Document JjJEKOeJ1nggJJL6wKEk0B6e
To: T. H. Huffman
117
A
Interoffice Communication
From: Date:
Subject:
D. C. Skokna February 1, 1989
// z-.o
ABERDEEN MONTHLY PROGRESS REPORT - JANUARY. 1989
VKIA
There were three first aid cases reported during January. As of January 31, the plant's employees had worked 3498 days or 4,582,106 manhours since the last lost time injury.
Key Statistical Information
J anuarv
Y.T.D.
PVC Production, MM Lbs.
38.9
154.1
Reactor Stream Factor, %
89.1
91.0
Resin Quality, % Prime
95.8
95.7
VCM Efficiency, Lbs./Lb.
1.0132
1.0157
Flexible Compound Production, MM Lbs.
6.9
25.9
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Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs.
97.3
6.6*
95.0 23.4
Rigid Compound Quality, % Prime
99.6
99.8
Plasticizer Production, MM Lbs.
1.7
7.0
Plasticizer Quality, % Prime
87.5
92.8
Energy Use, (EUI, %)
( 7.4)
( 3.8)
Fixed Cost Variance, $M
66.0
(70.2)
Variable Cost Variance, $M
241.5
1662.3
Variable Cost Price Variance, $M
161.8
1554.8
Variable Cost Efficiency Variance, $M
79.7
107.5
* Monthly production record.
Costs
Favorable costs in the M.M.&C. ($38.9M), Outside Professional Services ($27.6M), and Operating Supplies ($25.7M) categories were somewhat offset by Payroll ($15.1M) and Shipping ($20.2M) costs being above budget. The favorable M.M.&C. costs were due primarily to lower than budgeted activity.
Variable costs were favorable primarily due to favorable VCM usage in the PVC unit.
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VAB.0001190600
T. H. Huffman 2/16/89 Aberdeen Monthly Progress Report - January, 1989 Page 2
n training was given to a group of salaried and hourly personnel.
A PVC customer, General Cable, visited the plant prior to their signing a resin supply contract.
SPC training for recently hired personnel began in J anuary.
Eighty-two percent of the plant's natural teams met during January.
Environmental
Region IV EPA contacted the plant to request entry for
the purpose of doing surface and sub-surface soil and
water monitoring around past landfill sites.
A
contractor will be in the plant during February to do
this work.
J. C. Ledvina and D. L. Cohen held environmental training for operations, maintenance and engineering personnel.
D. C. Skokna Plant Superintendent
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VAB.0001190601
DISTRIBUTION
COVER LETTER
ENTIRE REPORT
Houston
J. D. Burns
X
R. T. Ferrell
X
T. H. Huffman
X
C. J. Matson
X
D. F. Harman
X
H. R. Flammer
X
R. R. Smith
X
K. J. Eggers
X
R. H. Gerlach
X
Ponca Citv
S. E. McGuire
X
R. L. Poe
X
H. J. Hall
X
Oklahoma Citv
H. G. Garrison
X
LCVCM Plant
R. A. Conrad
X
LCCP Plant
J. Friend
X
LC1AB Plant
J. W. Ware
X
Baltimore
L. R. Bauer
X
Hammond
J. B. Maher
X
Blane
C. R. Miller
X
Premiere
P. L. Foote
X
Aberdeen
RWS/DCS (File Copy), PJK, JEN, DWH, TFL, JEB, HGC, JEL, REP, BLT, RBN, SCH
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VAB.0001190602
SAFETY - B. L. Trego, J. V. Uptain
J anuary
Fiscal Y.T.D. 1989
Fiscal Y.T.D. 1988
First Aid OSHA Recordable
Total Injuries
Number of Restricted Workday Gases Number of Lost Workday Cases
Injuries by Department
3
0
3
0 0
6 2 8
1 0
3
1
4
0 0
Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office
Totals
Injuries bv Type
00 12 26 00 00 00 38
1 0 2 1 0 0
4
Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other
Totals
Non-Occupational Injuries
01 00 22 02 12 00 01 38
1 0 1 2 0 0 0
4
Lost Workday Cases Days Lost
Safety Record
01 0 20
2
72
Last lost time injury - 7/5/79
Days since -
3498
Manhours since -
4,582,106
On January 31, 1989, the employees of the Aberdeen Plant completed 3498 days with no lost time injury.
Topics for the plant safety meetings during the month included: Ladder Safety, Winterization of Equipment and Winter Ice Hazards, and Maintenance Weekly Job Planning and Safety Review.
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SAFETY - continued
The plant blood drive was successful with eighty-one pints of blood being collected. This is near the record set last year.
Anzon, a lead product supplier, provided a courtesy inspection of our lead handling area and offered advice as well as praise for our system.
Bruce Trego attended the American Association of Railroads Tank Car Safety course in Pueblo, Colorado on January 30 through February 3, 1989.
Routine dosimetry results for the month were:
Chemical
< PEL Number Percent
> PEL________
Number
Percent
VCM Lead Total Particulates
Monthly Injury Summary
78 98.7 13 100.0
5 100.0
1 0 0
1.3
0.0 0.0
Iniurv Class
Department
Description
Maintenance
First degree burn of left forearm.
Maintenance
First degree burn of left forearm.
Compound
Strain of neck muscles.
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VAB.0001190604
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ABERDEEN CHEMICAL PLANT INJURIES
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TOTAL INJURIES
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QUALITY DEVELOPMENT - D. W. Hollis
General Plant
1. A make-up session of Team Management was given the week of January 17 for new hires and people unable to attend the training last May. Five hourly personnel were included in this training.
2. SPC training for new hires was started January 31.
3. The Plant Manager's Natural Team met twice during the month. Main items of discussion were: 1) Planning QMP Management meetings for first and second level supervisors; 2) Planning of employee meetings to be held in February; 3) Communicating the status of the Compound survey.
4. Cao Chu-ba of General Cable visited the plant for review prior to signing a contract for resin supply.
Mechanical Department
There were seven natural team meetings held during the month. The agenda for all of the meetings included a brainstorming session on how safety can be improved in the workplace. The results of the brainstorming sessions were consolidated into the five most important items and submitted to the Safety Department.
The Quality Implementation Plan was updated.
All new salaried Mechanical Department employees and one hourly employee attended Team Management training.
Vinvl Department
The Department Head's Natural Team met once in January. Agenda items
included:
Employee Action Teams, Safety Suggestion Meetings, Key
Performance Areas, QIP Status, Klockner Status and Process Capabilities.
Each shift supervisor's natural team met during the month with the topics being employee safety suggestions and a discussion on Klockner quality issues and action steps.
Two employee action teams are active in the department; Unloading Team and the V-ll Dustbusters.
Plasticizer
Compound Department
Three customer visits occurred in January: Ted Nickerson visited Donnelly and Lamar; Jimmy Autrey visited Master-Halco.
Aberdeen hosted Anzon, Inc. (one of our suppliers of lead) for a plant visit. Their personnel conducted a "mock OSHA inspection" of the areas of our plant in which lead is handled.
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QUALITY DEVELOPMENT - Continued
Compound Department - continued
The Dry Blend Improvement Team held its first meeting in January. Two new teams were formed: Waste Oil Reduction Team and the Mill Scrap Improvement Team.
Two operators, Jack Wertz and Dave Gathings, attended Team Management Training.
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VAB.0001190607
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COST VARIANCES - D. C. Skokna
Variable Costs
Product
January 1989 Variance.
Efficiency
Price
_____________________________
Total
PVC Flexible Compound Rigid Compound Plasticizer
$ 75.6 (57.6) 28.1 33.7
$ 79.7
$ (61.6) 99.7 21.3
102.3 $161.8
$ 14.0 42.1 49.4
136.0 $ 241.5
PVC - Energy and VCM efficiencies were better than budget; and a correction to previously consumed calcium stearate caused this month's favorable efficiency variance.
Flexible Compound - Consumption of 610P and off-grade production were both above budget causing the unfavorable efficiency.
Rigid Compound - This month's favorable variance was caused primarily by the product mix.
Plasticizer - VRP recoveries were above budget; and, as a result, the month's efficiency variance was favorable.
Price Variances
610P (to flexible compound) AlfolR610 Resin (to Compound) Stabilizer VCM Freight Ti02 Alcotex Natural Gas Other Price Variances
Total
Fixed Cost Variances
- Payroll and Benefits - MM&C - Miscellaneous - TI&D - Clearances
Total
$96.8 85.2 19.4 17.4
10.6
(10.4) (10.5) (71.2)
24.5 $161.8
$M
($15.1) 38.9 35.8 7.8
( 1.4) $ 66.0
VAB.0001190608
COST VARIANCES - Continued Payroll and Benefits - Above budget overtime and a holiday caused the
unfavorable variance. M.M.&C. - This category was favorable due to low activity levels. Miscellaneous
Outside professional services were $27.6M under budget due to lower than expected use of contract engineers, as well as several
major items not occurring as budgeted (namely, $12,000 recruiting fee, and a $10,000 air modeling study).
Operating supplies were $25.7M favorable. Shipping costs offset these favorable items by $20.2M, primarily due to a problem in accurately accruing these costs.
VAB.0001190609
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OPERATIONS AND MECHANICAL DEPARTMENTS - P. J. Kober, Ted Lyon, Ted Nickerson
Operations/Mechanical Safety
There were two injuries requiring first aid treatment during the month. Two mechanics suffered minor first degree burns when they contacted hot steam tracing while installing the D700 reactor condenser lid. The Compound Department had one first aid case in January. An operator bumped his hard hat on a transfer line and jammed his neck. No injury was sustained. The Vinyl and Yard Department operated without injury in January.
The monthly safety meetings included brainstorming sessions on safety suggestions for inclusion in the plant's 1989 safety program. The Compound Department also reviewed ladder safety and discussed recent accidents.
VAB.0001190610
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VINYL - P. J. Kober, C. J. McDonald
General
1. A blend of dual suspending agent 5385 was produced and bagged for testing in Compound.
2. Four railcars of Isonox* 132 killed 5305 were produced for testing at Hoechst-Celanese Corporation.
3. Chem wash/rinse nozzles were checked for spray patterns in the old module. The D600 nozzle was adjusted to improve its pattern.
4. The resin raw materials in the 744 account were valued at $403.5M.
J anuarv
YTD
- Production
38.9
154.1
- Daily Rate, M Lbs./C.D.
1255
1253
- Total Reactor Charges
909
3644
- Charges/C.D.
29.3
29.6
- Reactor Stream Factor, %
89.1
91.0
- Rotary Dryer Stream Factor (#4-#8), %
84.8
85.2
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- Fluid Bed Dryer Stream Factor, %
93.1
95.6
- Resin Quality, % Prime
95.8
95.7
Reactor Downtime
Hours
Operational downtime (recovery scheduling conflicts, downtime to rinse chem wash tanks, new module rinse/charge water conflicts, waiting on particle size data before charging, inclement weather, low steam pressure, wash small blend tanks, taking water samples for toxic character istics testing, check old module reactor rinse spray patterns, clearing blend tank 646 air spargers, and no place to dump).
263.1
Maintenance downtime (hydroblast D700, D745, D600, D500, D400 and D743 shell and con denser, no place to dump while repairing fluid bed, D700 agitator fluid coupling, D700 agitator gearbox and motor, D744 seal, and miscellaneous instruments and valves).
549.6
Total Downtime
812.7
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VAB.0001190611
VINYL - continued
Reactor Downtime - continued
Dryer Downtime
% of Total Downtime
Reactor limited production
54.6
Operational downtime (centrifuge plugging, dryer cleaning, activator transfer problems, checking dust collector socks for leaks, flameouts and checking sifter screens).
14.1
Maintenance downtime (fluid bed plug flow exhauster bearings, fluid bed screener,
#5 Star valves, #5, #7 and #8 dust collector
air pulse, #4 transfer line leaks, safety belt guard installation on all centrifuges, plant air compressor maintenance, and various activator and centrifuge repairs).
31.3
Kev Maintenance Work - D. A. Miller, J. B. Hegwood
Reactor Area
Reactor 700 was shut down for repairs to its agitator gearbox and motor. The motor and gearbox both had bearing failures that were caused by a bad vibration problem. The fluid coupling is suspected to be the cause of this problem. The motor and gearbox were both rebuilt and put back in service. As a result of this failure, a vibration survey is being conducted to prevent this type of problem from occurring again.
Reactor 700 and 745 were shut down for hydroblasting during
the month.
This is a continuing part of the Klockner
Contamination Control Program.
Also during the month, reactors 300, 400, 500, 600 and 743
were shut down for hydroblasting. All reactor condensers
were hydroblasted from the bottom during the month. This was
done to prevent having to lift the condenser lids for
condenser cleaning.
This will significantly reduce the
amount of time to do this job. This new condenser cleaning
procedure will reduce downtime by at least twelve hours.
A new pressure regulator was installed in the supply line to the blowdown tank pump seals. This was down in order to correct a seal failure problem.
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VAB.0001190612
VINYL - Continued
Kev Maintenance Work - continued
Several repairs were made to the fluid bed dryer equipment during the month. The motor sheave and belts were replaced on the fan due to normal wear and the springs for the south fluid bed Kason were changed. The bearings and the seals on the plugflow blower were also changed.
Number six and eight Bird centrifuges were changed out and rebuilt due to normal wear and a trunion bushing failure.
The north ring seal water pump for the emission recovery system was rebuilt and a new rear housing was installed which had corroded.
There were five m ajor valves changed out in the reactor area during the month.
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COMPOUND - J. E. Nickerson, J. B. Autrey
General
Numerous test runs were completed in January. Rigid pellets were produced on Line V and sent to R&D for analysis. Also on Line V, a new pigment for 38401 Orange was successfully tested.
An initial test using encapsulated lead was conducted on compound
38931 White on Line I. We are waiting on analysis from R&D. Test
runs for low-smoke, low flame compounds 416-5E Natural and 271-
201B Natural were conducted on Line I. The 416-5E ran without
incident.
The 271-201B had processing problems which have
necessitated a reformulation. A test run is scheduled for mid-
February to produce the new reformulation.
A Dry Blend monthly production record of 6.56MM lbs. was set in January. This eclipses the old record of 6.15MM lbs. set in April, 1988.
Operating
Compound Production
Davs
Production (M Lbs.) Month Avk./Day Fiscal Y.T
Line I Line III Line V
Total
31 31 23.5
2016 3764 1098 6878
65
121
47
8140 14186
3594 25920
Downtime
Hours
Line I
- Product Changes - Quality Problems & Control - Dicer Problems & Maintenance - Banbury Seal Repair - Miscellaneous Maintenance - Transfer Problems & Limitations
82 26 23 17 15
10
Line III
- Product Changes - Transfer Problems & Limitations - Quality Problems & Control - Dicer Problems & Maintenance - Miscellaneous Maintenance
60 18 13
6 6
Line V
- Product Changes - Quality Problems & Control - Hot Oil Heater Maintenance - Crammer Feeder Maintenance
38
10
8 6
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VAB.0001190614
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COMPOUND - Continued
Operating Days
_____________Production (M Lbs. 1
Month
Ave./Dav
Fiscal Y.T.D.
Rigid Compound
31
6568
212
23358
Downtime
Hours
- Product Changes - Quality Problems & Control - Welex Problems & Maintenance - Transfer Problems & Limitations
64 41
9 5
Operating Days
Month
Production fM Lbs.l
Avg.. /Dav
Fiscal Y.T.D.
Plasticizer
29 1862
64
7202
Kev Maintenance Work - D. A. Miller, J. B. Hegwood
Plasticizer reactors R-2 and R-4 were shut down for repairs on their water and steam coils. The steam coil in R-4 reactor was leaking, which was caused by a support rubbing against the line. R-2 reactor water coil had a circumferential crack which could possibly be a fatigue failure.
The plasticizer Schenk filter was pulled out and cleaned and the leaking seals in the Schenk filter were replaced.
Compound Line III was shut down in order to change out the housing on the top hydro therm pump. This pump was leaking due to a steam cut.
The Line I Banbury seals were changed out.
Utilities - D. A. Miller, J. B. Hegwood
The Frick inerts removal system compressor failed and was replaced with a spare. A Patterson Enterprise representative was brought in for consultation on needed repairs on the Frick system.
The inboard bearing on #1 boiler feedwater pump was replaced due to failure.
The #5 boiler feedwater pump was rebuilt and a new modified impeller was installed to correct an operation problem.
The large booster water pump was overhauled.
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VAB.0001190615
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COMPOUND - Continued
Utilities - continued
The Pall air dryer was shut down for minor leak repairs to one of its three-way valves.
Two drain valves replaced due to installed.
on the sulfuric acid tank were leaks and one block valve was
The suction and exhaust valves were replaced on the first stage of #9 air compressor due to normal wear.
Safety lockouts were installed on lab exhaust fans for increased maintenance personnel safety.
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VAB.0001190616
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ENGINEERING - R. E. Polk, S. C. Hillman, V. L. Thornhill
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PROJECTS IN DEVELOPMENT - GENERAL
Lead Handling and Exposure Reduction
The use of encapsulated lead was tested on Compound Lines I and V to identify differences in handling and processing. Normal Q.C. testing did not show any differences. Samples have been sent to Ponca City for evaluation.
RCRA Toxicity Characteristic
Plant engineering and PED are developing methods to meet expected compliance limits of the future RCRA Toxicity Characteristic (TC) rule. The latest information available indicates publication of a final rule sometime after August, 1989, with one year to comply.
Resin Contamination Reduction
Engineering of short term items identified by the Klockner
Contamination Team is in
Most of these items will be
completed before or be included in the Fourth Quarter Capital
Budge t.
Coker Water Test Run
A water balance was completed for designing the new Coker water supply system. Specifications are being prepared for the iron removal/filtration system.
Vinvl DCS
A meeting was held with GED and plant personnel to review the proposed layout of the new control building to house the system.
Recruiting
By the end of January, all plant interviews were completed. There have been two process engineering job acceptances and two mechanical engineering job acceptances. Three of these started to work in January while one is scheduled to begin in August.
VAB.0001190617
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ENVIRONMENTAL - F. G. Jeanson
Water
All wastewater discharge parameters were within NPDES limits for the month of January. However, a bypass occurred during the month. Approximately 800 gallons of untreated water went to the storm sewer. This bypass happened due to the overfilling of one slurry of our blend tanks. The bypass was reported to the Mississippi State Department of Natural Resources.
Air
All of the seventy-one leaks found in the annual VCM leak survey were fixed except for two. These two leaks could not be repaired during normal operation by our Maintenance Department. Leak Repairs, Inc. has been commissioned to attempt to repair the remaining two leaks.
Superfund
Region IV EPA contacted the plant and requested entry to sample the past landfill sites. EPA will send a contractor, NUS, to do surface oil, sub surface soil, groundwater and surface water sampling. The contractor is
scheduled to arrive the week of February 6 to do the sampling. Conoco was
notified of the sampling that will be done.
Waste Management
January waste shipments included:
Two bulk loads of separator oil to Stauffer Chemical.
One partial truckload of Phthalic Anhydride spill Management.
stabilizer spill (7 drums) and (2 drums) to Chemical Waste
Two bulk truckloads of reactor culls to Sun Polymers.
Miscellaneous
Organized and held environmental training for plant technical and operational personnel. D. L. Cohen and J. C. Ledvina trained and updated personnel in air, water, solid waste and Superfund regulations.
Attended basic comprehensive course on Environmental Regulation presented by Executive Enterprises, January 17-19.
Investigated railcar fine received in December. No records indicated innocence so fine was paid to Louisiana Office of State Police.
Attended Mississippi Manufacturer's Association Enviro Committee meeting. Meeting was held to discuss issue of fee assessment on environmental permits.
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ENERGY CONSERVATION - D. A. Moore
January. 1989
Fiscal Y.T.D.
I. Energy Conservation Data
A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU
-7.36% -6.14% 2574.33 138.14
-3.83% -2.72% 2516.13 528.08
This corresponds to anadjusted CMA of and an unadjusted CMA of
50.14% 37.96%
51.47% 39.90%
II. Plant Energy Conservation Program
A. Maintenance
There were ten energy related items completed in January, 1989. All ten of these items were steam leak
III. Boiler Operation
Boiler
Combustion Efficiency % Jan..89 Fiscal Y.T.D.
No. 1 No. 2 No. 3
83.84%<u 83.64% 83.26%
83.62% 83.61% 83.22%
(1) Boiler #1 was operated six days during the month.
NOTE: The low EUI for January is largely attributed to cold weather
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MONTH
-------- 12 MONTH AVERAGE
HUMAN RESOURCE REPORT
PERSONNEL - J. E. Beall
EMPLOYMENT Sherry A. Ingwersen, New Hire Douglas E. Knittig, New Hire Thomas A. Madigan, Rehire Andy C. Wilson, New Hire
PROMOTIONS/TRANSFERS Veldon E. Messick promoted and transferred to Chief Process
Engineer Houston, TX. Rendell Newton promoted from Senior Process Engineer to Chief
Process Engineer. Vernon Thornhill promoted from Process Engineer to Senior
Process Engineer.
RETIREMENTS None
TERMINATIONS/RESIGNATIONS Theresa A. Beaty
TO/FROM LEAVE OF ABSENCE None
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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
78* 169 247
JANUARY, 1989________ MONTHLY PERSONNEL REPORT
Minority Employees #,
Salaried Hourly
7
66
Total
73 30%
0 Hourly Min. Hired ______0
% Min. Hired ______0
0
Hourly Min. Term. ______0
% Min. Term.
0
# EMPLOYEES MIN. EMP. % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD
16
7
44
0
000 0
0
12
7
58
0
000 0
0
39 10
0_
0000
0
24
4
17
0
0000
0
40
26
65
0
0000
0
33
10
30
0
0000
0
5
2
40
0
000 0
0
Number of Applicants:
Month
12 Year to Date 12
APPLICANT BREAKDOWN:
# Minority
5
% Minority 42%
# Female
1
% Female
8%
* Includes 1 Co-op Engineer.
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Hires (Hourly):
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o Year to Date ___0
Terminations (Hourly):
Month
0 Year to Date 0
Overall Turnover
0
Projected Annual Turnover ___0
VAB.0001190623
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ADMINISTRATIVE SERVICES - J. E. Little
There were no safety instances this month. Safety meetings concentrated on soliciting safety ideas to help develop FY1989 plant safety program.
Personnel/Training
Amy Vernon attended Team Management training January 17-20.
Judy Frossard and Jack Little attended AT&T's System 75 seminar January 16-
20.
Cost Savings
Savings due to competitive bidding were $9,342 for the onth, and $20,859 for FY1989.
Savings due to prompt discounts were $1,759 for the month, and $7,733 for FY1989.
Meetings
The department spent several days with Dave Lanciault, URC, in support of the PVC Compound Study.
Worked with Gabriel Bresler, MAC Group, January 25-26, discussing allocations to compound, variable cost, scrap, etc.
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SHIPMENTS BY PRODUCT - M LBS.
RESIN PLASTICIZER DRYBLEND COMPOUND
NUMBER OF SHIPMENTS BY MODE:
TOTAL
Jan. 1939
31,046 533
5,793 6,343
44,215
RESIN-Bulk
FISCAL
YEAR-TO-DATE
113,539 2,663
19,216 28,477 163,950
TOTAL
TOTAL
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VAB.0001190626
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LABORATORY - H. G. Coleman
Safety - There were no injuries in the Lab this month. The monthly safety meeting, presented by Brian Harrison, included a review of ladder safety and a discussion of slip hazards.
B. Customer Relations
Customer Contacts
1/18 - Brian Harrison visited Premiere Polymers to discuss dry blend Q.C. and color matching.
1/24 -
Harold Coleman accompanied John Levardsen
on his calls to Lamar, Gencorp (Toledo,
OH), UTC (Columbia City, IN).
Of
importance, quality assurance contacts were
established at Lamar and a resin
contamination issue was defined at
Gencorp.
1/25 -
Harold Coleman went with Shelly Blomquist on calls to Uniroyal Plastics and Nibco. Uniroyal presented some data relating scrap rates to high 5385 I.V.
1/26 -
Brian went with Tom Davis to Vycom to discuss processing and quality concerns regarding RP-421 WHT 110.
Requests for Corrective Action
There were no RCA's received this month.
Customer Problem Reports
Date
Customer
Product
Reason
1/4
United Thermal Plastics Philadelphia, PA
269-66 BGE 141 378-34 WHT 141
Streaks. Over-lubrication.
STATUS: Product returned (nine boxes total). Work on streaking problem continues.
1/9
Klockner Gordonsville, VA
5305
Shipped them four railcars outside their desired I.V. range (.71 .74).
STATUS: Shifted production I.V. target and re-routed railcars. RESOLVED.
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VAB.0001190627
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Customer Problem Reports - continued
Date
Customer
Product
Reason
1/16
Thermal Industries Pittsburgh, PA
378-34 WHT 142
Lumpy dry blend.
STATUS: Sample from Thermal Industries checked out good on moisture, static flow and rheometry.
1/23
Vycom Scranton, PA
RP-421 WHT 110
Inconsistent processing.
STATUS: Torque rheometry testing of retains showed little product variability; still unresolved.
1/25
Uniroyal Plastics Mishawaka, IN
5385
High I.V. causes high rates in Ensolite.
STATUS: Investigating process capability of eeting a .93 maximum I.V. for 5385.
Waivers Issued
Customer
Product
Reason
No.
Essex
5415
Static flow
1 H/T
C. 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, 1989.
Reactor Slurries
_________Drier
5265
5305
Number of Samples Average RVCM, ppm
907 123
26 0.714
76 0.581
- > I**- >-'iTbr"`
.
VAB.0001190628
LABORATORY - Continued
C. RVCM Summary - continued
RVCM of Shipment Samples
The following is a summary of the residual VCM analysis of shipment samples for the month of January, 1989.
Product
Number of Samples
5265 5305 5385 5415 5465 Dry Blend Debox Pond
38 156
27 65
0
34 24
3
0.300 0.375 0.487 0.073
0.146 0.227 0.192
D. Resin Process CaDabilities
5265
5305*
5385
5415
Bulk Density Inherent Viscosity
(vs. 0.715 - 0.754) L Color A Color B Color % on Pan
(vs. 2%, max.)
% thru 140 Mesh Dry time Mets I.R.
(vs. 95% of control) Hard Particles, (% > 10)
1.50 0.26
--
3.39 1.58 1.44 6.83
--
1.56 -------
--
1.93 1.04 (0.63) 2.53 3.83
1.22
3.42
1.33
--
--
--
--
2.48 0.59
--
2.00
--
1.56 2.67
--
1.37 0.83
--
--
8.2
0.50 0.56
--
2.53 -------
1.89 2.83 (0.33) 2.39
2.00
3.40 2.17 0.90
Average particle size.
microns
136.2
136.7
156.6 169.8
*Reflects recent changes in 5305 specifications.
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VAB.0001190629
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LABORATORY - Continued
E. Compound Quality Summary
Adjustments
M Lbs. m
Hardness Color/Clarity Hard Particles Heat Stability Contamination Dispersion Dicing Cross contamination
Total
24.0
--
--
10.0
--
--
--
----------- -------------------
34.0
(0.35)
--
--
(0.15)
--
--
--
---------------------------------------
(0.49)
Rejections M Lbs. (%}
--
--
--
39.9 (0.58)
59.3 (0.86)
--
24.7 28.3 27.6
9.0 188.8
--
(0.36) (0.41) (0.40) (0.13} (2.74)
F. Drv Blend Quality Summary
Rejections
M-Ifefi.
(%)
Stability/Torque/40 Mesh Stability/Torque/Color Color Torque/Color
Total
2.4
2.6
3.9
12,1 21.0
(0.04) (0.04) (0.06) (0.18} (0.32)
Compound SPC Test Results
nX
38401 - Hardness - Specific Gravity - Hard Particles
62 62 62
82.98* 1.377
21.1
*p -- *
.010
3.30
35031 - Hardness - Specific Gravity - Hard Particles
62** 59 62
49.94 1.364 5.76
. _ __
.005 2.14
Mill Temperature, F
All readings
325
Oven Temperature, 0C
62***
204.0
p
^_
* ** ***
All readings but one were 83. All readings but five were 50. All readings but three were 204.
VAB.0001190630
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LABORATORY - Continued
H. 5415 Control Resin Test Results
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Moisture Drytime Particle Size - 60 mesh
- 80 mesh
- 100 mesh - 120 mesh
- 140 mesh
- 200 mesh
Pan Bulk Density Color - L
A B Flow Time, sec * Hard Particles , 7 min. Inherent Viscosity
62 0.163 38 4.96 61 1.38 62 29.73 61 33.84 62 21.19 61 7.21 62 5.33 61 1.31 31 0.5022 26 100.45 26 -0.04 26 1.94 31 7.85 27 5.30 Did not run.
0.030 0.29 0.65 3.11 0.95 1.74 0.83 1.44 0.38 0.0062 0.19
0.20
0.44 0.49 3.74
I. Miscellaneous
1. Richard Williams now has a computer with faxing capabilities for sending files and receiving all data. It functions similar to a fax machine; the extension is 3642.
We went to three solution rinses on the Schotte I.V. unit to completely purge the previous sample and to eliminate this bias from I.V. results.
3. Brian Harrison completed four color matches for flexible applications.
4. Brian visited Premiere Polymers on 1/18 to discuss dry blend color matching, Q.C. testing, specifications, and
5. Brian attended Exceptional Presentations training in Houston on 1/19-20.
6. Brian participated in a discussion of impact modifiers with
Rohm and Haas personnel in Ponca City on 1/31.
7. Raw material specifications were approved this month. Distribution should be complete by the end of February.
8. A new oven was purchased to dissolve I.V. samples,
replacing one with faulty temperature control.
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VAB.0001190631
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LABORATORY - Continued
VI
I. Miscellaneous - continued 9. Our Q.C. Hunter colorimeter malfunctioned this month. Efforts to fix it were futile and it will be sent out for factory repair. Meanwhile, we are using the old Gardner unit with correction factors.
10. The old C02 fire protection system for our chemical store
room was replaced with a Halon system.
VAB.0001190632
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RESIN Ship Date 1/05/89 1/05/89 1/05/89 1/05/89 1/05/89 1/10/89 1/18/89 1/19/89
1/23/89
1/23/89
1/31/89
1/31/89
JANUARY 1989
Product
5385-1
5385-3P
5385-1
5385-3S
5385-1
Sifter Overflow
5415
5385
5265 5305
5305 5415
Pond Debox
Pond Debox Sifter Overflow
Amount
400 lbs.
100 lbs.
50 lbs.
50 lbs.
300 lbs.
2X5 lbs.
50 lbs.
1 lb.
10 lbs. 10 lbs.
50 lbs. 50 lbs.
1 lb. 1 lb. 1 lb. 1 lb. 1 lb.
Customer NAT 10 SPONGE & PLASTIC PLASTIC GROUP PHILIPINES WUEMSCHE HANDELSGESELLCT SOGEPLAST ARNA INDUSTRY PLASTIC Wexford Int'l. Techni-Chemicals Transamerican Chemical Corporation Carlon
Polysar Rubber
Talco Plastics
Entis Associates
COMPOUND Ship Date 1/11/89
1/18/89
1/18/89 1/19/89 1/27/89
1/31/89
Product
14331 CB 50 18931 WAT CL
38601 GRAY 553 38601 GRAY 571
322-80A NAT
16841 NAT
151-160C Charcoal 570
46851 BLK
Amount 50 lbs. 50 lbs. 1 Swatch 1 Swatch
2 lbs. 100 lbs.
100 LBS.
200 lbs.
Customer Times Fiber
West Penn Wire
Ron Walker Calvex Mfg.
John Levardsen Lord Chemical
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DRY BLEND Ship Date 1/10/89 1/12/89 1/23/89
Product 378-34 WHT 141 378-34 WHT 141 269-151 WHT 145
PLASTICIZER Ship Date 1/10/89 1/20/89
Product VRP VRP
Sample Shipments Page 2
Amount
1500 lbs.
3900 lbs.*
1 lb. & 1 color plaque
_________Customer Davis Standard Uniplast Int'l. J. P. Industries
Amount 5 gal. 1 gal.
_________Customer Wexford Int* 1. Robins Tire
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