Document JNE0Rwwv3o5dGVaVO4ejjLwqK

t To: T. H. Huffman IflIPM lllllifl Communication From~ c* Skokna February 19, 1990 ABERDEEN MONTHLY PROGRESS REPORT JANUARY, 1990 There was one first aid and one recordable case reported during January. The recordable case involved a maintenance employee who suffered caustic burns to his feet. At month's end, the Aberdeen plant's employees have worked 3863 days (3,125,576 manhours) since the last lost time injury. FY 1990 Kev Statistical J anuarv 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 39.9 90.0 96.6 0.9936 5.3 98.3 5.5 99.9 1.4 85.5 < 8.4> <10.8> 218.0 143.0 83.0 96.7 0.9995 23.7 97.9 17.1 99.4 5.6 89.5 <12.8> 19.4 268.0 Factors Resin Flexible Compound Rigid Compound Plasticizer 105.6 69.0 93.2 73.3 95.4 76.1 99.4 77.0 Waste Reduction Indices (%) Offsite, Hazardous Wastes Recycled, Hazardous Wastes Offsite, Non-Hazardous Wastes Vulnerable By-Products Total Waste Water Air and Water 157.7 57.9 74.6 100.5 113.8 82.6 141.5 60.6 81.3 95.7 115.7 83.3 (1) Three-month rolling average. VAB.0001190202 * T. H. Huffman 2/19/90 Aberdeen Monthly Progress Report - January, 1990 Page 2 Operations A clean wall agent was tested in reactor D745. Initial results are promising. Resin properties and quality were not significantly impacted. Lucidol 288 catalyst was used to make a 5415 resin batch. This is a less expensive material than the catalyst currently used. No noticeable difference was noted between normal production and the trial batch. More extensive trials are scheduled for February. Maintenance problems on Lines III and V, along with increased product demand, tightened flexible compound production schedules. A PLENEX polymer run was made on Line I. Demand for rigid compound surged during the month. On January 6, a new one-day production record of 356.6M pounds was set. The previous record was 351.6M pounds set on 6/1/85. Costs Variable costs were favorable due primarily to good VCM usage and to product mix effects in the compound department. Fixed costs were essentially at budget. OMP 1. Production of off-grade resin for 1990 YTD is 0.0326 lbs./lb. versus the FY1989 average of 0.0441. Most of the improvement is the result of the Vinyl Operations Superin tendent's Natural Team's changes in startup procedures. 2. The month's millscrap production in the flexible compound department was 0.0111 lbs. /lb. versus last year's average of 0.01968. The improvement was a result of procedural changes that were implemented by the Millscrap Reduction Team (This is Bill Davis's natural team. Bill is a shift supervisor). 3. CAPCO, a 5385 resin customer, visited the plant to learn more about our rigid compounding and quality control methods. 4. Twitchell's R&D manager visited the plant to learn about 5415 production. t j VAB.0001190203 mm T. H. Huffman 2/19/90 Aberdeen Monthly Progress Report - January, 1990 Page 3 5. Dayton Extruded Plastics (DEP) visited the plant to discuss dimensional stability problems they are having with our rigid compound. They agreed to participate in a D.O.E. involving the raw materials used in their dry blend. 6. All first and second level supervisors met with plant management to discuss barriers they experience to QMP. Also, information was exchanged about our plant's businesses. 7. Twenty-two employees were trained to be on the Facilitator Team. This group will work with the plant's natural teams. 8. On 1/26, a team evaluated the VCM Plant's quality systems. 9. Sixty-three percent of the plant's natural teams met during the month. Projects The alternate natural gas line was tested. We will begin using natural gas from ACG via the new line on 2/1/90. Savings are approximately $1000 per day. Doug Skokna Plant Superintendent rah A i mW VAB.0001190204 w mm DISTRIBUTION Houston J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin W. L. McClain Austin J. P. Stokes R. L. Poe X H. J. Hall Oklahoma City LCVCM Plant H. D. Garrison R. A. Conrad J. Friend LCLAB Plant Baltimore J. W. Ware L. R. Bauer X X Hammond J. Pavao X Blane Premiere C. R. Miller P. L. Foote Aberdeen RWS/DCS (File Copy), JDO, JEN, MRK, DAM, JEB, JRW, JEL, REP, BLT, RBN, SCH X X X X X X X X X X X X X X X X VAB.0001190205 SAFETY - B. L. Trego, J. V. Uptain Fiscal Fiscal First Aid OSHA Recordable Total Injuries 1 JL 2 6 8 Number of Restricted Workday Cases 1 2 1 Number of Lost Workday Cases 0 0 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries bv Type 00 02 26 00 00 1 29 Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Non-Occupational Injuries 12 01 12 01 00 01 0 2 1 0 2 2 2 0 8 Lost Workday Cases Days Lost 2 18 Safety Record Last lost time injury - 7/5/79 Days since - 3863 Employee hours since - 5,125,576 On January 31, 1990, the employees of the Aberdeen plant completed 3863 days with no lost time injury. "Hand Injury Prevention" was the principle topic for safety meetings during the month. The new Safety Handbook was completed and is ready for distribution in February's safety meetings. K rnmmmmmmmmmmm PRMMff VAB.0001190206 SAFETY - Continued Routine dosimetry results for the month were: Chemical <_________________________ Number VCM Lead Total Particulates 75 100.00 15 88.2 8 100.00 >_________________________ 0 2 0 0.0 11.8 0.0 lalacy class RWC Maintenance Maintenance Caustic bums to both feet. Cut - right fore finger. \ VAB.0001190207 CAPCO (Cement Asbestos Products Company), which buys 5385 resin, visited the plant to learn about rigid compounding and Q.C. of rigid compound. CAPCO will begin manufacture of pipe at its Van Buren, AR facility during the first quarter of 1990. The additional pro duction will increase Vista's position from 24MM pounds to 36-40MM pounds. Twitchell's R&D Manager, Dwight Barry, visited the plant this month to learn about the production of 5415 resin. Twitchell produces coated yarns which are woven to make patterned fabrics. As a part of the visit, Dwight talked with the Technical Service Lab personnel and discussed their capabilities. Dan Preston from Dayton Extruded Plastics visited to discuss problems which DEP has experienced. The nature of the problem is dimensional instability (swell or shrink of the extruded part). As a result of our discussion, we decided to do a DOE involving the raw materials to their dry blend product. The experiment was designed and sent to Dayton for review. The material for each experimental run will be blended at Dayton's plant where the DOE runs will be made. Manager's QMP Meeting H All of the first and second line supervisors met with plant management to discuss barriers they experience to QMP and also to receive information about the plant business. Meetings were held each of two days with half the group attending each day. The feedback from the meetings was positive and all involved agreed the meetings should be held annually. Q-Scorecard Submittal The plant Q-Scorecard was submitted for approval on January 26. The scorecard included goals in the following areas: 1) Natural Teams; 2) Cost Control; 3) Safety; 4) Waste Minimization; 5) Quality; and 6) a Linkage Measure. Development of departmental support scorecards has begun. Facilitator Training A meeting was held on January 23 to train all those who agreed to be a part of the Facilitator Team. There are twenty-two trained facilitators who will work with the plant natural teams. The natural teams will be taught team techniques and work on a project in their department as their case study. VCM Plant Quality Systems Evaluation An evaluation of the VCM plant's quality systems was performed on January 26. People involved were Mike Kane (Aberdeen), Dave Hollis (LCCP), and Jim Hall (Houston - Purchasing). All involved agreed that the exchange was mutually beneficial. COST VARIANCES - D. C. Skokna Variable Costs Product Total PVC Flexible Compound Rigid Compound Pla3ticizer $136.0 53.2 14.4 14.4 $218.0 $1165.5 176.6 271.9 $1624.6 $1301.5 229.8 286.3 Z9,*Q $1842.6 PVC - VCM use was below budget. Flexible Compound - The favorable variance was due to product mix effects and a lower than normal scrap rate. The reduced scrap (0.011 lbs./lb. versus 0.0145 lbs./lb. standard) is due to the successful efforts of the Millscrap Reduction Team. Rigid Compound - A favorable product mix effect was partially offset by above budget raw material consumption. Plasticizer - VRP yields were above budget to give the overall positive variance. Price - VCM - Resin to Rigid Compound - Resin to Flexible Compound - Alfol* 610 - 610P to Flexible Compound - Natural Gas - Other Variances Total $1209.2 245.6 143.8 17.4 16.4 < 38.0> 30.2 $1624.6 - Payroll and Benefits - MM&C - Miscellaneous - TI&D - Clearances Total <$58.4> < 34.7> 88.5 14.3 8.1 <$10.8> Overtime in operations and maintenance was above budget due to operational needs and the holiday. M. M. & C. - Material costs for the Compound Department repairs were above budget. .'"'"S VAB.0001190209 COST VARIANCES - Continued Miscellaneous: Major variances in this category were Moving. Home - $13.3M favorable. Unclassified - $18.4M favorable. RFS transferred to this prolect's capital AFE - $21.3M favorable. T.L.& D. - This category was $14.3M unfavorable due to a $16.1M unfavorable FICA variance. The FICA is based on cash payroll which includes five pay periods this month. wmmmmmmmmmmmmm VAB.0001190210 VINYL - J. D. Olson, K. W. BIrck Safety The Vinyl Department did not have any first aid or OSHA recordable Injuries during the month of January. The monthly safety meeting topic for the monch vr^s hand safety. A video tape on hand safety and pinchpoints was viewed and discussed. Gg-PSrfll 1. 5385 was produced this month in the New Module. 2. Reactor D745 was used to test a new reactor clean wall technology. The new technology appears to have the potential to replace reactor chem wash and rinsing. There has been no detectable adverse effect on any resin physical properties. 3. Lucidol 288 catalyst was used to produce a batch of 5415. There was no noticeable difference between this resin (in cluding Mets IR testing) and other 5415 resin normally made with Witco 939 catalyst. L-288 is a less expensive raw material. More extensive testing will continue in February. 4. The resin raw materials in the 744 account were valued at $345.4M. - 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 % 39.9 1287.1 105.6 928.0 29.9 90.0 71.7 96.8 96.6 Reactor Downtime Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks, New Module rinse/charge water conflicts, no place to dump, waiting on Q.C. data before charging and filter changes). Maintenance downtime (hydroblast reactors and drill condensers D700 (IX) and D745 (2X), drill condensers D742, D743 and D744, repair agitator fluid coupling D742, repair agitator seal D300, repair Topaz unit, replace safety discs on D742 and D743, and miscellaneous instrument and valve repairs). 143.0 1162.6 95.4 3349.0 27.2 83.0 70.7, 86.3 ^ 96.7 Hours 278.5 463.8 VAB.0001190211 < mmmf RHNMMNMpMa f m A VINYL - Continued Drver Downtime Reactor limited production. Operational downtime (centrifuge plugs, check for dust collector leaking, clean dryers, activator transfer problems, and flameouts). Maintenance downtime (centrifuge repairs, rotary and fluid bed repairs, shear pins, repair rotary valve, clean fluid bed scrubber, and repair Trunion bearings. 75.3 12.4 13.3 Kev Maintenance Work - J. B. Autrey, J. B. Hegwood Reactor 745 was shut down during the month for hydroblasting and condenser drilling. This was done as part of the clean wall test run. The condenser was drilled and brushed in order to remove as much buildup on the tubes as possible. The condenser was then swabbed with the clean wall agent. Reactor 700 was shut down during the month for hydroblasting and condenser drilling. This was done as part of the contamination control program. Reactors 743 and 744 were shut down for condenser drilling during the month because of cooling control problems. Reactors 741 and 742 were shut down during the month for safety disc replacements. This completes all safety disc replacements for the year. Number seven dust collector was shut down for repairs to its screw conveyor and stub shaft during the month. The screw conveyor and stub shaft were replaced with a newly designed model. Number eight dryer was shut down during the month for repairs to its inlet screw and Trunion. The inlet screw was pulled and repaired and the Trunion was replaced. The fluid bed dryer was shut down for cleaning and Bird repairs during the month. The demister pads were pulled and cleaned because of an excessive calcium carbonate buildup. The Bird centrifuge was pulled and replaced with a spare because of an excessive vibration problem. The main breakers were replaced on the east hot water charge pump and the old unit dump Sweco motors during the month. All instrumentation for the low molecular weight project was calibrated during the month. Numbers three and four VC Corken compressors were removed and rebuilt during the onth. There month. six major valves changed out in the reactor area during the VAB.0001190212 COMPOUND - J. E. Nickerson, K. G. Akins Safety The Compound Department worked without injury in January. The topic of the monthly safety meeting was pinchpoint awareness. The topic of this safety meeting was recommended by the team investi gating the November incident in which an operator severed the tip of his finger it a closing door. General Several maintenance problems caused some unusually high downtime in the Compound Department in January. The increase in downtime, coupled with increasing flexible compound demand, tightened production schedules. Line III was down eighty-two hours during the month awaiting parts to repair the FCM starter. Replacement of Welex seals was responsible for forty-five hours of downtime in the dry blend unit. Line V was idle for the entire month of January due to a combination of light orders and repairs to the twin screw gearbox. Line I was down for twenty-eight hours during production trials of Plenex polymer formulations. On January 6, the dry blend unit produced 356,554 pounds to set a new one-day production record. The previous record was 351,560 set on June 1, 1985. The setting of this new record was particularly significant as it came at a time when demand for our rigid compounds surged and the production schedule was extremely tight. Operating Compound Production Davs Line I 28 Line III 27.5 Line V 0 Total % Prime Capacity Utilization Factor Downtime bine I Production (M Lbs.) Month Avg./Day 2126 3219 ____0 5345 98.3 .690 76 117 0 8232 13151 23722 97.9 .761 Hours - Product Changes - Plenex Compound Testing - Miscellaneous Maintenance - Mill Maintenance - Quality Problems and Control 77 28 16 11 4 - FCM Starter Repair - Product Changes - Quality Problems and Control - Dicer Problems and Maintenance - Miscellaneous Maintenance 82 58 9 8 6 x VAB.0001190213 COMPOUND - Continued Operating Days Month Rigid Compound 28.5 5470 Prime 99.9 Capacity Utilization Factor .932 192 Downtime Hours - We lex Maintenance - Product Changes Miscellaneous Maintenance - Quality Problems andControl 53 50 28 19 Operating __Davs Month Avg./Day Plasticizer 29 % Prime Capacity Utilization Factor 1614 85.5 .733 Fiscal Y.T.D. 17097 99.4 .710 Fiscal Y.T.D 6400 89.5 .770 J. B. Autrey, J. B. Hegwood The Line V twin screw extruder was shut down for repairs to its speed reducing and drive gearboxes during the month. The speed reducing gearbox was replaced with a new gearbox. The twin screw gearbox was rebuilt after it was found that a bearing failure had occurred. The vacuum jets on plasticizer reactors R-l and R-2 were removed for cleaning during the month because of an excessive calcium carbonate buildup. The first quarterly PM program was completed on the dicers in the compound area this month. This should help reduce downtime and maintenance cost on dicers. Numbers one and two Welex were shut down during the month for repairs. The gate was replaced on #1 Welex because of a leak. The shaft, sheave and seals were replaced on #2 Welex. The temperature control loops were calibrated and the water flow meters cleaned on plasticizer reactors R-l, R-2, R-3 and R-4. The starter on Line III FCM drive was replaced during the month. A VAB.0001190214 - J. B. Autrey, J. B. Hegvood The alternate natural gas line was tested during the month. We will start using natural gas from ACG Company on February 1, 1990, due to favorable pricing. The automatic water valve was repaired and the continuous blowdown line was replaced on boiler #1 during the month. 4 The east propane pump was removed, rebuilt and reinstalled during the month. The control valves on boilers #1 and #3 were removed and rebuilt during the month. i VAB.0001190215 ENGINEERING - R. E. Folk, S. C. Hillman, C. J. McDonald PROJECTS IN - GENERAL 5305 Graininess Work Decalcified water will be used instead of DI water for the calcium free water test run. Ion exchange with sodium will be used to remove the calcium. The test run is scheduled for March. The EVC clean wall test kicked off in January. The clean wall has reduced reactor fouling and cull production. It also eliminates the final reactor rinse to sewer. A closed reactor temporary addition syste: is being constructed for longer term testing. VCSM Work on the assignments continues on schedule. Plant engineers are still writing process descriptions/procedures, operator interface guidelines, and creating graphics panels. The team reviewed and re vised process control diagrams (PCD's). TC Wastewater Compliance Air stripping of rinse water in the blend tanks apparently will reduce VCM levels below TC compliance levels. The test run was cut short because it created high hard particles in the resin. A revised rinsing procedure will be tested. Alternate Gas Supply The new supply line is operating. February pricing with the new line will save approximately $1000/day. Baehouse Replacement DCE is designing a new air baffling system. Improper baffling has led to premature bag failures. Plasticiser COD Reduction A screening design showed no potential to reduce plasticizer COD by adjusting the variables tested. Reaction time was the most significant variable and we already operate at the optimum value. \. mmmmm VAB.0001190216 l * CO CO 3 si S s! Ol L*-J c<nn sUJ 3 cn _j cn -* 5 3 *: t CO ass S id CO CO U cn S id aaaa. cn u. u CO 2SE"- <c CO OS CO a 3 SE CO u cn ei q us ... 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POLK. S .E . HILLHAN, C J . HeDONALD r ENVIRONMENTAL - F. G. Jeanson Water / All wastewater discharge parameters were met for the month of January. Air A meeting was held with the State to review our new air permit with the engineers that would be working on it. They had several additional items they wanted in the air permit application. The application was revised per the comments of the State and a second meeting was held to discuss the revisions. The air permit is expected to be issued in February. Waste Make-up RCRA training was completed for all persons who missed during the month of December. Waste shipments for the month included: - One bulk load of floor sweep to Chemical Waste Management's (CWM) Lake Charles, Louisiana facility. - One bulk load of lead bags to CWM's Emelle, Alabama facility. The Governor of Alabama proposed to increase taxes on all imported waste disposed of at Emelle, Alabama by 550% to $120/ton. Sunerfund We received a copy of NUS's report to EPA on the investigation of the four sites on our property. A meeting with EPA is scheduled in February to review the report and recommendations. Miscellaneous I attended Hazardous Materials Manager training during the month. Total environmental costs for the 1989 calendar year were calculated to be $2.4 million. The new dryer baghouses were $1.5 million of this total. The SPCC Plan Survey was completed during the month. Two work orders were written to repair dikes. I attended Interaction Management and facilitator training during the month. VAB. 3 an-90 HASTE REDUCTION INDEX SHEET * OVERALL EXCLUDIN6 'TOTAL HASTE HATER* MON-RECYCLED HASTE RECYCLED/SQLB HASTE 1*1 1 Offsite. Hazardous Hastes 3 MONTH MR! 90 YTD 1989FY 89.551 79.491 96.601 88.981 B5.681 91.291 103.511 94.961 109.511 157.661 141.511 100.681 a. Land Ban Hastes s. Hazardous Solids c. Nan-Hazardous Treated as Hazardous O.001 113.041 173.951 0.001 87.041 L60.BBZ 244.741 111.191 95.771 II. Recycled Hazaraous Hastes 57.921 60.571 103.511 !Ii. Offsite. Mon-Hazardous Haste a. Recycled b. Ncn-Recycled 74.641 81.30Z 95.371 141.401 67.081 109.021 78.161 98.39Z 95.031 IV. Vunerable Bv-Products 100.541 95.651 U1.36Z V. Total Haste Hater 113.761 115.671 95.011 VI. Air 4 Hater a. SARA - Air t>. SARA - Hater c. Nan-SARA - Air :. t!or-SARA - Hster * 82.55Z 63.321 91.901 85.751 85.951 1228.631 1249.251 31.377. 42.441 k/V .v 117.431 88.051 592.12Z 98.301 37.2JZ iHHMPMNipWI II i VAB.OOOl190219 Jan-90 HASTE SECTION INDEX SHEET Offsite. Hazardous Hastes a. Land Ban Hastes 1. Phtbaiic Anb*vdride b. Hazardous Solids 1. Stabilizer S oill 2. Floor Seeeo4 c. Mon-Hazardous Treated as Hazardous 1. Plast. Filter Cake nL* Lead Baa* s 3. API Siuda* e 4. Pit tl Solids Recycled Hazardous Hastes a. Rec+ycled 1. Se oarator Oil 2. Safety# Kleen Solvent 1988FY 321409 2412 2412 7906B 16989 62079 239930 61670 68640 29620 80000 653226 653226 651700 1526 POUNDS 19B1FY 90 YTD 3 Nonth 329304 6006 6006 145636 0 0 124941 0 0 B9465 22425 67040 22037 5097 16940 22037 5097 16940 233833 56573 67860 29380 80000 123599 0 30100 66540 26959 102904 0 16200 66540 20164 688080 688080 686210 1870 126685 126685 12S7B0 905 93288 93288 92600 688 III. Offsite. Mon-Hazardous Haste * a. Receded 1. Orues 2. Pallets 3. Alusinua Cans. Paper, and Box 4. Scrap Metal b. Non-Recyd ed 1. Landfill 2429430 247201 49600 145600 0 52000 2182229 2182229 2357718 247500 49600 145600 300 52000 2110218 2110218 632415 B6295 10950 45999 496 28850 546120 546120 447085 B6185 10950 34405 396 40434 360900 360900 IV. Vunerable By-Products a. PVC 1. Culls 2. Vacuus Vent Oust 3. Sifter Overflon 4. Pond Resin 5. Pit 12 Resin 3597456 3597456 471409 329480 801007 1915560 80000 4076656 4076656 330521 541016 504106 2621013 80000 1101753 1101753 55210 165981 59151 794452 26959 891821 891821 33690 124275 49939 663753 20164 V. Total Haste Hater i. Effluent 1. Pond 6 VI. Air Ir Hater 5. SARA - Air 1. VCft 4424987560 4278245861 1638930897 1241168141 4424987560 4278245861 1638930897 1241168141 4424987560 4278245861 1638930897 1241168141 646617 73316 73316 604682 65694 65694 172508 20177 20177 131603 15500 15500 VAB.OOOl190220 m 9Mft - Ihtr 1. KOI 2. Nt^ctvl ntwu kHMM - Mr 1. Particulatat 2. Bulfor Mori* Moi WW - tlfttar 1. in 23*. cr*n 4. NH3 1W! 3I99VT 90 fll MO S 22 33 2mM 2A3M 904 309040 43409 mm 199*1 1379 333 21 warn 213*0 990 274344 447* 33140 17321ft 1199 223 m **s rmu 351 114304 27374 1917ft flli*lWA*l 237 1* 4 141 2004 20144 270 99*1 22917 14137 1 217 VAB ENERGY D. A. Moore A. Unadjusted EUI ( 8.0%) B. Adjusted EUI ( 8.4%) C. BTU/Lb. Product 2661.0 D. Total Energy Consumption MMM BTU 138.1 ( 12.0%) ( 12.8%) 2764.0 524.3 A. Maintenance There were sixty-four energy related items completed in December. Fifty-two of these items were steam leak repairs. The remaining twelve were steam trap repairs. No. 1 No. 2 No. 3 83.4% 83.2% 82.9% 83.5% 83.4% 83.1% mm* r* P II VAB.0001190222 jawuww loon ftraamial - J. . Bull Nona Paul J. Kobar - Transferred to Lake Charles Chemical Plant aa Plant Superintendent. Gary Sanders - Employee bid from Compound Utility to Lab Trainee. S^*il*s Gray - Returned from Maintenance Helper to former poaition. Lab Lead Technician. Tommy Staten - Employee bid from Lab Technician "A" to Maintenance None None None VAB.0001190223 * ABERDEEN, MISSISSIPPI Salaried Employees HourIt Employees Total Employees mSnmo.monthlt report" 76* Minority Employees #, % 172 Salaried 6 82 248 Hourly 66 38* Total 72 29Z Nev Enploreea Terminations n 0 0 Hourly Min. Hired % Min. Hired o 0 Hourly Min. Tan. 0 % Min. Ten. DEPARTMENTS PAS agMyrnYPPS MIN. EM?. *MIH. MEO WTttF.fi YTTI T^M. Yjp TURNOVER YTP. Warehouse 16 Gen. Plant 13 15 16 8 53 0 00 0 0 5 31 0 0 0 0 o 0 Maintenance 41 Laboratory 24 Compound 40 41 24 38 10 24 0 0 0 0 0............ 0 5 22 Q 0 0 0 0 0 26 67 0 0 0 0 n 0 Vinyl 33 33 10 30 o 0 0 0 q 0 Plasticizer 5 5 2 40 0 0 0 0 0 0 Number of Applicants: Month 0 Tear To Date 0 APPLICANT BREAKDOWN: # Minority 0 % Minority 0 # Female 0 % Female 0 * Includes 1 Co-op Student. Hires (Hourly): Month 0 Tear To Date 0 Teninations (Hourly): Month 0 Tear To Date 0 Overall Turnover 0 Projected Annual Turnover 0 i VAB.0001190224 m r IS 00 I LU L I Is- I r- i I 4| 1 CT* i 00 1 O* 1 in t ro 1 CM 4 1 1 CM 4 i * 00 4 1 1 CM 4 1 | 00 4 1 1 A 4 1 1 4 I I ft CM 1 m t CM 14 O 1fc ro i4 CM 1_A D I I I t I Ch i in i ro i <t> ro IS I i i I I CM t I Ii I Ii II t* CO i o 1 tn i ro i CD 1 a> i in I $ Is4 i j o * t 1 in 4 t | ro 4 i | CD 4 1 1 ^ 4 i 1 in 4 . 4 14 <D 1 O 1 O 1 4 1 O 1 4 I CD I 84 I 1 CO CD is CD t t <d I a> I I I I sss LU I I I I I CO I ro I Io 14 oo o I 00 t I I SI Bs i i < i in i r- m CM s i UJ I CM t in oo t in CM COCO I Ir j i SIS I CM I I I I i Ui t I 1 1 t Ui I I CO I i i ro i o*1 * OI CM I I I I in CM CD si j I t I I Io II CD- in i in * CM *\ 4 in in cm 4 in CMm iOn Ii s 4i sCO D I in I CJ II CM I o* CM I Si I 1 in m CM CM I ro i in 4 i iiI 4 OIo Ii II OC II <D iO io o> UI III 00* i i CM I 4 ro 1s I I ** o tiII ro I OI I I II II I I I I t I $I o Si s in I CD CD CD I i in i I I CM i ro oeco i I I CM I I in in 4 ro 4 00 CM ro i i r5o i 4 co Si S I ro I i t i i i i r a. i Si V I I I I I I I I I I I I 1 I I I I I I 00 I <t J I I I I% OCO I UJ I 8 1 I I UI CO I s 4 00 s s 00 s CD S 4 a> in CinD 4 in s i4 O s $ g ro I I I in i in o * o CM in i cm i t i i ro t in t i i i i i D 4 CM Sro ii in s3 4| 4 CD 00 CM 00 * <D in CM s 8 in m4 CM CM ro s CM MO O* S in in 4 in 8 in 4 M0 CM In in oo CM s sm <D 4 ro ro o in 1 4 s s jin i in c a A *^ A| ^4 1 <D $ i s 1 * l<D is 1rt 1 1 (CM iro CO o CO ~<c t r z CO CO CO s sj wmm VAB.0001190225 tv ADMINISTRATIVE SERVICES - J. E. Little i Safety There were no safety instances this month. The department viewed the Hand Safety Training video. Cost Savinas Savings due to competitive bidding were $13,731 for January, and $62,839 for FY1990. Savings due to prompt payment discounts were $1755 for January, and $8,876 for FY1990. Warehouse - Finished Goods Inventory Slow moving inventories are still a major concern. Fred Williams and Linda Michels are reviewing the various compounds. Flexible - Line I Line III Line V Rigid TOTAL SLOW MOVING 451,478 221,089 135,176 71.720 879,463 Included above are 98M pounds of slow moving. Training compounds. 1/23/89 - Pat Wells and Tommy Cummings attended facilitator training. 1/29 - 2/02 - Pat Wells attended The Management Process (TMP) in Hous ton. - Judy Frossard, Paradox software - PMS conversion to PC application. Leo Ezell is cross-training in the raw material warehouse. - Janice Minga is cross-training for Stores Supervisor coverage. Meetings 1/11 - 1/15 - QMP Managers Meetings - Mike Swierc, Tommy Cummings and Pat Wells attended. 1/15__:__1/25 - VMS updates (Maintenance and Administrative Services). m RVMlIMpVI mmmrnmmmmmmmm VAB.0001190226 Continued Meetings - continued mi - John Stokes visited Aberdeen for a compound overview. 1/18 Dan Miller and Randy Polk - AFE cost tracking. 1/22 - 1/24 - Jack Little reviewed VMS implementation and startup problems at the Lake Charles Chemical Plant. 1/25 - OASIS Team - overview and plant operations. .1 JT VAB.0001190227 k AIIIMII CIHICil PLAIT SlirriM AIALTSIS JAI0401 1000 -S0RBIIPI&RBUBT1S9 DRTI iPSRVAvMVPvTltSf - piblic ioiti 1PT/ITC I1C1AIGI IlSIl-BOLl IISII-PACIAGIO 22,111,(10 9,194,490 348,750 368,050 216,960 0 fluibli comm-mi 1,SIT,OH iuiiiu comm-PACUGiB 2,912,120 IIG1B C0BP08RB-B8L1 iigii covom-nciuD 4,813,690 191,282 559,700 234,995 a 696,900 4,200 0 9 0 0 pusTicini 87,960 352,000 0 TOTAL 31,778,542 11,117,20$ 348,750 SUBMITS B! 101t- BOLI: tmm 1I8II iuiiiu comm iicii comm PUSTICIUI IA1LCAI ISO 11 26 2 COSTOHI PIC1IF h COUOI CAIIIII 49 50 04 1 22 02 TOTAL JAIIAIT 198 50 78 TTD P5BLIC m/iTc BIC1AKI 72,107,220 38,616,570 341,750 1,117,704 941,750 0 S,Til,700 3,470,ISO 11,561,305 511,921 0 0 14,524,190 1,896,000 621,434 17,000 0 0 437,969 1,223,000 364,000 197,345,593 46,959,398 712,750 TOTAL 258 15 49 4 320 mi* iisii iuiiiu comm IIOIB C0IPO9ID PUSTICIUI TOTAL TTD PACIAGI9: tJAIDIRT* BISII iuiiiu comm mu comm PUSTICIUI TOTAL JAIIAIT 553 113 47 3 82 10 90 691 126 C6ST08I! P1CI0F conoi CAIIIII 3 12 19 63 28 91 24 104 239 16 54 10 210 IOIC COIT1IIH A1I/0PS 0 + 1 0 0 0 0 0 0 10 3 0 0 10 13 905 66 146 19 1,131 TOTAL 25 106 10 1 142 ms* BISII ILIXIBLI COIPOHB II6IB COIPOIID PUSTICIUI TOTH TTI 18 51 0 0 79 261 2 0 6 27 0 1 9 1 00 103 369 2 1 24 8 1 1 34 93 370 35 2 190228 500 r LABOMTQRX - J. R. Williams A. Safety - There were no safety incidents in the Laboratory for January. The monthly safety meeting topic was "Hand Safety" with Richard Williams in charge of the meetings. B. Customer Contacts - None. C' Customer Q.C. Problems Reports 1/30 - American Mirrex - When samples were tested from this railcar, there were "brass slivers" found in all compart ments . This was traced back to the failure of a piece of manufacturing equipment during the extreme cold weather. D. Requests for Corrective Action - None E. Product Waivers Customer Grain Systems Product 80273G WHT lio Reason Low Fusion Torque 1 H/T Eagle 80273G WHT 110 Long Fusion 3 R/C F. RVCM Summary RVCM of In-Process Samples The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of January, 1990. Reactor Slurries ________Drier 5265 5305 Number of Samples Average RVCM, ppm 924 133 67 0.795 44 0.747 Samples The following is a summary of the residual VCM analysis of shipment samples for the month of January, 1990. Product Number of Samples Average RVCM. ppm 5265 5305 5385 5395 5415 5465 Dry Blend Debox Pond 40 102 57 0 63 0 80 16 6 0.565 0.414 0.578 0 0.062 0 0.155 0.670 6.579 VAB.0001190229 LABORATORY - Continued (based on dryer "regulars") 5265 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 1.44 0.64 -- 4.60 3.17 2.83 2.27 -- 0.62 -- -- -- ------- 138 Flexible Compound 5305 2.13 1.27 0.60 2.40 3.50 2.50 3.08 -- 1.23 -- -- -- -- 148 5385 1.58 0.67 -- 4.00 ---2.50 2.13 -- 1.44 1.00 -- -- 13.9 160 5415 1.30 1.05 4.56 3.33 6.17 1.17 4.73 1.17 2.55 1.57 2.4 173 Hardness Hard Particles Heat Stability Contamination Dicing Cross Contamination Totals Adjustments M Lbs. (%) 31.0 --------- --- 10.0 -- --- 41.0 (0.58) -- (0.19) -- -- - --- (0.77) M Lbs. (%) 7.5 25.5 -- 6.0 4.2 44.5 (0.14) (0.48) -- (0.11) (0.08) (0.02) (0.84) A Torque Rheometry Total Ui (0.06) 3.6 (0.06) 1. Minor problems with the load cell on the Syntech tensile tester were resolved through Dave Cox working with their technical people. 2. Several extra COD samples were run in support of the plasticizer test run. 3. Support was provided to Engineering in testing numerous samples for RVCM during two separate test runs. m VAB.0001190230 w mmmm LABORATORY - Continued J. Miscellaneous - continued 4. Dave Cox participated in the Dayton Extruded Plastics DOE project. 5. A hard particle problem was experienced when using Aluche: AC-712K in 34862 GRY 546 for AT&T. This material was unable to be reprocessed into acceptable product. This is the second incident of this nature from using Aluchem AC712K. VAB.0001190231 A 1 RESIN Ship Date 1/11/90 1/11/90 1/19/90 1/23/90 1/23/90 1/23/90 1/26/90 1/26/90 1/26/90 1/30/90 1/31/90 1/31/90 1/31/90 1/31/90 SAMPLE SHIPMENTS JANUARY 1990 Product 5385 Pond Resin 5385 5385 5415 Pond Resin 5265 5305 5415 5385 Debox Pond Resin Pond Resin 5385 Pond Resin Amount 200 lbs. 250 lbs. 5 lbs. 200 lbs. 100 lbs. 5 lbs. 50 lbs. 50 lbs. 50 lbs. 4400 lbs 2 lbs 5 lbs. 5 lbs. 100 lbs. 50 lbs. COMPOUND Ship Date 1/05/90 1/15/90 1/19/90 1/22/90 1/23/90 1/23/90 1/23/90 Product 18031 WAT CL 18961 NAT 16851 CB 50 240-128B GRY 568 240-170B GRY 568 2153 NAT 18961 NAT 9-746 CMPD. 9-746 CMPD. Amount 500 lbs. 500 lbs. 100 lbs. 500 lbs. 500 lbs. 1500 lbs 100 lbs. 1 lb. 1 lb. Customer PANIMEX (CHILE) LTDA. IFER DOMINICANA C. A. Dow Chemical El Paso PVC Essex SIMAQUIMICA Sheller-Globe Dayton Extruded Plastics CENTURY ESLON LTD* Sedco Pipe HAROLD VELAZQUEZ INYECCIONES INDUSTRIALES C* ITOH Conex of Georgia Customer Universal Plastics Vista Chemical - Austin P. W. Pipe Encore Wire Corp. Precision Trim SIMAQUIMICA FABRICA SANDALIAS BLUE STAR VAB.0001190232 Sample Shipments/Jan. 1990 Page 2 COMPOUND (Cont.) Ship Date Product 1/24/90 384 FR NAT 419-33D NAT 1/25/90 34643 NAT 35851 NAT 35852 NAT 1/26/90 15041 CB 50 1/26/90 38601 NAT 2153 NAT 1/29/90 9-712 9-746 9-803 9-856 DRYBLEND Ship Date 1/10/90 Product 426-90 WHT 110 Amount 250 lbs. 250 lbs. 100 lbs. 100 lbs. 100 lbs. 1500 lbs. 1500 lbs. 1500 lbs. 2 lbs. 2 lbs. 2 lbs. 2 lbs. Customer West Penn Wire Corp. ALCAVE Precision Trim Encore Wire Corp. Pushpa Int'l. Corp. * Amount 250 lbs. Customer IFER DOMINICANA C. A. VAB.0001190233 mmm 4 * 40 ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) A NUMBER OF NJURIES J*B7F MAMJJASON OJ'WF MAMJJASQN DJ'89F MAMJJASQN DJ*90 TOTAL INJURIES O OSHA RECORDABLE VAB.0001190234 si/rus ABERDEEN ENERGY CONSUMPTION 12 MONTH AVERAGE VAB.0001190235 DEPARTMENTAL JS ANALYSIS REPORT DISTRIBUTION LioT RUS, JFC, JVIJ, DEPARTMENT HEADS, FILE 1A/ 2/89 THRU 2/ 4/90 -A' \ ^ <\ I I 3i Ui Ui L9 CO $<D 4 1/1 CSI $ 00 CM m 00 $ 8 CM 004 III I < 00 0 t CM tii in ro o $ro $ CM m5 ro CM CM CM in 00 CM CM iono ro ro i CM O CM I IIIII O ro ro in 'On* i OO 1 4 I4 1 f O 4 1I CM 4 o ro I <1 tIIIP> j ro i in CM CM \I co in 4 ro ro 'O ro 09 O I O oo -* CM IIII 0 hCO O 1 1 'O 4 1 1 O o t 1 oCM 1 t o 1 1 o 0 1 1 *o in 01 1 101 o10 1 o CO 40 1 X 1 tn 1 o 1 00 i ro 1 O' t 0 1 4 tn I o ( 0 i CM I ro 1 0 1 0 Ui i 41 4i 41 41 41 4 sc t o r ro i l **-- 1 0 1 ro a $ O IIIII o 0I 0 II1II M> 0 1 t CO CM 1 in i i o O 1 1 $ 0 1010i 0 10 A $ fw | in t r 1 O' 4 1| in 4 i | r i 41 4 CM 1 1 4- 1 co aUcLunuJeotcH_nn--l iiiiii if>n*4 O' 111111 <0X> GO 11 111 in cr4o--o t1 *11 iCnM rC0oM O in in i * in CM 1 1 in CM 1 1 0 i i 0 0 1 1 0 in i i in 'O i r*- 1 1 ro i in i CM i CM 1 CM 1 ro i O' 1 0 i 0 1i 1 1 i O' 1 i s I UiOUl i CM 1 CM 1 O' 1 CM i CM ro i 3C 3C i 1 in 1 O' 1 ro i ' CM * iHHM H* h* 4 1 4 in \ t 4 CM 1 1 4 0 1 1 fu ro i iOC 1 i CM 1 1 i iui ee 1 i 1 1 i i> tor- 1 i 1 1 i iq<eco 1 t 1 1 i ro in in o*. CM in in o in CM mO 1 i 1 m f 0 in in 1 in i 0 1 CM I in CM CM *o s in o- 1 co i O' 1 in 1 in ro t CM MD 1 1 in 00 CM 1 ro i CM a CD 1 0 1 i i t CM 1 i i1 in r0o CM fO 1i i1 0 1 in i i 1 o0 1 CM i i 0 1 o ii o mi 'O ro CM iiti CM in IO in CM <D oo in CM in r 1 1 in i i in i 9 in CM 1 1 1 1 in O4'00 CM ro in ro 0 ro 11 4 'O 1 1 CM i t O' 1 1 CM CD f 1 CD 1 1 fw oecnKOC in CO sc CM CM 'O CM ro CM 1 'O i 0 1 CD CM 1 CM 1 ro i 1 in 1 -O 1 ro a i 1 CM 1 CM 1 $ 'O 00 ro ro to CM CM 0 1| 4 ICM in cm ro CM 4 CM in CM o CM C0M0 m cm rCoM cm cn *44 O CM 'O CM v w CM UI tn 13 U. cui s to Knot ut to I 1 UI utoi ii u 9 UI S! $ to II Ui fs o t<nc ui <c rtHMHM ***** VAB.0001190236