Document MJnE7JVVO1bqQn2NBxLKL606x

conoco Faxed 1/24/83 Interoffice Communication to : R. D. Gamblin From : John Friend Date : January 24, 1983 Subject : 1983 OBJECTIVES - ABERDEEN CHEMICAL PLANT Attached are the proposed 1983 objectives for the Aberdeen Chemical Plant. The production and cost objectives are based on this month's reforecast, although variances are versus budget. Our highest priority in maintenance improvement is training. Our primary weakness is maintenance supervisory skills which will be addressed in a thorough supervisory improvement program conducted by MED and the plant. Our maintenance supervisors need to be trained in making a plan, working the plan and followup. Some close one-on-one, on-the-job training is included. Also, general skills upgrading is a serious need and is addressed in the objectives. We too often see repairs which fix the symptoms rather than the problem. By developing and implementing some training programs specific to our plant, we hope to see improvements in the quality of re pairs. Although not addressed in the objectives, Rick Snowden has developed a maintenance cost performance equation (discussed in his recent memo to you) which we hope will allow us to measure our maintenance performance on a cost basis. Overall quality control in the resin area is a major concern of mine. This year we hope to implement tracking systems which will specifically define our performance. With the tracking data generated this year, we can then identify our true performance and set quantitative objectives in 1984, Another very important program for us in 1983 is our resin dryer improve ment project. We know that our dryers have been neglected over the years, but we will begin to upgrade them with the extraordinary maintenance money in this year's budget. However, by using the knowledge already gained in Oklahoma City and the input of DuPont dryer experts, we will be able to prioritize the upgrading to achieve the most benefits the quickest. We should also gain significant energy savings with this program as evidenced by the improvements made at Oklahoma City. I hope the objectives can be finalized soon so that I can get back to the department heads with the official objectives for 1983. rah attachments VAB.0001183713 r NAME John Friend JART A. QUANTITATIVE GOALS Results 1982 Objectives 1983 SAFETY 1. Occupational Injuries a) Lost Time b) Medical Treatment c) Total Injuries d) Restricted Workday Cases 2. Improve VCM exposure for vinyl depart 7.9% >PEL ment employees exposed above the PEL without respiratory protection (% of personnel dosimeters). 3. Assure reliability of the plant fire water system through implementation of a comprehensive PM program. PRODUCTION 1. Achieve the 1/83 reforecasted resin production (assumes no sales, trans portation or raw material supply con straints). 314 MM lbs. 2. Produce 50 MM lbs. of PVC compounds (assumes no sales limitations). 38 MM lbs. 3. Achieve the 1/83 reforecasted dry blend production (assumes no sales 1imitations). 42 MM lbs. 0 Demonstrate ultimate unit capacity for 100 M lbs/day the high margin rigid profile dry blend (168A) produced to gaylord boxes. 5. Improve waste reclaim by processing pond resin through the new pond resin reclaim system. 400 M lbs. 0 4 32 2 4%>PEL 4-1-83 380 MM lbs. 50 MM lbs. 50 MM lbs. 200 M lbs/day 2000 M lbs. Actual Results 1983 VAB.0001183714 14 h-. V P. T NAME John Friend .'ART A. QUANTITATIVE GOALS Results 1982 Objectives 1983 Actual Results 1983 COST CONTROL 1. Reduce energy consumption per pound of production on an adjusted CMA basis. 2. Minimize the impact of severe cold weather by reduction of downtime due to freezeups. 3 Improve efficienci and thereby achieve a favorable variable cost efficiency variance from budget ex cluding product mix variances. 4 Achieve a favorable fixed cost vari ance from budget excluding deprecia tion variances. 5 Reduce production of sifter overflow. 6 Reduce VCM consumption per pound of resin produced. 7 Control overtime as a percent of straight time hours worked. 41.2% Below 1972 46.0% Below 1972 40 reactor - days downtime 10 reactor days downtime $111 M Favorable $300 M Favorable $856 M Favorable $145 M Favorable 0.00473 lbs/lb. 1.01237 lbs/1b. 0.00319 Ibs/lb 1.01190 lbs/lb 8.7% 8.5% QUALITY CONTROL 1. Reduce plant justified customer action requests by 10%. * 2. Improve 5385 particle size control and thereby reduce the shipments requiring particle size waiver. 21 4.1% Waived 19 2.5% Waived 3. Continue the significantly improved control of H-grade and mi11 scrap production in compound as measured by the percent of total production. 1.75% 1.75% H-grade and mill - H-grade and scrap mi 11 scrap 4. Improve 5465 viscosity control and thereby reduce the shipments re qu*iri*ng viscosity waiver. 10.8% Waived 7.0% Waived VAB.0001183715 i NAME John Friend A xJART A. QUANTITATIVE GOALS Results 1982 Objectives 1983 Actual Results 1983 ENVIRONMENTAL 1. Receive no penalizing citations for pollution violations. 2. Eliminate reportable VCM relief valve discharges since the two that occurred in early January, 1983. 3 3. Improve slurry stripping performance and reduce the number of days the slurry average is above 400 ppm VCM. 18 days 4. Obtain a new, favorable State operating permit for air emissions. Demonstrate compliance with the revised NPDES discharge limits by startup and operation of the biodisc unit. 6. Improve operation of the wastewater treatment system by implementation of revised operating procedures and operator training by 6-1-83, 0 0 After 1/15/83 10 days 3-1-83 4-1^83 6-1-83 PERSONNEL 1. Improve employee communications through One series of more plant manager's information meet meetings ings with all employees. Six series of meetings 2. Maintain current utilization of minor ities in the blue collar workforce. 3. Achieve a female hiring rate of at least 10% of new hourly hires. No hourly hiring in 1982 OTHER 1. Reduce combined 0739 and 0744 inven tories . $2.79 MM year-end $2,60 MM year^ inventory end inventory VAB.0001183716 k- .'ART A. ^r**i QUANTITATIVE GOALS NAME John Friend A Results 1982 Obj ectives 1983- Actual Results 1983 . OTHER - (Continued) 2. Complete total fixed assets inventory 20% complete 100% complete 3. Achieve a capital expenditure level within +1.5% of the 1/83 reforecast. 34% below cash +15% flow improvement target 4. Improve capital project execution by use of the newly implemented scheduling procedure and thereby achieve a yearend net for all projects of no more than two months behind the total pro ject schedule. 2 project months VAB.0001183717 1 ? I' Ml . ? :i PART R STRETCH GOALS John Friend NAME Results 1982 Obj ective 1983 Actual Results 1983 SAF ETY 1. Occupational Injuries a) Medical Treatment b) Total Injuries c) Restricted Workday Cases PRODUCTION 1. Produce 420 MM lbs. of resin. 2. Produce 53 MM lbs. of PVC compounds. 3. Produce 80 MM lbs. of low molecular weight resins. 6 36 3 314 MM lbs 38 MM lbs 48 MM lbs 3 28 1 420 MM lbs. 53 MM lbs. 80 MM lbs. COST CONTROL 1 Reduce energy consumption per pound 41.2% of production on an adjusted CMA basis. Below 1972 48.0% Below 1972 2 Eliminate reactor downtime due to freezeups. 40 reactor - days) 0 reactor-day^ downtime downtime 3 Improve variable cost efficiencies ex cluding product mix variances. $111 M Favorable $450 M Favorable 4 Reduce fixed costs excluding deprecia $856 M Favorable $300 M Favorable tion variances. QUALITY CONTROL 1 Reduce plant justified customer action requests by 19%. 2 Improve 5385 particle size control and thereby reduce the shipments requiring particle size waiver. Reduce H-grade and mi 11 scrap produc tion in compound. 21 4.1% Waived 1.75% 17 1.5% Waived 1.50% H. VAB.OOOl 183718 * 'I. 'r -P *1 I NAME John Friend A PART C. SPECIAL PROJECTS TO BE ACCOMPLISHED DURING YEAR (NON QUANTITATIVE) i ^^^ m -- i i ^i i Results Achieved 1. Improve our most pressing deficiency in maintenance through a supervisory skills improvement program conducted by plant and MED personnel. 2. Improve maintenance performance by implementing an extensive skills upgrading program: a) Send two I&E personnel to MED's basic instrumentation course. b) In conjunction with MED, develop and begin implementation of site specific instrumentation training. c) Provide basic instrumentation and mechanical seal training for operations personnel. d) Send three mechanics and three supervisors to MED craft school. e) Send the I&E supervisor to MED's instrumentation for engineer's course. f) Re-train all mechanics in align ment. 3. Work with R&E, Marketing and the Business Area to fully develop 168A dry blend (RP-200) such that consistent quality product can be supplied at high production rates. 4. Design and install a system which minimizes the falling hazard associated with, hopper truck loading. t 5. Develop and implement a comprehensive resin dryer improvement program in conjunction with DuPont dryer experts, Oklahoma City and PED. VAB.000113719 i-1 John Friend NAME i * V PART C. ____________________________ _________ ______________ ____ _________ .. __ ____ ___ _________ __________ ________________________I_________________________________ ^____________________________________ . SPECIAL PROJECTS TO BE ACCOMPLISHED DURING YEAR (NON QUANTITATIVE) Results Achieved 6. Provide a management tool for better resin quality control by implementing a tracking system for amount of resin waived, graded "B" and ungraded. 7. Evaluate the feasibility of consoli dating two large vinyl cooling towers and thereby shut down the two old cooling towers. 8. Develop and implement a comprehensive pre-trip inspection program for empty VCM, alcohol and phthalic anhydride cars. t. Evaluate a backwash filter on the VCM charge line for reduction in personnel exposure caused by filter element changeout requirements. 10. Improve low molecular weight resin production by working with R&E to minimize condenser fouling. 11. Develop a plant emergency communica tions plan. 12. Improve relations with local media and governmental authorities by con ducting orientations and plant tours. 13. Develop a supervisory identification program to improve the selection and development of potential supervisory candidates. 14. Install a new bed plate in the fluid bed dryer to increase drying rates and minimize plate pluggage due to localized stagnation. VAB.0001183720 name John Friend p* i t \ PART C. SPECIAL PROJECTS TO BE ACCOMPLISHED DURING YEAR (NON QUANTITATIVE) Results Achieved 15. Develop the Line I modernization project to provide an adequately modernized system in a timely manner. 16. Complete Manufacturing's Compound/ Dry Blend/Plasticizer Study in order to improve the plant's abilities to determine each product's cost and each operation's weaknesses in cost performance. 17. Develop a new hourly hiring program to improve interview procedures, establish applicant testing and pro vide expanded new employee orienta tion. 18. Maintain adequate inventory to fill all 5465 orders which have at least five days lead time (unless produc tion priorities are shifted by the Business Area.) 19. Work with the Business Area, R&E and DuPont to determine the most mutually beneficial plan for interim produc tion of EPD's new compounds. m-m'.tr-' VAB.00011F3721