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VAB.0001190699 ^JU> C To-. T. H. Huffman Interoffice Communication From: Dole-. Subject-. D. C. Skokna November 17, 1988 ABERDEEN MONTHLY PROGRESS REPORT OCTOBER, 1988 VISTA Safety There were two first aid ca&ea reported during the month. As of 10/31, the plant's employees have worked 3,406 days or 4,453,381 manhours since the last lost time injury. Key Statistical Information Month end 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, Z Prime Energy Use (EUl %) Fixed Cost Variance, $M Variable Cost Variance, $M Variable Cost Price Variance, $M Variable Cost Efficiency Variance, $M 37.0 91.4 95.9 1.017 6.7 92.9 5.6 99.9 1.8 93.8 0.6 ($ 17.8) $402.5 $491.1 ($ 88.6) Costs Fixed costs were essentially at budget. Variable costs were $88.6M unfavorable due-to above budget use of VCM and calcium stearate in PVC production, and correction of prior month's inventories for raw materials used in the Compound Department. VAB.0001190699 VAB.0001190700 T. H, Huffman 11/17/88 Aberdeen Monthly Progress Report Page 2 QMP - The plant celebrated everyone's efforts In the quality process with "Quality Appreciation Day". A Manager's award was presented to each team that had made a presentation to management. The event was veil attended. - Thirteen employees attended the "Excellence in Mississippi" conference held in Jackson. Attendees, which included other State businesses, exchanged ideas on quality improvement. - Three stabilizer suppliers were surveyed by a purchasing, manufacturing and P&P team. D. C. Skokne Plant Superintendent rah VAB.0001190700 VAB.Q001190701 DimiHrrioH BOUSTCNs PONCA Cn: COVER LFi'lB* J. D. BURNS p. T. FERRELL T. H, HUFPMAN c. J. MATSCN D. E. Tmm H. R. HAMPER R. R. aura K. J. EQCERS D. H. SANDERS S. E. MCGUIRE R. L. POE H. J. HALL ENTIRE REPORT X X X X X X X X X CCVER LETTER AND CUP CKIAHCm CTIY: H. G. GARRISON X IAKE CHARLES VOt PLANT IAKE CHARLES CH1M1CAI. PLANT: R. A. CONRAD J, FRIOT) X Safety Section and X TAKE CHARLES UB PLANT: J. W. WARE X BALTIMORE; L. R. BAUER X MUD: J. B. MAHER X BLANK K.H.YMERS: C. R. MDIR X PREMIERE KI3MEKS: P. L. FOOTE X ABERDEEN: WS/DCS (FilE COP?), PJK, JEN, DWH, TFL, JEB, VEM, HOC, JEL, REP, RBN, BLT * VAB.0001190701 VAB.0001190702 SAFETY - B, L. Trego Occupational Injuries October Fiscal Y.T.D, 1989 Fiscal Y.T.D 1988 First Aid OSHA Recordable Total Injuries 22 __0 1 21 2 JL 2 Number of Restricted Workday Cases Number of Lost Workday Cases 0 0 0 0 0 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 00 00 22 00 00 _0 22 0 0 1 1 0 2 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 11 00 00 00 11 00 _0 JL 22 1 0 0 1 0 0 _ 2 Non-Occupatjonal Injuries Lost Workday Cases Bays Lost 00 00 1 14 Safety Record Last lost time injury 7/5/79 Days since - 3,406 Manhours since - 4,453,381 On October 31, 1988* the employees at the Aberdeen Plant completed 3*406 days with no lost, time injury. Topics for the plant safety meetings during the month Included: Chemical Hazards, Annual Fire Training, VCM/Lead/Asbestos/Nolse Compliance Training, and Maintenance Weekly Safety and Job Reviews. A new safety shoe policy was Implemented on October 1, 1988, which improved the benefits for all employees. There was an increase in allotment amount er. well as the number of approved styles. A VAB.0001190702 VAB.0001190703 SAFETY - Continued Routine dosimetry for the month were as follows r Chemical K PEL Number Percent __________ > PEL Number Percent VCM 71 97.3 Lead 10 100.0 Total Particulates 3 100.0 2 2.7 0 0.0 0 0.0 Both of the VCM overexposures were with benefit of respiratory protection. Monthly Injury Summary Injury Class Department Description FA Maintenance Muscle strain., lower abdomen, FA Maintenance Laceration of third, right finger. A VAB.0001190703 VAB.0001190704 QUALITY DEVELOPMENT - IK W. Hollis General Plant 1) The Aberdeen plant celebrated everyone's efforts in the quality process with Quality Appreciation Bay. A Manager's Quality Award was presented to each team that bad completed the management presentation of their solutions. Approximately 120 employees turned out for the event. 2) The Aberdeen quality efforts were evaluated using the Ford Q-101 guidelines. The Aberdeen rating was 106 versus 140 expected by Ford for average. The main item contributing to this lower score was documentation of the quality systems. The Ford guidelines are being reviewed for setting 1989 goals. 3) The Excellence in Mississippi conference in Jackson was attended by thirteen people for the Vinyl, Compound, Laboratory, Engineering, Administrative Services, and Quality Development Departments. This conference showed the quality efforts of other companies in Mississippi and can be used to generate ideas for use in Aberdeen. 4) Purchasing, Manufacturing and R&D personnel performed quality surveys on three tin stabilizer suppliers* Kortor-Thiokol and Witco had well developed quality programs with M&T in the early development stages. Morton-Thiokol had a strong research department which will help in developing a partnership with a supplier. 5) Dave Hollis and Boh Schettek of Purchasing attended an AMA Vendor Quality Assurance seminar. This seminar concentrated on why you should form partnerships with suppliers and how to evaluate suppliers to pick the best one for a partnership, 6) Dave Hollis attended the first meeting of the RCA Team, Goals for the team were discussed and will be finalized at the next meeting. Other members of the team are Jim Rogers (leader), Dave Morgan, Cynthia Simien, and Tom O'Brien. 7) The Plant Manager's Natural Team met twice in October. Items discussed were the team's goals of reducing QMP barriers and hov to make more time available for the QMP process. Also discussed was the SRC and Team Management training needed and schedules of classes. Administrative Services 1) Natural teams met four times this month. Discussions included: a. Fiscal 1988 goal results and fiscal 1989 goal setting. b. Timecard errors c. AFE tagging d. Time management and barriers to QMP A VAB.OOOl190704 VAB.0001190705 QUALITY DEVELOPMENT - Continued Administrative Services - continued 2) Three project team meetings were held: a. Spare parts inventory - 2 b. Lead abatement - 1 3) Mike Swiero met with two major suppliers to discuss quality issues: a. Gulf Coast Marine - pipes/valves/fittings b. Southern Electric - electrical 4) The warehouse was operated sixteen months without a mie-shipment During this period, 2560 orders/84,591,516 pounds were shipped. Compound 1) The Dry Blend Improvement Team met and set priorities on what they would like to accomplish. The Product Change Team has completed its goals. 2) Operators on Line I began charting actual resip usage per blender. This will aid us in determining the accuracy of the Probatcher weigh-up. 3) Uammered-finish transfer lines were installed from the Line 1 Sweco to the bagging hopper and to the boxing hopper. These new lines are expected to reduce streamers in the final product produced on Line 1. Lab 1) The Dry Blend portion of the Compound/Dry blend database was completed this month by D. S. Cox. All in-process compound and dry blend data is now being stored on disk and simultaneously sent to the production units. 2) B, J, Harrison completed two SQC analyses of Dayton Extruded Plastics' 269-151 White 145 runs which demonstrated that the TJnivox control system has reduced the variability of dry blend production. Mechanical There are three active project teams in the Mechanical Department. The topic of the Mechanical Superintendent's Natural Team was 1988 goal results and 1989 goals. A departmental meeting was held for all salaried employees to review 1988 performance and set 1989 goals. All completed project teams participated in the QAD activities. VAB.0001190705 VAB.0001190706 QUALITY DEVELOPMENT - Continued Vinyl 1) The department's natural team met twice during the month to coordinate day-to-day operations, brainstorm barriers to QMP, discuss employee involvement teams and the Quality Implementation Plan. 2) Four employee activity teams met during the month: The 5265/5305 Contamination Team met with RAP personnel to detail their findings. The V-ll Dustbusters met with the Department Head to review their progress and request funding to complete modifications on one of the screeners. The modified screener will be used to prove that the recommendations will improve the screener and justify further expenditures. A team of operators from f,C,r shift met with PED-tiouBton to design the hose hook-up station which will be a part of the Low Molecular height Expansion Project. The Plasticizer Loading/Unloading team met with Process Engineering to review their recommendations for inclusion in a capital project being considered for the tank farm. 3) The Operations Superintendent and Engineer met with the KQIT (Klockner Quality Improvement Team) in the continuing effort to define and eliminate the problems of contamination and "wavy" film at Klockner. 4) Personnel from UTC-Automotive (5415 customer) visited the plant during October. The visit included e detailed plant tour and process description. A VAB.0001190706 VAB.OO01190707 COST VARIANCES - D. C. Skokna Variable Costs Product October, 1988 Variances - $M Efficiency Price Total PVC Flexible Compound Rigid Compound Plasticizer Total ($61.7) ($65.7) 34.7 4.1 ($88.6) $358.1 40,0 27.4 65.6 $491.1 $296.4 ( 25.7) 62.1 69.7 $402.5 PVC Variances - $61.7M unfavorable* VCM consumption was above budget but within the control limits* Stearate consumption was well above budgeted levels due to test runs and controlling static while producing 5385 and 5415 resins* Flexible Compound - $65.7M unfavorable. Correction of the September DIDP consumption resulted in a $57M unfavorable October variance* Rigid Compound - $34.7M Favorable Correction of the September tin stabilizer consumption caused a $34.BM favorable October variance. Price Variances $M VCM Natural Gas 61OP Alfol 610 All Other Price Variances $391.2 43.9 52.6 58,2 ( 54.8) $491.1 Fixed Cost Variances $M Payroll 4 Benefits M. K. & C. MJ scellaneous T, 1. 4 D. Clearances Total $0 ( 52,7) 41.1 ( 21.1) 14.9 ($17.8) A VAB.0001190707 VAB .0001190708 COST VARIANCES - continued M.M. & C. costs were above budget due to the purchase of a set of Welex blades ($17.6W), recovery system compressor parts ($23.3M), and other parts used in the flexible compound unit. Costs for the quarter should be near budget. Miscellaneous costs were below budget as several "Outside Professional Services" expenditures did not occur. Taxes were above budget because of the FICA tax on the recently awarded 5% bonus. VAB.0001190708 VAB.0001190709 OPERATIONS AND MECHANICAL DEPARTMENTS - T. tyon, P. Kober, J. Nickerson OPERATIONS/MECHANICAL SAFETY There were two injuries to Mechanical Department employees requiring first aid. One General Mechanic suffered an abdominal muscle strain while moving some heavy equipment, and a. second General Mechanic suffered a minor laceration to a finger while handling a gearbox pinion shaft. The Vinyl, Yard and Compound Departments worked without injury in October* The topics of the Mechanical Department*$ October safety meetings were VCM and Chemical Wash Piping Specifications, and Reactor Bolted Joint Specifications. Annual fire training and health training were conducted in October, These training sessions will extend into November. Fire training includes both fire extinguisher and fire hose hands-on training. A VAB.0001190709 VAB.0001190710 Vim - P. J. Kober, C. J, McDonald GENERAL 1. An Teonojr 132 kill 5305 railcar was made for testing at Eoechst Celanese. 2. 5415 was produced In the old module In reactor D600 this month. 3. A power outage caused high hard particles for a week. receivers had to be recovered and cleared. VCK October Production, MM lbs Dally Production Rate, Mlbs/c.d. Total Reactor Charges Charges, Reactor Batches/c.d. Reactor Stream Factor, % Average Dryer Fate, V. lbs/hr, Resin Quality, % Prime 38.6 1245 906 79.2 91.4 73.0 95.9 Reactor Downtime hours - Operational downtime (recovery scheduling conflicts, power failure, downtime to rinse cherc wash tanks, new module ritiee water/charge conflicts, waiting on particle size data before charging, no place to dump, loss of steam and air pressure, recovery receivers full, the local power company switching our power supply, and false charging 5415 ingredients in D600 preparing to produce 5415.) 490,3 - Maintenance downtime (D300 agitator seal change, D3C0 agitator gearbox replacement, put new condenser on D400, repaired D700 jacket, revised D745 temperature controller. Installed new "smart" temperature controller on D700, old module recovery line leak repairs, Nodicon revisions, B6QG agitator lip seal repairs, and miscellaneous instruments and valves,) 149.2 Dryer Downtime Total Downtime 639.5 Z of Total Downtime - Reactor limited production - Operational downtime (centrifuge plugging, dryer cleaning, activator transfer problems, checking duet collector socks for leaks, flame-outs, checking sifter screens, dust collector back-ups and a power failure). 83,2 11.0 VAB.0001190710 VAB.0001190711 VINYL - Continued Dryer Downtime - Maintenance downtime (change socks on dryers #8, 05, 07, #4, change screens and repair sifter on fluid bed, repair #6 gas valve, repair Star valve on dryers 05 and #8, repair #6 exhauster, 5415 slurry feed pump, air sweep maintenance on dryers #7 and 05, and various activator and centrifuge repairs). % of Total Downtime 5.8 Key Maintenance Work Reactor Area* ** - The 903 recovery compressor in the New Reactor Unit was rebuilt and installed. The new compressor was rebuilt using a new stainless Steel body section, spare cones and a spare rotor. The new stainless steel body is being used in order to improve the life of the recovery compressors. - The 904 recovery compressor in the New Reactor Unit was pulled, and inspected. This compressor wa6 badly worn and most major parts were unusable. A usable compressor was built from several new parts. A new cast iron body was used along with new stainless steel cones and rotor. - The reactor agitator seal for D-300 reactor was changed out due to an excessiive oil leak that was caused by a bearing failure on the gearbox agitator seal shaft. ** The D-300 reactor gearbox was pulled out for Inspection due to a high noise and vibration level. The gearbox was found to have a bad bearing on the output shaft. The gearbox was disassembled and rebuilt using stocked parts. All bearings, seals and gaskets were replaced. The gears were in good condition and they were reinstalled. - The North and South recovery condensers in the Old Reactor Unit and the Cast and West recovery condensers in the New Reactor Unit were chemically cleaned due to a fouling problem caused by a power outage, - The cooling water tower pump for 500 and 600 cooling water towers was removed and sent out for repairs due to excessive wear and then reinstalled. - There were six major valves which were changed out in the Old Reactor Unit and New Reactor Unit during the month due to leaks. ft VAB.0001190711 VAB.0001190712 o COMPOUND - J. E. Nickerson* J. B# Autrey General An experimental product, Chlsso E23023 Black, was produced on Line V. Another experimental run of this product is scheduled for late November. Flexible Compound Operating Days Month Production Qi_ Pounds) Average Operating Day Fiscal Rate Y.T. Line 1 Line 111 Line V Total 31 31 21.5 2296 3788 810 6894 74 122 38 2296 3788 810 6894 Downtime Hours Line 1 - Product Changes ~ Miscellaneous Maintenance - Transfer Problems and Limitations - Dicer Problems - New Transfer Line installation - Quality Problems and Control 78 16 15 13 11 5 Line 111 - Product Changes " Paw Material Availability - Transfer Problems and T,Imitations - Dicer Problems - Steam Repair on Mill - Take-off Conveyor Maintenance - Quality Problems and Control - Pull Roller Maintenance - Miscellaneous Maintenance Line V 87 10 9 8 8 8 6 6 5 - W&P Maintenance - Product Changes - Quality Problems and Control 58 46 14 A Rigid Compound Operating Days Dry Blend Unit 31 Production - M lbs Month Avg,, /Day YTD 5638 182 5638 VAB.0001190712 VAB .0001190713 COMPOUND - continued Downtime Product Changes Quality Problems and Control Welex Problems and Maintenance Transfer Problems and Limitations Miscellaneous Maintenance Screener Problems and Maintenance Haw Material Unavailability Univox Problems Hours 36 34 34 31 R 6 6 5 A Operating Days Plasticizer 30 Production - M lbs. Month Avg. /Pay YTD 1867 62 1867 Key Maintenance Work - A major overhaul of Welex in Dry Blend was completed. The bowls drive shaft sheave had deteriorated to a point where the shaft and sheave required replacement. All bearings and seals were replaced on the main shaft and the jack shaft. The main shaft and the jack shaft assemblies were also replaced. - A modfied gump screener bowl was installed. The modification is a project to upgrade the pressure rating of the screener bowl. - The heating/cooling coile in both H-3 and R-4 plasticizer reactors developed leaks and were repaired. VAB.0001190713 VAB.0001190714 UTILITIES - Number 1 and Fumber 2 boilers were shutdown for annual inspection, during which time the relief valves were tested, safety systems were inspected, and the firebox/vater systems were inspected. The fuel/air ratios were also adjusted to improve the combustion efficiency of the boilers. - Number 2 boiler was shutdown for repairs. The front and back walls were removed from the boiler and the refractory, pressure wall and the outer skin were replaced. - The dewpoint for the Deltech air dryer was improved from a -40C to -90C and the plant air pressure to the Vinyl unit was boosted by running one Reciprocating Joy compressor in conjunction with the West Joy Centrifugal compressor. The wiring to the boiler house alarms for the Deltech was also repaired. These repairs and changes were made as part of winterization for the air dryer area. - The intercoolers, aftercoolers and jackets for #8 and #9 Reciprocating Joy air compressors were acid treated as part of winterization of the air dryer area* - The West walk--in catalyst freezer was shutdown due to a problem in the freon system. The freon system had seme debris in it and the oil pump was bad. The repairs were made and the freezer was put back in service* * VAB.0001190714 VAB.0001190715 ENGINEERING - R. E. Polk, R. B. Newton, S. C. Hillman PROJECTS IN DEVELOPMENT Coker Water Test Run The water treatment unit has been placed into operation. Tiro reactor batches have been charged with Coker water. Evaluation of the resin and slurry samples is still underway. Klockner Contamination Team A team of one plant engineer and two R&T personnel has been formed to identify ways to alleviate contamination problems with 5305 resin. Alternate Natural Gas Pipe Line Two meetings were held at the plant to review the proposed contract between Vista and Gulf Fuels, Inc. Lead Handling Process Improvements A status report concerning the various lead handling improvement projects was issued and reviewed with plant management. A meeting involving Operations, RAD, and plant engineering was held to plan encapsulated lead testing. A VAB.0001190715 VAB.0001190716 u au os a ii M UJ II u cb a~ ii n (i a. ii to Hi m (/> QC ffi & a u 1: K crj u 11-1 A5 o iu a ti ui E jwn J . r. . t_E_ LJ D=) utt> Qc ...j ac 3 ^ w u. 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LU Jjj 3: _l 3K d h- d Uj O -- r *: *-- CJ LJ ui cn d tn j* a -- XI c; u/ d CD to U tn <s ^ id Q in lS5 ...J __| & s u a; a *-J tn a z c? k< m a. accxJ^LcSaiiA a c=r : u > " 1- W *3C l X aUL d 3 IB Ll C a: pi a: 10 x CS LlJ 4 co --i 1--. o 111 1 U Ul -- err CO U (Jj ft:' - *2. -U L.J t-J * ^au t-- z ta q-. l_l -- t cn -- ? u n l- in ui in M7 ac * it i t.) a e: tn <C O D C3 =3 ip tn CB <E UJ U sE3 & J a a: ^ <E UJ -- P5 CK ...I ^ -J J5 CA CC C-J a 2^ L*J uu t-1 tn > ,.j M4 ; > >- si t_) ft! d: UJ U LU f. 1 --I V~_ Z O* P era t/i UJ ui UJ -t -j cn ra h a uj ^ lj u-l U_J c J UJ Q yj tLU u. ^ ^ u e ft 4: p v cn or uj ca ar iac u_ <C -3 L'J ..j U.I >-- ^ !G3-- O. LL. tW UJ K ^ <r a: *ijtjl <r c> o CSS ___I IS U3 (J (k E CA Z 1.3 Z SS 5; s -_I CL 3* ^ h- i--i --1 f Z LJ (_J Z O ui m *t &r *-- --1 Ll. 3l *,, LJ_ ifi 1/7 SNummaoiaBa napietfWBitfaaennmaDtfiAmtfopiniDC'n- U. M l*. <i> ui r> co a- ri n * -c -1 41 S v a ^ c< -a- r-;i r~t 1-.. o -- . -o 41 -o cOinh~h~r^(~--0`-0--eo3oacrt4`j'nr'.cT*cDti7inr''inir3io ^ <r r cpuupuupccidu. u- i. u u w w t: ,.1 __1 :sa n; i VAB.00011907I6 VAB.0001190717 h ENVIRONMENTAL - F. G. Jeanson Water An excursion occurred on October 31 * 1988, when we discharged 34.4 pounds of Ammonia to James Creek. Our daily limit ie 27.9 poundB per day. This incident was reported to the State. All other wastewater discharge parameters were within NPDES limits. Air Bobby Whitaker with the Mississippi Department of Natural Resources visited the plant to do an inspection of air emission sources. The inspection is done annually and he found no violations at our plant. A contractor was commissioned to do a bagging study that would result in reduced fugitive emission calculation factors. These factors are used to determine VCM fugitive emissions that we are required to report under SARA Section 313. By doing this bagging study* VCM fugitive emissions can be reduced by one-third. The bagging study is scheduled for the week of December 5. Waste Management October waste shipments included: ** One load of floor sweepings to Chem Waste, - Two loads of separator oil to Stauffer. - One load of culls to Sun Polymers. - One load of stabilizer spill and plasticizer filter cake to Chem Waste. Two samples were sent to Chem Waste to be re-certified: API solids and PA spill material. Miscellaneous Attended Ammerman Media Training. Attended Hazardous Waste in Mississippi Seminar. VAB.00011907I7 VAB.0001190718 ENERGY CONSERVATION - D. A. Moore I. Energy Conservation Data ^ Unadjusted EU1 % ^ Adjusted EU1 % October, 1988 0.60% 20.03% Fiscal YTD 0,60% 20.03% BTU/Lb, 2409 2409 Total Energy Consumption WMM BTU 127.6 127.6 Note: This corresponds to an unadjusted CMA reduction of 42.6% and an adjusted CMA reduction of 53.8%. II. Plant Energy Conservation Program Maintenance There were seventeen energy related items completed in October. Fifteen of these Items were steam leak repairs. The remaining two were steam trap repairs Boiler Operation Boilers Vo. 1 Mo. 2 No. 3 Coubustion Efficiency % Oct*, 1988 Oct.T 1987 83^(2) 83.7^ 83.6(1^ 83,6^ 83.3 83.3 Note: (1) Boiler timbertwo was operated eight days during the month. (2) Boiler timber one was operated twenty-three days during the imnth. (3) Boiler nmber one was operated thirteen days during the month. (4) Boiler nunber two was operated eighteen days during the month. A VAB.0001190718 VAB.0001190719 HUMAN RESOURCE REPORT PERSONNEL - J. E. Beall EMPLOYMENT James M. Edvards, Jr*, Rehire PROMOTIONS/TRANSFERS ., #- William Caldwell promoted from General Helper to Lab Trainee. Richard Pace promoted form General Helper to Lab Trainee, RETIREMENTS None TERMINATIONS/RESIGNATIONS Robert E. Lee* Jr. TO/FROM LEAVE OF ABSENCE None VAB.OOOl 190719 VAB.0001190720 A Aberdeen, Mississippi Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations DEPARTMENTS Warehouse n. Plant Maintenance Laboratory Compound Vinyl Plasticizer PAR 16 13 41 24 40 33 5 75* 171 246 OCTOBER, 19S8 . MONTHLY PERSONNEL REPORT Minority Employees #, X Salaried ____ 7_ g% Hourly Total fr7 39Z 74 30Z 0_______ Q Hourly Min. Hired % Min* Hired Hourly Min. Term. % Min. Term. Q 0 Q Q # EMPLOYEES MIN. EMP. % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD 16 7 44 0 0000 0 14 7 50 0 10 0 0 0 0 39 10 25 0 0000 0 24 4 17 0 0000 0 40 27 67 0 0000 0 33 10 30 0 000 0 0 5 2 40 0 0 --Q_ 0 0 0 Number of Applicants: Month _______Q Year to Date APPLICANT BREAKDOWN: // Minority _Q _ Z Minority # Female p % Female 35 Q 0 * Includes 2 Co-op Engineers. Hires (Hourly); Month Q Year to Date 10 Terminations (Hourly): Month i Year to Date 5 Overall Turnover .6% Projected Annual Turnover 3.5% VAB.0001190720 OVERTIME AND ABSENTEEISM VAB.OOOl 190721 ev *4 <n in i--i fs HX O' no os rg - U. 00 9 kT| 9 *5 04 r* cn Cs| r*> r-g & e*iW s CM IPs --I CD PM M Ca CM D so O e O (9 to uu o o O>s* >9 0 9' mo ct> 9> o >e ri PM B O CO OJ nh U in fr S cv ft Oc>mg u"l ,8--0< cPmM O os CM ^ m in T3 0 4 c G tt I. 9 Q -C l I l I t> A Up*vi ^iTi IrA- hA* o u r^- o oo p^. <A P4 r* P* ^ lA CD o ^A Co u O o iA P" in o Min mPJi in h- O O it> \n P-4 CN n*. r"l N * $0 H h oo Os P4 r-. lA <N SC r^. a* n lA <N i"t fA n> 9w *m nj A* fl s uP Hu H _1 4 5 I-* 5 Ch g u K01 k01. o <q 0* l 4> * B A VAB.0001190721 VAB.0001190722 ADMINISTRATIVE SERVICES - J. E. Little Safety There were no safety instances this month. Safety meetings included dock safety and the importance of reporting near-miss accidents. Persotinel/Ttaining New Hire: Amy Vernon waa hired to replace Linda Michels - promoted. Resignation: Robert E, Lee - Storekeeper Jack Little attended the Excellence in Mississippi conference October 7 1988. Tommy Cummings was selected as our SPC expert while Pat Wells was nominated for facilitator training. Cost Savings Savings due to competitive bidding were $6822 and savings due to discounts were $1594 during October. Contract for the new AT&T switch was executed 10/31/88. A VAB.0001190722 VAB.0001190723 IABCRflDPta1 - H. G. Coleman A. Safety The Lab operated Injury-free this month. J P. Williams led the monthly safety meeting by presenting a film entitled "Chemical Safety and Health Hazards*'. B. Customer Relations Customer Contacts 10/12 - Alsco, a resin customer and toll producer of dry blend, visited Aberdeen to discuss dry blend quality control and to see our facilities. 10/20 - 1TTC Automotive was boated on a routine customer visit. 10/27 - H. G. Coleman visited Hoechst to discuss resin Q.C. and their new raw material specifications. Requests for Corrective Action Rate Customer Product Reason 10/14 U-Brand Upper Sandusky, OH 90172D Aluminum bar In product. Date Customer Product Reason 10/03 Prestollte Wire Sidney, HE RESOLVED STATUS! Bevade product; 852 Natural Fines and streamers; cross~cont. watched closely for defects. Customer Problem Reports 10/07 Vinyl Building Products 290-61 WHT 121 Oakland, NJ Sticktng/buming. STATUS: Product being reformulated. 10/07 Silverline Plainfield, NJ 376-6 WHT 141 Clumps Inconsis tent processing. STATUS - PBS to re-issue formula with less lubricant. VAB.0001190723 UBOKA1CRX - Continued VAB.OOOl 190724 B. Custcmer Relatlooa - cent* Customer Problems Reports - cant. Date Customer Product Reason 10/14 Ifedflariburg-Duncan 5415 Oklahoma City, CK Reduction (15%) in productivity. STAHS: Could fird nothing abromal; PRS ruming planetary gear dry times. 10/37 Product SpeMalHaa 5415 New Albany, IN Extmder processing problems. STATUS: Problem due to customer's new equipment or using wrong resin (5385 application). 10/18 Flexible Tecteologtes 17121 VJC Abbeville, SC Gxitafrinsticti (large particulates). STATUS: Recurrence of earlier problem with same lot; all bad material now isolated. RESOLVED 10/19 Central Plastics McPherson, ks 17462 MJT Cross-contandnation; hard particles; surging. STATUS: Crosa-contanrinatioci and hard particle spikes missed by regular Q,C. 10/19 Klockner Gordonsville, VA 5305 Contanination. STATUS: Railcar sent to D.C, Holding. Klockner team working on contamination problem. 30/21 Thermal Industries Pittsburgh* PA RP-100 WRT 142 Color match - WPT 141 versus WET 142. STATUS: Brian Harriscr to visit customer to discuss color needs. 10/28 Polytex Pittsburg, PA 317-166 WITT 144 C3tfif>s; carrot unload railcar. STATUS: Similar to two other ccnplaiats about mid--September dry blend production; suspect raw material prob] or. 10/31 Dayton Extruded Plastics 269-151 VET 145 Chops; build-up In receivers. Dayton, OF STATUS: See tfoewe. 10/31 Teoex 18031 CB50 Elk Grove Village, H. STATUS: IHS is irwestigating. Wscoloration of floor material.. VAB.0001190724 VAB.0001190725 LAE - Continued Customer Relations - Continued Waivers Issued Customer Product Reasoi No. Essex 5415 Bulk Density and Particle Size 1 R/C Essex 5415 Particle Size 1 R/C Grimell 5265 Bulk Density 2 E/C Intex 5305 Bulk Density 1 R/C Nibco 5265 Bulk Density 1 E/C Tenex 5385 Bulk Density 1 E/C United Tech 5415 Particle Size 1 R/C C. RVQi Sunaary HVCM of In-Prooess Satples Hie follcwing Is a suomary of residual VEM results on in process sanples. None of die reactor daily averages exceeded 400 TO! FV(K during the month of October, 1988. Reactor Slurries Dryer 5265 5305 Nurber of Semples Average, KVCM 904 127 29 0.4 78 0.4 KVtM of Shipment Samples The following is a sucttery of the residual VCW analysis of shipment sarnies for the nonth of October, 1988, Product 5265 5305 5385 5415 5465 Dry Bleid Pond Debox No. of Sables 42 129 40 59 0 Average KPtM, ppm 0.1 0,2 0.2 0,1 42 0.1 14 24 0.5 0.1 Resin Process Capabilities 5265 5305 5385 5415 Bulk Density 0.75 0.50 1.46 0.44 Inherent Viscosity 0.31 0.81 0.25 0.47 "L" Color Value "A" Color Value 5.75 6.33 3.93 4.00 4,33 4.44 VAB.0001190725 VAB.0001 190726 LftB " Continued D. Regin Process Capabilities - continued 5265 5305 5365 5415 "A" Color Value 6.33 4.00 ------- ------- "B" Color Value 1.67 0.69 2.00 2.67 % on Pan (vs. 2% meet,) 1.52 ------ 1.52 -- 1.78 4.00 -- (0.67) X thru 14CH 0.36 0.58 1.00 1.98 Drytime -- Mets X.R. (vs. 95% of Control) -- ___ 0.67 1.67 - 0.86 (0.32) Hard Particles CS 10) -- ---- 15.8 10.3 Compound Quality Sunnary Hardness Oalor/Clarity Herd Particles Heat Stability Contamination Dispersion Dicing Streamers Gels F. Dry Blend Quality Summary Adjustments M Lbs. (%) 64.0 (0.95) ---- -- -- -- -- -- -- ----. -- -- -- ---- Tbtal 64.0 (0.95) Rejections m ij>s. (%) 7.6 18.0 187.7 10.5 15.5 82.8 4.2 1.5 3.0 330.8 (0.11) (0.27) (2.79) (0.16) (0.23) (1.23) (0.06) (0.02) (0,04) (4.92) Rejections MIfrg. (1) Color Torque Color/Torque TOTAL Cennound SPC Test Results 38401 - Hardness Specific Gravity Hard Particles (20") 35031 - Hardness Specific Gravity Hard Partlcl.es (21) Mill Tarperature Ovai Temperature 7.8 3.9 3.9 15.6 (0.14) (0.07) (0.07) (0.28) Tl X 60 80.4 59 1.379 57 23.5 59 49.9 59 1.375 59 5.2 58 327.3 All readings 204C 3 0.80 0.006 4.6 0.59 0.009 2.5 7.3 A VAB.0001190726 VAB.OOOl 190727 lABORATOFff - continued H, 5415 Control Resin Test Results nX3 Moisture Dry Time Particle Size - 6f*f - 80K - 1O0M - 12*4 - 1404 - 2004 Pan Bulk Density Cblor - L A B Flow Time Hard Particles, 7 Min. Inherent Viscosity 62 0.164 0.030 31 5.05 0.35 62 1.41 0.55 62 28.08 3,12 62 33.90 1.39 62 22.10 1.83 62 7.79 0.99 62 5.43 1.56 62 1.29 0.39 31 o.sm 0.0055 31 100.60 0.345 31 -0.16 .353 31 2.25 .80 30 7.52 0.90 62 5.06 2.27 30 1.014 0.014 H. Miscellaneous 1. H. G. Coleman and B. ?. Sizeaore attended the Excellence In Mississippi conference on 10/7. 2. H. G. Goleman and M. TaTHe gave lab tcurs during the Educators Open Reuse. 3. H. G. Coleman attended the Scientific and Gcnputlg? Autonation Shot? In Philadelphia on October 26. A demonstration of labVantage , one of the software packages Tecaimended by EDS for the Lab database, was witnessed. 4. B. J. Harrison ccnpleted dry blend and compound color matches during the month. 5. B, J* Harrison attended the SPC color and appearance division regional technical conference In Newport, Rhode island, on 10/3-4/88. VAB.000H 90727 VAB.0001190728 O OSHA RECORDABLE TOTAL INJURIES s3fynrNt jo yjennN VAB.0001190728 VAB.0001190729 A SHIPMENTS BY PRODUCT - M LBS. 0CT' 1988 FISCAL YEAR-TO-DATE RESIN PLASTICIZER DRYBLEND COMPOUND 26,871 452 4,731 7,729____________ . 26,871 452 4,731 7,729 TOTAL 39,783 39,783 NUMBER OF SHIPMENTS BY MODE: RESIN-Bulk RAILCAR 112 VISTA TRUCK TRAILER ON COMMON CUSTOMER BULK VAN A FLAT CAR CARRIER PICK-UP CONTAINER TOTAL 51 2 89 254 Package 5 7 7 19 Export PLAST.-Bulk Package DRYBLEND-Bulk 'Package Export COMPOUND-Bulk Package Export TOTAL OCT 2 17 152 ro i--< 2 3 9 3 48 59 62 1 6 13 38 39 61 141 4 1 30 22 20 125 475 VAB.0001190729 VAB.0001 190730 SAMP LE SHIPMENTS A RESIN Ship Bate 10/18/88 10/20/88 COMPOUND Ship Date 10/04/88 10/04/88 10/10/88 10/10/88 10/11/B8 OCTOBER 1986 Product 5385 5415 Amount. 50 lbs. 50 lbs. Product 46851 BLK 18031 WAT CL 18961 WHT 366 17462 NAT 17461 WHT 34311 NAT Amount 100 lbs. 5 lbs. 1 plaque 2250 lbs. 50 lbs. 1500 lbs. Customer Quaker Color Ferro Corporation Customer Donnelly Corp. VISTA - Ponca City ITW Corp Weed Corporation AHR Cable 10/13/88 10/25/88 10/24/88 10/28/88 10/28/88 10/31/88 OTHER Ship Date 10/04/88 10/06/88 10/07/88 46851 BLK 17462 NAT 18162 NAT 18031 WAT CL 17462 BLK 17462 GRY 545 16851 NAT 15072 NAT 46351 BLK 46851 BLK Product Soya Epoxy T-831 Stabilizer Aroer. 3492-T1 610P Plast. Calcium Stearate 100 lbs.. 50 lbs. 50 lbs. 50 lbs. 800 lbs. 200 lbs. 100 lbs. 100 lbs. 100 lbs. 100 lbs. Amount 5 gal. 1 gal. 25 lbs- 5 gal. H gal. Donnelly Corp. Prototype Plastics Extrusion Co., Inc. Athens Plastics, Inc Central Plastics Inc Vista - Ponca City Lord Corporation Customer VISTA - Ponca City VISTA - Ponca City VISTA - Ok. City VAB.0001190730 VAB.0001190731 ENERGY USAGE A /LE 4. .t> o < : 9 U --C | ) Y E 4R S BY M O N T H S X >00m Oi l lV IS fO N S fi YSR CO W i. Monthly 12-Month Moving Average VAB.0001190731 VAB.0001190732 VAB.OOOI 190732 VAB.0001190733 ABERDEEN PLANT PRODUCTION . 10/01/87 - 09/30/88 4 Budget Actual Cumulative VAB.0001190733 VAB .0001190734 ABERDEEN PLANT EFFICIENCY 10/01/87 - 09/30/85 POUNDS OF RAW MATERIAL/POUNDS OF PRODUCT A VAB.0001190734 >MM VAB.0001190735 ABERDEEN PLANT INVENTORIES 10/01/87 - 09/30/08 VAB.0001190735 VAB.0001190736 ABERDEEN PLANT QUALITY PERFORMANCE 1Q/Q1/87 - 09/30/88 VAB.0001190736 VAB.0001190737 DisnusuricN COVER USHER ENURE REPORT COCERIZTER AND (W HOUSKH: j. d Bums X Ri E. LJSlfcdJHL X R. T. FERRELL X T. H. HUFFMAN X R. E. SWANTKGW5KI X D. F. HAFMAN X H. R. HAMER X r* r* airffl X K. J. EGORS X D. H* SAHSRS X FCNCA Cm: S. E. MXUIRE Ha L. POE X X H. J, HALL X c. h. sims X (KlAHHA CilYt H. G. GARRISON X TAKE CHARLES V(M PLANT fL A. GOKAD X LAKE CHARLES CHBttCAL PLANT: J. FRIHC Safety Section and X TAKE CHARLES LAB PLANT: J. V. HARE X BALTUCKE: L. EL BAUER X HAtQD: j. el mm X BEANE PCOMSS: Ca Ra X TmiE FQLXMERS: P. L. FOOTE X ABERDEEN: HWS/DCS (FILE USY) cot, pjk, HUH, TEL. KLF, JEB, VOU HOC, JEL, REF* REN VAB.0001190737 VAB.0001190738 SAFETY - K. Fogg, J. V. Uptain Occupational Injuries First Aid-, 0$HA Recordable Total ...Inj uries tyumb&x of Restricted Workday Cases Number of Lose Workday Cases June 1 0 1 0 0 Fiscal Y.T.D. 1988 8 _3 11 0 0 Fiscal Y.T.D 1987 8 6 14 2 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Re c eiving /WaTehou& e Office Totals Injuries by Type 12 02 06 01 00 0 _0 1 LI 2 1 8 1 2 __0 14 Cuts and Abrasions Eye Injuries Burns Bruises StraioB/Sprains Stings. Other Totals Non-Occupational Injuries 04 00 14 02 00 00 1 11 7 2 1 1 3 0 0 14 Lost Workday Cases Days Lost Safety Record 1 10 13 125 4 28 Last lost time injury 7/5/79 Days since - 3,283 Manhours since - 4,274,987 On June 30, 1988, the employees of the Aberdeen plant completed 3,283 days with no lost time injury. One injury requiring first aid treatment was reported. Respiratory protection training was completed for those people requiring that training. The Central Safety Committee met in June* The Local Emergency Planning Committee for Monroe County mat In June. A video tape and pamphlet for SARA 313 conffcmications was completed. VAB.0001190738