Document Jr1DK7vpNRgbewzOqvRX8g9J2
To: T. H. Huffman
Htwofflm Communication
From:
Date:
Subject:
D. C. Skokna April 23, 1990
ABERDEEN MONTHLY PROGRESS REPORT MARCH, 1990
Safety
There was one first aid care reported during March. As of March 31, the Aberdeen plant's employees have worked 3922 days (5,209,719 manhours) since the last lost time injury.
FY 1990 Kev Statistical Information
March
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
40.2 93.7 98.2 1.0029
6.3 98.1
5.8 100.0
1.3 79.0 < 0.7> < 5.3> 204.0
219.8 86.3 96.7
1.0011 36.1 98.0 28.4 99.5 9.0 88.2
< 10.0> 135.9 447.8
CaDacitv Utilization Factors
Resin Flexible Compound Rigid Compound Plasticizer
Operations
106.3 80.4 95.1 55.4
99.0 77.1 78.7 71.9
A temporary clean wall injection system was tested on D745, but it failed due to inadequate dispersion of the clean wall agent. A modified system will be tested in April.
A trial run to make 5305 using decalcified water was successfully
completed. tion.
Samples were sent to customers and BASF for evalua
In the compound unit, some twenty-four hours were devoted to PLENEX polymers development on Line I.
Rigid compound demand continued to be strong with 2.5MM pounds
being tolled for Gold Bond.
Oooob^
T. H. Huffman 4/23/90 Aberdeen Monthly Progress Report - March, Page 2
1990
Costs
Variable costs were favorable due to good raw material efficiencies in the resin unit and flexible compound unit, and to product mix effects in the flexible and rigid compound units.
Fixed costs were essentially at budget.
OMP
1. Ninety-five percent of the plant's natural teams met during March. Ratings for the plant's thirtyeight natural teams_as of 3/31/90 were 5.1 - up two points from the last measurement.
2. The finalized version of the Q-Scorecard was presented to the facilitators. The facilitators are responsible for helping to communicate the details of the Q-Scorecard to all employees.
3. A full review of Uniroyal, specifications was performed. These specifications will be proposed, to Uniroyal by Marketing for their approval. The specifications include the most recently requested requirements.
Doug Skokna Plant Superintendent
rah
CCR 000006336
DISTRIBUTION
COVER LETTER
ENTIRE REPORT
Houston
J. D. Burns
X
R. T. Ferrell
X
T. H. Huffman
X
C, J. Matson D. F. Harman
X X
H. R. Flammer
X
R. R. Smith B. J. Bean
X X
R. H. Gerlach
R. D. Gamblin
yu. L. McClain
X
x
X
J. P. Stokes
X
Austin
R. L. Poe
X
Oklahoma Citr1
H. J. Hall H. D. Garrison
X' X
LCVCM Plant
R. A. Conrad
X
T-CCP Plant
J. Friend
X
LCIAB Plant
J. W. Ware
X
Baltimore
L. R. Bauer
X
Hammond
J. Pavao
X
Bl ane
C. R. Miller
X
Premiere Aberdeen
P. L. Foote
RWS/DCS (File Copy), JEB, JME, SCH, MRK, JEL, DAM, RBN, JEN, JDO, REP, BLT
X
CCR 000006337
SAFETY - B. L. Trego
First Aid OSHA Recordable
Total Injuries
March
1 0 1
Fiscal Y.T.D. 1990
7 U 10
Fiscal Y. T.D. 1989
6 _2
8
Number of Restricted Workday Cases
0
2
1
Number of Lost Workday Cases
0
0
0
Tniurles bv Department
Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office
Totals
Iniuries bv Tvoe
00
02
06
11 00
JL
1 10
0 h
6 0 0 0 8
Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains Stings Other
Totals
0 0 0 0i 0 1 0 1
2 1 2 .1 0 2 2 10
1 0 2 2 2 0
_1 8
Non-Occupational Injuries
Lost Workday Cases Days Lost
Safetv Record
03 0 84
2 42
Last lost time injury * 7/5/79
Days since -
3922
Employee hours since - 5,209,719
On March 31? 1990, the employees of the Aberdeen plant completed 3922 days with no lost time injury.
Topics for the plant safety meetings during the month included reviews of Che new Plant Safety Handbook, Safety Attitude, Contractor Safety, Off-theJob Safety, and Severe Weather Operations.
SAFETY - Continued
A seatbelt survey was done to see how many Aberdeen employees wear seatbelts to work. It showed that over 40% wear seatbelts now versus 27% in a similar 1987 survey.
Annual physical examinations were given this month. The Health Examinetics van was here during the week of March 5, 1990.
Routine dosimetry results for the month were:
Chemical
VCM Lead Total Particulates
< PEL
Number
Percent
77 100.0 17 100.0
6 100.0
> PEL
Number
Percent
0 0.0 0 0.0 0 0.0
Monthlv Inlurv Summary
Injury Class
Deoartraent
Descriotion
FA
Laboratory
Wasp sting, left arm.
006339
ccR 000
QUALITY MANAGEMENT PROCESS - K. R. Kane
The finalized version of the Q-Scorecard was presented to the facilitators. The facilitators are responsible for helping to communicate the details of the Q-Scorecard to all employees.
Ninety-five percent of the plant's natural teams met in March with 100% expected in April.
A full review of Uniroyal Plastics specifications was performed.
These specifications will be proposed to . .liroyal by Marketing for
their approval.
The specifications include the most recently
requested requirements.
00063*0
COST VARIANCES - D. C. Skokna
Variable Costs
Product
March. 1990 Variance. $M
Efficiency
Price
Total
PVC Flexible Compound Rigid Compound Plasticizer
$68.5 53.1 70.7
U, 7 $204.0
$551.5 186.8 143.2 19.3
$900.8
$620.0 239.9 213.9 31.0
$1104.8
PVC - Raw material usage and product mix were both favorable. Debox production was 55% below budget.
Flexible Compound - Raw material use was $25.7M favorable, and product mix was $24,311 favorable.
Rigid Compound - Essentially all of the favorable variance was a result of the product mix.
Plasticizer - High "VRP" production was the primary cause of the favorable variance.
Price Variances
3M
- VCM Resin to Rigid Compound - Resin to Flexible Compound - 610P to Flexible Compound - Natural Gas - Other Price Variances
Total Fixed Cost Variance*
$540.1 143.7 138.6 13.5 12.2
52,7. $900.8
Payroll and Benefits MM&C Miscellaneous TI&D Clearances
Total
<$37.3> 17.8 11.8 5.9
<___3-^1 <$ 5.3>
CCR 000006341
Payroll and Benefits - Overtime was high in maintenance for Welex repairs in the rigid compound unit, repairs to the Line III FCM compounder, and centrifuge repairs in the resin unit. Compound department overtime was high due to vacations, illnesses, and National Guard duty.
M. M. & C. - Contract costs were below budget, but these were partially offset by material costs for compound unit repairs and centrifuge repairs.
COST VARIANCES - Continued Miscellaneous: Major variances in this category were:
- Packaging Supplies - $17.3M favorable. - Operating Supplies - $10.3M unfavorable (due primarily to preparing for
work stoppage). - Casualty Loss - $13.2M unfavorable (due to Worlanan's Compensation
payments).
cca 0000063^2
J. D. Olson, J. M. Vlnoski
Safetv
The Vinyl Department had no first aid or OSHA recordable injuries during the month of March.
The monthly safety meeting topic was "Off-the-Job Safety".
General
1. The temporary BUS-80 injection system was tested on D745 in March. The system failed to keep the reactor vails clean due to inadequate dispersion of the BUS-80 in the reactor. The test was discontinued and a new test with a modified injec tion system is planned for April.
2. The decalcified water test run was completed in March. High resin calcium levels are believed to cause Klockner's graininess problem. Tests show the 5305 resin produced with decal cified water had 4 ppm calcium (20% of normal). Samples were sent to Klockner and BASF, and results are expected in April.
3. The resin raw materials in the 744 account were valued at
$414.5M.
:
- March
YTD
- 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
%
40.2 1295.6
106.3 95.6 30.8 93.7 84.6
1000.0 98.2
219.7 1207.1
99.0 5159.0
28.3 86.3 75.4 90.2 96.7
Reactor Downtime
Hours
- 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 0-ring leaks).
241.3
Maintenance downtime (hydroblast reactors and drill condenser on D745, replaced agitator seal on D400, replaced control room Topaz battery backup unit, and mis cellaneous valve and instrument repairs).
224.7
eta o000063<*3
VINYL - Continued
Downtime
Reactor limited production.
Operational downtime (centrifuge plugs, dryer cleaning, and flameouts).
Maintenance downtime (centrifuge repairs, replace #6 Bird, shear pins, exhauster maintenance, sparge pipe replacement. Bird boot repairs).
* of Total Downtime 78.2 8.3
13.5
Key Maintenance Work - J. B. Autrey, J. B. Hegwood
- Reactor 745 was shut down for hydroblasting and condenser drilling during the_ month as part of.^the contamination control program.................
The S.A. module Uestfalia centrifuge was shut down for pre ventive maintenance work during the month. A factory repre sentative along with a mechanic disassembled and recon ditioned the centrifuge.
Number 8 Bird centrifuge was removed from service during the month and replaced with a spare. The centrifuge that was re moved was rebuilt and will be used as a sparge.
The old reactor unit recovery condensers were shut down during the month for cleaning because of pluggage.
- The motor on the west fan of #6A cooling tower was replaced because of bad bearings and windings.
- Reactor 400 was shut down for seal replacement on two different occasions during the month. The two seal failures were caused by a plugged lip seal flush line. The line was plugged with resin which stopped the flov* of water to the seal.
- The vinyl control room Topaz unit was taken out of service and replaced with the Topaz unit from the compound control room because of bad batteries and a bad system control board. A Topaz service technician is being brought in to service both units and make any needed repairs.
There were eight major valves changed out in the reactor area during the month.
CC 000634 4