex
truder screen pack to plug. Two events must occur simultaneously to
cause a problem. The dry blend screener must fail (tear) and con
tamination must be present. This problem is under investigation
with a capital project scheduled for the 2FQ91.
!
The new low mole dump system for D-600 was started up this month. One batch of 5305 was made with the system. Work continues to optimize the new controller.
PS
pi
mmmmmmmuI
--mmmmmmmmmmmmm
VAB.0001189956
mm
ENSIKEIIM - R.E. POLK, S.C. HIUHAN, H.t. KANE
AKIKEN CHEMICAL PLANT APPMVEI CAPITAL PMJECTS
AFE NMKR
Mil A51V AA09 MM MI 9 M29 1719 M09 M59 M99 FAA9 FA99 F779 6549 6459 1719 6759 6919 6139 1749 AMI 1576 ISM
HM
F59I F450 6540 6411 6430 1500 1510
m
NAM 1530
PROJECT IESCRIPTION
STATUS
ALTEMATE NAVVBAL MAS PIPELINE
TNI STSTEN NAS SEEN STASTES IP AM IS IPERATIMAL. PMCRLIST ITERS ARE IN PRMRESS.
VINTL VALVE *NAK
IMTAUAUM IS IN PIMNESS AM PIANNEI FM CRNPLETIM IN SCTMEN.
PLANT ELECHSCftL 9P6AAK
CSNSTMCTIM l$ CMPLETE. TNI PMJECT SILL IE CLMEI TO FIELI CNMRIS IN OCTIKI.
VINTL CNM|, SYSTEM MKMIZATIW
EMMEMIM IS IN PRMRESS. COKTRRL HM CRMTINCTIM IS PLANO FM CORPLETIM IN RCTIIER.
INERTS ICRWAL WICATIMS
CMWMCTIM IS IN PROMESS IITR CMPLETIM SCROOUI FM MVEROER.
PROPANE STMMMME AREA KINK SYSTEM
CMPMINI mm TRANSFER STSTEM
IMTAUATIM IS COMLETE. THE PROJECT HILL IE CLISEI TO FIELI CHANGES IN OCTIKI. IMTALLATIM IS CMPLETE EXCEPT FM PMCRLIST ITERS. FIELI CLISME IS PLAMEI FM OCTRKR.
LEA! HAMLINS AM EXP6SME REMCTIM
IMTAUiTIM IS IN PRMRESS VITH CMPLETIM PLANK! FM MVENKR.
CMPMM LINE 3 SEIMNLK LEAS HAMLIN6 IMS LEAI ITERS RAM KER PLACE! IN MK|. PMJECT CINPUTIM IS PUNNE9 FM 11/90.
CMPMM Sill MIME MIAKIM
INS LEAR ITEM NAK KEN PLACE! M MKI. CMPLETIM IS PLANK! FM 10/90.
RAILCAR ClEANIM MCI
KSIM IS IN PMttSS. PMJECT CONPLETIM IS PLAMEI FM 11/90.
COMOVM LINE 5 KATES PLASTICIZER
TK PMJECT IS CMPLETE AM IPERATIMAL. IT SILL K CLMEI TO FIELI (NAMES IN MVEIKI.
LM MIECILAI KI6NT RESIN EXFAMIM
INSTALUTIM IS CMPLETE EXCEPT FM P0KK1ST ITERS. TK STSTEI MS SEEN PLACE! INTI MERITION.
MTCIS M4 I 5 CSMARINAHM REMCTIM 1MTALUTIM IS SCKMLO FM CMPLETIM IN MVEIKI.
MTM.EM IIV.VALVE AM CMHTE REPLACERENT KSIM IS IN M9MCSS. PMJECT COVUTIM IS PLANO FM KTOIU.
NEI MTEIIAMUSES
TK MIIIML SCOPE K MM IS COHPLETE AM TK PMJECT RILL IE CLOSE! II FIELI CMMES IN KCEHEI.
CMPMM SEVER REVISIONS
CLOSE! TO FIELI MARKS.
HASTE III IEMCTIM
CLMEI TO FIELI CMMES.
VCX SIMT 6LASS KHACERENT
KSIM IS IN PMMESS. PMJECT CMPLETIM IS PLANKS FM CCT6KI.
PLANT NAIM IECTCLE
IEIM IS IN PIMOCTR. PMJECT CMPLETIM IS PIANO FM KTOKI.
PUNT IlfEHM TALK REPLACERENT
CLMEI TO Fiai CRMKS.
KMCE1 EURE I MORE CMPMM PROJECT
IMTALLATIM IS CMPLEIE M ALL IESIREI MIIF1CATIMS Tl IATE. FIELI CLISME IS PLANK! FM OCTIKI.
0L1 NOMLE RKRKIY SYSTEM ACCESS
KSflN IS HMUTC. IMTALLATIM IS PLAMEI FM 7/91.
RECOVERY VACNi PROP PRESSME RELIEF
KSIM IS CMPLETE. INSTALUTIM IS PLANO FM 7/91.
PLASTICIZER 4MR0NR AM ONLRARIM REVISING IESIIN IS IN MIMCM MITN CMPUTIM PLANO FOR BCTOKR.
MYREM TRANSFER LINE ELMK
INSTALUTIM IS CMPLETE. TESTIM IS IN PRMRESS.
5305 RESIINAL VCR IfMCTIlN
CHRNMCIMN IS PIANO TO K6IN IN OCTOIER VITH CMPLETIM IN JANHMY.
TC SPILL CRMiHMST
IMTALLATIM IS CMPLETE EXCEPT FM PMCRLIST ITERS.
TC CMPLIANCE PMJECT
IMTAUATIM IS CMPLETE EXCEPT FM PMCRLIST ITERS.
REACTOR SLMRI SItIPPIM IPTIHIZATIM
KSIM IS IN PMMESS VITH CMPLEITM PLANO FM KTOKI. INSTALUTIM IS PLANO FM MVEIKI.
PLANT RATER SISTER
EMIKEIIM II IN PMMESS. PMJECT CMPLETIM IS PUNO FM NIH991.
VEST INCINERATM REPLACERENT
KLIVEIT K TK INCSRERATH IS PLAMEI FM 3/91. PROJECT CONPLETIM IS PLAMEI FM 5/91.
HISCELLANERM CRPJEAL PROJECTS < 15R
EMipilK If IN PMMESS M 31 PMJECTS.
EAST KUKRI K TK INCMEMTM IS PLANKS FM 5/91. PMJECT CMPLETIM IS PLANO FM 7/91.
FMIGTVRE AM IFFICE ERNIPNENT
CLOSE! Tl FIELI CRANES.
VAB.OOOl189957
EHVgfiffHBHIAL - F. G. Jeanson
Water
All wastewater discharge parameters were met for the month of September.
Work continued on preparation of the NFDES permit application. Samples were taken of all the outfalls. Results from these samples will be avail able in the first part of October. All other items in tfre permit appli cation were completed. A meeting was set up in October with the State to review our water permit application once it is completed.
Waste
Shipments for the month included:
- One bulk load of API sludge to CWM in Ensile, AL.
Two bulk loads of stormwater solids to CWM in Emelle, AL.
Two applications for hazardous waste treatment facilities were submitted by private companies to the State.
The remedial investigation (RI) plan was revised to include the State's comments. A revised schedule for completion of the RI was sent to the State. Completion of final report is scheduled for February, 1991. Start-up of the RI will be in the second week of October.
Work continued on air permitting issues. A meeting was held with Legal, Environmental and the Plant to discuss our options and the contractor proposals. One contractor was chosen. A follow-up clarification letter was sent to the contractor to get a more specific estimate for their services.
The BUS-80 systems were completed and reactor rinse to the sewer was eliminated. Testing of our wastewater to pond #3 showed it to be below the 200 ppb limit. Samples of our filter cartridges were taken and sent to a contract lab for TCLP analysis. Miscellaneous
I attended the Vinyl Institute Health, Safety and Environmental Meeting and the Vinyl Chloride Safety Association conference this month.
Corporate I attended the MMA Environmental update.
I shipped a bulk load of vent dust to Royal Flex in Canada.
D. A. Moore
Fiscal Y.T.D.
A. Unadjusted EUI
<6.0%>
B. Adjusted EUI
<5.8%>
C. BTU/Lb. Product
2645.0
D. Total Energy Consumption MMM BTU 136.51
II. Plant Energy Conservation Program
< 6.7%>
< 6.9%> 2624.0 1584.69
There were fourteen energy related items completed in September, 1990. Twelve of these items were steam leak repairs. The remaining two were steam trap repairs.
fa
No. 1 No. 2 No. 3
83.2% 83.1% 83.0%
Fiscal Y.T.D.
83.4% 83.2% 83.0%
J---L -- - -J
j-lLl-.
uy
i ii 11
VAB.0001189959
mmm
flBPTHMgTOr f,f 0
Beall
Joseph R. Ganc - Process Engineer - New Hire Greg S. Norman - Project Engineer - New Hire
NONE
None
Carma Cook - Summer Process Engineer
h
VAB.0001189960
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VAB.0001189962
DEPARTMtuirtL HOURS ANALYSIS REPORT
DISTRIBUTION LIST RUS, JFC, JVU, DEPARTMENT HEADS, FILE
16/ 2/39 THRU 9/36/96
I
DEPARTMENTAL HOURS ANALYSIS REPORT
DISTRIBUTION LIST RUS, JFCt JVU, DEPARTMENT HEADS, FILE
9/ 3/96 THRU 9/36/90
43
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VAB.0001189963
m
- D. A. Barclay
There were no reportable safety Instances during the month of September. Tommy Cummings, Plant Accountant, fell at his home and broke his hip. He will be absent from work at least three months.
At month-end, we had five natural teams with a total of thirty-eight points for an average per team of 7.6 points.
Processed
Invoices Working Fund Checks Written Cost Savings Through Bid Process
ltaufih
913 36
$5,478
Y.T.D.
12,996 244
$166,638
4 k
Compound "AM Grade Compound Off-Grade (BC & Compound MSP - 90 Millscrap Dry Blend "A" Grade Dry Blend Off-Grade Resin Type I
H)
Resin Type III Vacuum Dust Obsolete/Overaged Compound
Total Packaged Warehouse
3,904,664 453,487 90,112
175 f 008
271,497 25,308
441^800
44,950 301,046 1.224.973 6,932,845
VAB.0001189964
uiihii ciaicu mu iiimK uuitis
21f212 Iff!
-tlirWR !1 NONCTSmuc
ItSIl-IILL WU-MCIAOU
,21 111,111 )2 1,322
fUlIILI comrawii
T3 2,671
ntimi covMD-ncucn ,3 171,451
in MSISKSS
22,611
inn cwND-HU tii enom-ricuai
,4 242.241 ,991 411
T0LLIK - B9U 32UIK - MCUtD
mnicnii
216,691
mu 9$,U6,tfl
Himm n mm-
ROM
m/iTc eih/toll
mu.iii
226,196
6 6
,1 121,121
276,764
6 6
66
224,221 6
6 6
6 616,666 06
179,496
499,319
,6 716,464
, ,1 221 2(2
F2ILIC IPT/1TC
,241 716,962 ,3 622,296
,116 724,646 ,2 426,496
,14 963,236 ,32 111,121
,13 232,222 ,1 664,439
IXCI/T0LL ,2 332,323
6
6 6
14,111
66
,31 664,316 ,2 666,166
6 6
,12 422,222
222,223
6 6
,6 6 796,666 6 164,969
,2 142,242
,2 422,323
,2 333,233
,242 222,222
,141 222,222
,13 669,919
tnmmtt USII nniKI C2V22H mil comm ruiticim
TOTAL SimiBII *TTI*
IISII lumucomm mu comm niiricixit
mu TTI PIC116U:
turnum USII iluiui comm mu couom punicim
20T1L ttmwi *ro*
mu mUHl C2K22D mu comm UASTlCIIIt
mu TTI
UILCil 172 6 27 1 266
FICKIf CUIIII 29 27 05 0 25 6 15 29 72
1,111 319 142 11 262 21 24 6
2,266 349 CISTOIKt COMM new CUIIII
s 15 21 79 1 12 66 27 196
656 52 111 76 975
me COMIIII 111/IPS
96 66 60 69
6 6 0
0
66
14
36 167 271 666 26 162
63 926 1,122
66 51 61 66
91 71 2 1
51
165
h
mu 224 14 52 16 322
2,777 219 564 133
3,516
TOTAL 29 166 13 9 147
294 1,236
125 4
1,659
*
VAB.0001189965
T^BOBATOBT - j. H. Edwards, Jr.
A. Safety - There were no safety incidents in the Laboratory during September. The monthly safety meeting topics were "Forklift Train ing" and "Infection Control Training*.
B. Cnitmmr Contacts - Lou Macakanj a with Nibco visited the Plant to talk to us about our 5265 quality. We discussed the 5265 windows of control and how we could improve our communication with Nibco. Lou told us how important it is for us to look at our quality data in a statistical light and a customer's perspective. He told us that we need to be proactive on explanations for trends and out-ofcontrol points.
8/27
9/18
Southwire reported that two compartments of 5415, railcar #580005, had high contamina tion and rejected the car. Aberdeen Q.C. retains and samples taken from the returned car all showed to be within specification.
Vinylume reported having problems with several gaylord boxes of RP-180 WHT 141. The product did not melt down like previous shipments of RP-180. Also, the product has a "magnetic" quality in that it sticks to your hand. The Aberdeen Technical Service Lab is investigating.
9/20
Formtech reported white streaking in brown
profile made from RP-91 WHT 110. Their
scrap
increased from 0.25% to 4.0%.
Attempts to duplicate this white streaking
in the lab have failed. Samples have been
sent to Austin R&D to identify the composi
tion of the white streaks.
10/01
Southwire reported that two compartments of 5415, railcar #45873, had high contamination and rejected the car. Samples sent from Carrollton to Aberdeen showed high contam ination and Aberdeen Q.C. retains showed high contamination. This material was made during a start-up of the fluid bed dryer after being down for cleaning and main tenance .
9
VAB.0001189966
LABORATORY - Continued
D
Customer
Product
Blane Polymers
5395
Particle Size
Dayton Extruded Plastics
RP-151 WHT 145
Color
Gold Bond
E. 2M_!an&X
MS&
RP-28 WHT 122
Semples
% on 40 Mesh
The following is a summary of residual VCM results on in-
process samples.
None of the reactor daily averages
exceeded 400 ppm RVCM during the month of September, 1990.
No. 1 R/C 1 R/C
1 R/C
Number of Samples Average RVCM, ppm
RVCM of
934 149
38 0.156
100
0.391
The following is a summary of the residual VCM analysis of shipment samples for the month of September, 1990.
Product
Samples
Average RVCM. ppm
5265 5305 5385 5395 5415 Dry Blend Debox Pond
38 151
68 8
34 56 20
4
0.077 0.094 0.213 0.169 0.038 0.051 0.123 1.127
i VAB.0001189967
ubobatqry - Continued
(based on dryer "regulars")
5265
5305
5385
12
Bulk Density Inherent Viscosity
(vs. 0.715 - 0.744) L Color A Color B Color % on Pan
(vs. 2%, max.) % thru 140 Mesh Mets I.R.
(vs. 95% of control) Hard Particles, (% > 10) Average particle size,
microns
0.57 0.82
7.56 4.00 5.67 0.71
-------------------
0.46
-- -----------------------"--"
131
0.80 1.33 0.52 2.67 4.33 3.00 0.85
--- -----------------------
0.48
-- --
-----
137
1.38 0.69
3.78
2.33 1.93
--
2.22
-- ----
5.8
158
1.46 0.49
6.00
1.44 1.39
--
0.36 7.33
-- ....
1.38
mi
1.42 0.67
6.17
6.00 3.00 0.50 3.64 2.99 1.44 0.5
174
Hardness Color Hard Particles Contamination Dicing Cross Contamination Streamers Metal
Total
H Lbs, m
75.0 85.9 -- -- --
--
<1.38> <1.58>
-- --
-- -----
160.9 <2.96>
M Libs. HI
3.2 43.6 195.3
4.5 10.5 18.2
4.8 1.7 281.8
<0.06> <0.80> <3.59> <0.08> <0.19> <0.33> <0.09> <0.03> <5.19>
Torque Rheometry Color
Total
Rejections
M Lb.
5.3 <0.10>
12.8 <0.24>
1. All six laboratory natural teams met once during the month.
2. The "Symphony" software proved to be unacceptable to use as a database program for raw material certificates of analysis and specifications. "Paradox" was purchased this month and recording was started on this new software.
VAB.0001189968
mm
mmm
RESIN Ship Date 9/04/90 9/05/90 9/05/90 9/05/90 9/06/90 9/06/90 9/05/90
9/11/90
*
9/12/90 9/20/90 9/25/90
SAMPLE SHIPMENTS SEPTEMBER 90
Product 5385 5415(New Tech.) 5385(New Tech.) 5415(New Tech.) 5415(New Tech.) 5415(New Tech.) 5305(New Tech.) 5385(New Tech.) 5415(New Tech.) 5385 5395(New Tech.) 5385 5415
Amount
Customer
50 lbs
Henkel Corporation
50 lbs.
Essex Group
800 lbs.
Uniroyal Plastics
1000 lbs.
Pierce Plastics
50 lbs.
Southwire Company
50 lbs.
United Technologies
50 lbs. 50 lbs. 50 lbs.
Leon Plastics
100 lbs.
RESISTENCIAS KARSTAN
50 lbs.
Twitchell
100 lbs.
Henkel Corporation
2X5 lbs. Achilles USA, Inc.
COMPOUND Ship Date 9/13/90 9/19/90 9/20/90 9/26/90 9/27/90
Product Millscrap Chunks 27121 NAT MSP90 Pellets 35852 NAT 17462 BLK
Amount 3 lbs. 100 lbs. 5 lbs. 50 lbs. 50 lbs.
Customer Wexford International Mr. Mike Skoag Wexford International Rohm & Haas Coalman Cable
)
VAB.0001189969
NUMBER OF NJURlES
ABERDEEN CHEMICAL PUVNT INJURIES
(TwaMi Month Running Totals)
40
i 1
i
m
20
15
10
5
0
JASON OJtF MAMJJASON EXT89F MAMJJASQN 0J'9CF M A M J J A S
TOTAL INJURES
O OSHA RECOROABLE
VAB.0001189970
I VAB.0001189971