Document MGJN44jwpL4kw8BqXYnKxLwX9
ABD00282792
VINYL - D. W. Hollis/M. L. Nathan
Safety
The Vinyl and Yard Departments operated with one medical case type injury in August. The injury involved a cut to an Operators arm caused by an exposed insulation cover.
Shift safety meeting topics for the month included review/discussion of the plant's Emergency Plan.
Production
.1 Production, MM Lbs.
2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days
August
35.1 1133.5
867.0 28.0 92.2
12010.0 49.2 31
Y.T.D. (Fiscal 1985)
380.6 1136.4 9302.0
27.8 89.7 10043.0 60.5 335
Vinyl Department production for August was 35.1MM pounds.
Reactors
The reactor stream factor for August was 92.2%. Downtime in the reactor area occurred as follows:
1) Operational Downtime: Accounted for 48.2% of the total downtime and was due to reactor recovery scheduling conflicts and downtime due to severe weather conditions which included an extended power outage on 8/16.
2) Maintenance Service Downtime: Accounted for 2,6% of the total down time and was due to cleaning reactor AMS injection ports and slow vent lines.
3) Maintenance Repair/Revision Downtime: Accounted for 49.2% of the total downtime and was due to five reactor valve changeouts, agitator seal replacements on 600, 700 and 745, agitator kicker blade in stallation on 300 and 500, and agitator gearbox rebuilding on 745.
The dryer stream factor for August was 49.2%. Downtime in the dryer area occurred as follows:
1) Reactor Limited Production: Accounted for 91.7% of the total down time. Dryers were shut down when possible for energy conservation. Advantage was taken of the downtime to perform shutdown type work such, as dryer cleaning and dust collector sock changes.
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ABD00282793
VINYL - Continued
Dryers - continued
2) Operational Downtime? Accounted for 5.8% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning, transfer activator problems, and downtime due to power outages.
3) Maintenance Repair/Revision Downtime: Accounted for 2.5% of the total downtime and was due to activator, centrifuge and screener repairs.
Product Quality Summary
Resin Type
Prime
"BC"
"H"
% of Total Production
5265 5305 5385 5425 5465 Debox Sifter Overflow Pond Resin
Total
1,999,099 2,879,851 18,298,717 7,188,241 2,009,260
-
-
192,400 32,567,568
6,750
-
1,986,800
-
-
517,780
-
-
2,511,330
-- -
-
59,029
-
59,209
5.7 8.2 57.7 20.5 5.7 1.5 0.2 0.5 100.0
Quality performance for August was 99.8% customer grade with 0.2% "H" grade production.
A total of six railcars were shipped as "B" grade during the month which represented 5.0% of the 121 total resin hopper cars shipped.
Load Date Ship Date Car No.
Customer
7/15/85
8/02/85 ACFX 55814 Grifco
Product 5385
Reason Contamination
7/22/85
8/09/85
PTLX 41857 Continental 5385 Plastics
Contamination
7/27/85
8/13/85 VIPX 45805 Wexford
Debox
Quality
7/25/85
8/16/85
VIPX 45303 Extrusion 5385 Technology
Contamination
7/27/85
8/20/85
PLCX 41627 Extrusion 5385 Technology
Contamination
8/07/85
8/22/85 PTLX 41592 Silverline 5385
Contamination
The vinyl area received thirty-one short lead time emergency type orders comprising 12.8% of the 243 Aberdeen resin shipments in August.
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ABD00282794
VINYL - Continued
Monthly Variable Cost Performance
Variable costs for the month were favorable at $2778.5M resulting from net price and efficiency variances of $2784.9M favorable and $6.4M unfavorable, respectively. Resin variable cost for the month was 16.641 C/lb. vs. the budgeted 24.605 c/lb.
The $2784.9M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $2716.4M; VCM freight, $40.6M; and utilities, $43.3M.
The $6.4M unfavorable efficiency variance can be attributed to unfavorable efficiencies in raw materials, $48.5M. Positive efficiency variances included VCM, $8.3M; and utilities, $45.9M.
VCM efficiency for the month was 1.00398 lbs. VCM/lb. PVC versus the budgeted 1.00500 lbs. VCM/lb. PVC. Year-to-date efficiency is 1.00076.
Year-to-date variable cost efficiency variances in the Vinyl Department totaled $913.1M favorable.
Energy Performance/Progress
1. Plant energy consumption for August was a record 2326 BTU/lb. The previous record was 2338 BTU/lb set in May of this year.
2. A total of seven steam leaks and one steam trap were repaired during the month.
General
1. Packaging for the month totaled 631,279 pounds.
2. Resin raw material in the 744 account totaled $270.7M at month end.
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