Document Q8JjZZOa3EDDgGxNd4jebGEE

To: T. H. Huffman A Interoffice Communication From: Date: Subject: D. C. Skokna September 22, 1988 ABERDEEN MONTHLY PROGRESS REPORT AUGUST, 1988 There were one first aid and one recordable (MTO) cases reported during the month. As of 8/31, the plant's employees have worked 3,345 days or 4,369,280 manhours since the last lost time injury. SARA 313 COMMUNICATIONS On 8/16, an Open House was held for members of the medical community. Informational pamphlets were mailed to residents of the Aberdeen area. Key Statistical Information Month Y.T.D. FVC Production, Ml lbs. 39.2 Reactor Stream Factor, % 95.2 Resin Quality, % Prime 95.0 VCM Efficiency, lbs./Lb 1.0148 Conpcund Production, Ml Lbs. 6.7 Carpound Quality, % Prime 98.0 Dry Blend Production, Ml Lbs. 5.0 Dry Blend Quality, % Prime 99.1 Plasticizer Production, Ml lbs. 1.2 Plasticizer Quality, % Prime 91.7 Energy Use (CMA Reduction, %) 52.1 Fixed Cost Variance, $M (203.6) Variable Cost Efficiency Variance, $M 29.0 Variable Cost Price Variance, $M (3,231.4) Variable Cost Variance, $M (3,202.4) 415.7 89.7 1.0146 80.6 57.4 18.1 51.9 25.0 650.7 (23,314.3) (22,663.6) Downtime in the vinyl unit was primarily caused by recovery system conflicts and rinsing the chem wash tank. In the compound unit, Line I operated 30 days. Line III operated 31 days, and Line V operated 23 days. Fixed costs were unfavorable due to moving expenses, overtime costs to operate Line V, and several large maintenance projects. VAB.0001190771 '-:c lil M ..-f|l lf.-ra -V 'T I '^1 | 'I nt' ,M'. > * t ^ I ............... T. H. Huffman 9/22/88 Aberdeen Monthly Progress Report Donnelly and Lamar (compound customers who supply the auto industry) were visited. Donnelly emphasized that we need to follow Fordfs Q-101 quality system. Ford was also visited to learn more about their Q-101 system. Natural teams met in all departments. Plans for a "Quality Appreciation Day" were set - the date is 10-13-88. This event will recognize all plant employees' efforts in the quality improvement process. D. C. Skokna Plant Superintendent tls 41" .. ;r.h rt-s :: .;TI -liaitfc'it VAB.0001190772 -hi. -.Hfc.-ia '- ! - ' ; -i.v.1 r- -! |- J t DISTRIBUTION COVER LETTER NITRE REPORT COVER LETTER AND QMP HOUSTON: J. D. BURNS X R. E. LEH'KUHL R. T. FERRELL X T. H. HUFFMAN X C. J. MATSON X D. F. HAFMAN X H. R. FLAI'MER X R. R. SMITH X K. J. EGGERS X D. H. SANDERS X PONCA Cm: S. E. MOGUIRE X R. L. POE X H. J. HALL X C. M. STARKS X OKLAHOMA CTIY: H. G. GARRISON X LAKE CHARLES VCM PLANT R. A. CONRAD X LAKE CHARLES CHEMICAL PLANT: J. FRIEND Safety Section and X LAKE CHARLES LAB PLANT: J. W. WARE X BALTIMORE: L. R. BAUER X HAEMOND: J. B. MAHER X BLANE POLYMERS: C. R. MILLER X PREMIERE PCOMERS: P. L. FOOTE X ABERDEEN: FWS/DCS (FILE COPY), PJK, DWH, TEL, JEB, VEM, HGC, JEL, REP, REN, SAFETY A 1 p-rf- .Ml. -- ,.1j-.-||..,,,| , 1T|. f:r, 1-rri ;.* fci.:ia-* . i -i. m - VAB. OOO1190773 salf?! s-t: jj:. ! . . 1 * i ^T:S't? " -I a, ?!=: r-*..- PLANT FIXED COSTS - D. C. Skokna Major Category Payroll and Benefits MM&C T&I Miscellaneous Variance vs. Budget August, 1988, $M August YTD (42.5) (75.2) 9.5 (95.4) (203.6) (246.5) 65.7 110.6 95.2 25.0 Payroll and Benefits - The unfavorable variance was caused by overtime operation on Line V and higher than budget benefit charges. MM&C - Several extraordinary projects were completed during the month, causing the unfavorable variance. The largest was reactor condenser replacement. ($41.8M) Miscellaneous Moving, Home Assistance -($82.8M). Several major moves were cleared or accrued. Also, a $10.3M accounting error (J. Ware's Move) will be corrected next month. Ouside Professional Services - ($17.1M). Costs associated with SARA 313 work caused this category to be above budget. A VAB.0001190774 '"Up*' If .T1-I . A SAFETY - B. L. Trego Occupational Injuries First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases July 0 0 Fiscal Y.T.D. 1988 Fiscal Y.T.D 1987 02 00 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Non-Occupational Injuries t Lost Workday Cases DAys Lost Safety Record Last lost time injury 7/5/79 Days since - 3,345 Manhours since - 4,369,280 On August 31, 1988, the employees at the Aberdeen Plant completed 3,345 days with no lost time injury. Topics for the plant safety meetings during the month included: Bum Prevention, Nitrogen Handling Safety, Safety Awareness, Use of Personal Protective Equipment, Injury Prevention Performance Review, and Maintenance Weekly Safety and Job Reviews. `t -in. rll(^ LI-.... h. i .,41. VAB.0001190775 SAFETY - Continued A Chemical Numb e r PEL Percent Number PEL Percent VCM 73 100.0 Lead 10 Total Particulates 3 0 0.0 1 0 The single lead over exposure was with benefit of respiratory protection. VAB.0001190776 l ItT V \*'T ;!T?I t Y+M- "I> s H-- -5 hi.-. ' .1.  NUMBER OF INJURIES ABERDEEN CHEMICAL PLANT INJURIES L ^ z=i+. ,!! *- iMf-i-r :i 'H -t--i -!**; i wfcfn m^s r ^ - -v -*p'ir^ VAB.0001190777 hi J HllliaMMlUBgCyOU: m .s-.H . ---h rf-. .. r - r- --Ji*-!! -:t -iflfl 1 sK'lItdCeI-hy*?-.* W u< r.M in. sC,r;jt -r. A QUALITY DEVELOPMENT - D. W. Hollis Attended a meeting with R & D, purchasing and manufacturing personnel to determine important items to be discussed during the tin stabilizer audits scheduled in October. Visited customers Donnelly and Lamar to determine their quality needs for the future. Donnelly emphasized following the Ford program. Visited a Ford representative and gained better understanding of their program. Planning a "Quality Appreciation Day" to recognize the plant employees* efforts in the quality improvement process. Awards will be presented to teams that have completed their projects. Two Plant Manager natural team meetings were held to plan the Quality Appreciation Day and to determine a process that this team needs to improve in the Aberdeen plant. VAB.0001190778 I :r `-."S-tf.:* rl :-* ~ HI i* Hl| j , fl4l -J- * i [ : ifrrfH jKUH'tSfrTpmr.ifc*'*! J l: P ' -Hrh-iT- i . v r j. 'i vp :| . d|l VINYL - P. J. Kober, C. J. McDonald Safety There was one medical treatment injury in Vinyl this month. Operator sprained his knee while inspecting the fluid bed dryer. An "A" The monthly safety meeting topic was a review of this years accident record and prevention of accidents. Shift safety meetings to discuss recent accidents and proper handling of tote bins were also held. Quality Management Process The Department Natural Team met four times during August to coordinate daily activities and to continue the Quality Implementation Plan. The Quality Implementation Plan was also reviewed with all Vinyl and Yard employees at the monthly safety meeting. The quality video "Everything Can Be Improved" was shown. There are three active employee involvement teams in the department. All three teams met during the month. The V-ll dust team is designing dryer equipment modifications to reduce dusting. The Plasticizer Unloading Team is finalizing their formal presentation of recommendations to plant management. The 5265/5305 Contamination Team is investigating modified polivic addition to reduce reactor wall scale. Also, additional equipment and railcar washing are being tested. Production 1. Production, MM lbs July 39.2 Y.T.D. (Fiscal 88) 415.7 2. Daily production rate, M lbs/c.d. 1263.8 1237.1 3. Total charges 4. Charges, reactor batches/c.d. 934 30.1 9857 29.3 5. Reactor stream factor 95.2 89.7 6. Dryer rate, average lbs/hr 9313 9387 7. Dryer stream factor 70.7 68.8 8. Accounting days 31 336 The reactor stream factor for August was 95.2%. Downtime in the reactor area occurred as follows: 1. Operational Downtime: Accounted for 88.3% of the total and was due to recovery scheduling conflicts, downtime to rinse the chem wash tank, waiting on particle size data before charging, new module rinse/charge conflicts, no place to dump, holding reactors to test Isonox 132 as an emergency kill, and power outages. VAB.0001190779 "t* r. ............................................. '.Ml. I i -li- :I .! -'.-j ffci . !% .... .i VINYL - Continued Reactors - continued 2. Maintenance repair/revision downtime: Accounted for 11.7% of the total and was due to hydroblasting and drilling the condenser on D700, changing the agitator seal on D743, replacing the fluid drive coupling on D745, repairing the F-50 charge line in the old unit, new unit compressor repairs, and miscellaneous valve repairs. Dryers The dryer stream factor for August was 70.7%. Downtime in the dryers occurred as follows: 1. Reactor limited production: Accounted for 80.3% of the total. Dryers were shut down when possible for energy conservation. 2. Operational downtime: Accounted for 8.5% of the total and was due to centrifuge plugging, dryer cleaning, activator transfer problems, checking dust collector socks and sifter screens for leaks, flame outs, transfer line pluggage, and power outages. 3. Maintenance repair/revision downtime: Accounted for 11.2% of the total and was due to activator repairs, centrifuge repairs on several dryers, replacement of #4 centrifuge motor, repairs to the #7 trunion rollers, replacing #7 gear box, replacing #4 exhaust motor, screener maintenance, and fluid bed leak repairs. Product Quality Suimil Resin Type Prime 5265 5305 5385 5415 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 2,837,632 5,384,197 14,864,055 14,142,651 -- -- -- -- -- 37,228,535 "B" "H" -- -- -- -- 1,204,140 572,460 -- -- 1,776,600 -- -- -- -- -- -- 64,975 107,300 172,275 % of Total/W V A- ^ V to Production 7.2 13.7 37.9 36.1 0.0 3.1 1.5 0.2 0.3 100.0 A VAB.0001190780 i !*J. -=h W I* 111.'-I y+M-1'1. Ji . l- - .s VINYL - Continued Monthly Variable Cost Performance Variable costs for the month were unfavorable at $2338.OM resulting from an unfavorable price variance of $2253.5M and an unfavorable efficiency variance of $84.5M. Resin variable cost for August, 1988, was 26.659 versus budget of 20.691 cents per pound. The unfavorable price variance was due to VCM pricing at $2285.9M unfavorable. VCM efficiency for the month was 1.01475 pounds per pound of PVC produced versus the budget at 1.00756 pound per pound. This resulted in a unfavorable variance of $52.1M. The major causes of the VCM efficiency are related to railcar scale differences and accounting of resin used by Compound/Dryblend. Alcotex had an unfavorable variance of $15.1M. The Variance is due to increased 5415 production and the poor quality of the Alcotex used this month. Energy Performance Plant energy performance for August, 1988, was 2830.4 BTU/pound. General The resin raw material in the 744 account was valued at $277.8M Isonox 132 was tested as an emergency kill this month, but is not efficient enough for this use. A VAB.0001190781 1 i" * T 4 -4<r-| rJIllJf.-! H-'k.L-i i-:.i li In:i i :?i. -ii. i . . - COMPOUND - J. E. Nickerson, J. B. Autrey Safety The Compound Department worked without injury in August. The August monthly safety meeting topic concerned a review of plant accidents. Quality Management Process The Compound Department's Operations Superintendent Natural Team met in August. The nmeeting included all the compound shift supervisors. Topics included; color charting for dryblend and plasticizer, alcohol residual charts for P-1, and the decision that in the future, all operating procedures for Compound will be written by the shift supervisors and/or operators. The compound Shift Supervisor Natural Teams all met in August. Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line III Line V Total 30 2159 72 31 3520 114 23 1032 45 6711 24879 42025 13666 80570 Line I operated thirty days in August at an average rate of 72M pounds per day. Major items affecting production efficiency were: product changes, 106 hours; dicer problems and maintenance, 28 hrs; resin weigh-up problems, 10 hrs; and transfer line pluggage, 7 hrs. Line I was scheduled down one day to complete the new screener system tie-in and start-up. Line III operated thirty-one days in August at an average rate of 114M pounds per day. Major items affecting production were: product changes, 72 hours; quality problem 37 hours; and miscellaneous maintenance, 8 hrs. Line V operated 23 days in August at an average rate of 45M pounds per day. Major items affecting production efficiency were: product changes, 39 hours; hot oil pump problems and maintenance, 26 hrs; maintenance on intensive cooler, 8 hrs; pelletizer problems and maintenance, 7 hrs. VAB.0001190782 J'' I ' ! . i i I ii !n -|uJ| jr|n .. | .. j j : j, L qipi i- : | n| Vi". v COMPOUND - continued Quality performance for flexible compounds for August was 2.0% off-grade of which 98.9% was due to mill scrap. "BC" production was 1.6%. The raw material requirement for flexible compounds was pounds of raw material per pound of compound versus a standard (YTD is 1.00820). 1.00082 1.01196 The variable cost variance for compound was $477.8M unfavorable with $440.4M unfavorable due to price and $37.4M favorable due to efficiency. The efficiency variance due to product mix was $71.4M favorable. The only major raw material efficiency variances was Jayflex 366 plasticizer at $130.4M unfavorable. This is a new raw material that was not budgeted for fiscal 1988. Total compound inventory increased 406.9M pounds in August to 9.45MM pounds. Dry Blend Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 4998 161 57379 31 -- 322 Dry blend operated 31 days in August at an average rate of 161M pounds per day. Production included 80172C WHT 110, 80273G WHT 110, 90172D WHT 110, RP100 WHT 142, RP421 WHT 110, RP460 WHT 110, A10-001 BGE 347, 186-139 WHT 111, 269-66 BGE 346, 269-151 WHT 145, 317-166 WHT 144, 378-06 WHT 141, 378-80 WHT 112 and 378-83 NAT 100. Dry Blend production was hindered by: product changes, 38 hrs; Univox problems, 34 hrs; Quality problems, 24 hrs; Welex problems and maintenance, 13 hrs; cleaning and maintenance of Gump screeners, 10 hrs; and waiting on blender transfers, 5 hrs. Quality performance for the month of August was 99.1% customer The raw material requirement for dry blend was 1.00612 pounds of raw material per pound of dry blend versus a standard of 1.00491 (YTD is 1.00606). The variable cost variance for dry blend was $381.4M unfavorable with $459.3M unfavorable due to price and $77.9M favorable due to efficiency. The efficiency variance due to product mix was $118.1M favorable. The only major raw material efficiency variances were Supercoat filler at $10.3M favorable and titanium dioxide at $25.3 unfavorable. Year-to-date variance for titanium dioxide is $38M favorable. A VAB.0001190783 V'll ** il-5,i'jvKfriL|ii ixjfur. \' v ft- IL'M-rf'fjr - -1-1 l! v-.sinp. I *TW -f* T ................... ! h ! A |l- ri COMPOUND - continued Production, M Pounds Operating Days Month 1373 25 Operating-Day Rate 55 - Fiscal Y.T.D. 4 19425 327 Plasticizer operated twenty five days in August at an average rate of 55M pounds per day. Production included 61 OP and 108P. The Plasticizer unit lost considerable production during August due to failure of the inert gas system and one reactor agitator drive. VRP production totaled 110M pounds (9.0%). The raw material requirement for plasticizer was 1.03647 pounds of raw materials per pound of plasticizer versus a 1.10084 standard (Y.T.D. is 1.09213). The variable cost variance for plasticizer was $51.4M unfavorable with $90.7M unfavorable due to price and $39.3M favorable due to efficiency. The major raw material efficiency variances were Alfol 610 alcohol at $14.6M unfavorable and phthalic anhydride at $21.8M unfavorable. Year-to-date Phthalic anyhdride variance is $66M favorable. The efficiency variance due to product mix was $1.2M favorable. E"erey Compound Dry Blend Plasticizer Usage (BTU/Lb) Actual Standard 1849.4 761.2 2030.1 1758.0 720.0 1550.6 A VAB.0001190784 m p- - PLUiHil.f r ..Kb;' i -.J: f. ..u.^v, I MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - D. A. Miller, J. B. Hegwood Safety For the month there was one first aid injury recorded. A general mechanic bruised his knee while working in the Dry Blend basement. The monthly safety meeting topic was a review of this years safety performance and a presentation of the Quality Implementation Plan. Quality Management Process The Quality Implementation plan was reviewed with all mechanical department employees during the month. Training Four mechanics and the Maintenance engineer spent 5 days in Carbon Steel pipe welding training. Vinyl The 903 recovery compressor was removed due to a seal leak and the shaft was repaired. The fluid coupling for the 745 reactor agitator failed and was replaced. The Chem wash pump in the old unit was replaced and the spare pump was overhauled. The following mechanical seals were changed during the month: - North blowdown tank pump seal in the New Unit - 743 reactor agitator seal - North VCM transfer pump seal - 903 compressor, inboard and outboard seals - nA" compressor, outboard seal The following major valves were changed during the month: - 744 main dump valve - 700 slurry dump valve - 500 slurry dump valve - 700 chem wash return valve - Old Unit slurry dump control valve The condenser on 700 reactor was drilled and the shell was hydroblasted. A VAB.0001190785 .s^pi i MECHANICAL DEPARTMENT - continued Dryer Area The pond resin centrifuge for //I dryer was removed and is in the process of being rebuilt. The fluid bed dryer pick heater was repaired and a steam check valve upstream replaced. The #1 dryer rotary valve was changed out and overhauled. The high pressure seal water pump for the dryer building was rebuilt. The fluid bed dryer south kason rotary valve was changed out and the spare valve was overhauled. The North East trunion roller on #7 dryer was changed out. Compound, Dry Blend, Plasticizer The diverter valve to 490/475 series silos was pulled and rebuilt. The vacuum system blower was pulled, cleaned and rebuilt. The East mill in the Quality Control lab was replaced with a spare and the old mill overhauled. The following work was accomplished in the Compound area: - Line I was shutdown for two days so that some general maintenance could be performed. Several stem leaks were repaired and the oil in all gearboxes and mills was changed. The input shaft seal on "A" blender gearbox was replaced and the seals on the Stuart Bolling mixer were replaced. - The lid on Line III "A" blender was replaced. - The Line V intensive cooler blades were tightened and the seal in the single screw hot oil system pump was replaced. The following work was accomplished in the Dry Blend area: - The lid was regasketed on MD" blender - The sprockets and chains were changed out on blenders "B", "C", and "D". The following items were accomplished in the Plasticizer Unit: - The gear box and agitator shaft on R~1 reactor was rebuilt and the seal was replaced. - The rupture disks on R-4 reactor were replaced. VAB.0001190786 | .li. <-*. I. ;e . : t-i-H--:. > | K.IC 11 I MECHANICAL DEPARTMENT - continued - The suction gas heat exchanger was replaced and the gas after cooler was cleaned on the inert gas machine. The spare inert gas compressor was also installed. Utilities Number 3 boiler was shutdown for inspection after discovering a hot spot on the north side. Some refractory damage had occurred which allowed the hot spot to develop. The Boiler was entered and repaired. Approximately ten square feet of the wall was replaced. Number 1 water well pump motor failed and was pulled out for repairs and returned for service. Repair work to the Bio disk system was started and is nearly complete except for regenerating of the Bio-mass. A r-" !1p VAB.0001190787 A tltbrLM.IMPhi .faMI-ljW-- . r- MECHANICAL ENGINEERING - R. E. Polk AFE F786/F557 - Resin Quality Improvement Concrete and mechanical work is complete except for final process tie-ins. These are scheduled to be completed during the upcoming module outages scheduled for the week of 9-19. I&E work is 99% complete and system checkout is in progress. Both reactor modules are scheduled to start-up using the new suspending agent systems at the conclusion of the reactor outages. AFE A538 - Reactor Condenser Revisions The retubed condenser for D-400 has been received. Installation has been delayed until mid-late October due to resin demand. AFE D608 - Dryblend Orbitran Replacement Construction is complete and the unit operational. Minor punchlist items and as-built drawing documentation are in progress. Completion is planned for 11-1. Maintenance training on the new scale systems has been arranged for early October. AFE D638 - Boilerhouse MCC Replacement All pre-shutdown work has been completed. The MCC will be energized during the week of 9-19 in coordination with a plant steam outage. Project completion is planned for early November. AFE F598 - Line I Screeners Installation of the system is complete except for the new transfer system piping. This has been delayed due to poor delivery dates for material. The new screener was successfully started-up using the old transfer piping. It will be operated in this manner until early October. AFE A678 - Dryblend Transfer System Improvements Installation iscomplete including punchlist items. will be closed to field charges in September. The project AFE F587 - Laboratory Addition Installation iscomplete including punchlist items. will be closed to field charges in September. The project AFE D707 - VCM Unloading Fire Protection Installation iscomplete including punchlist items. will be closed to field charges in September. The project A VAB.0001190788 .................... H+-T- I* Fip iKJ-*! hJ *l: n ,n -4r-. (i- f i -lintel# pqytri-tti-! sirffr-i <- <:= ^ '.ri-c-;c:: -.l: ir---F -,-t iir i-i iJ't -Mi!!i-PrHfJ| . 11 |T-. I - J 1. r i-- - -...............a- -t MECHANICAL ENGINEERING - continued AFE D628 - Compound Resin Supply Valves Installation is complete including punchlist items. will be closed to field charges in September. The project AFE D648 - 745 BME Addition System Modifications Mechanical installation is complete and the system is operational. Punchlist items are in progress and will be complete by 10-1. AFE A658 - Additional 5415 Production In The Old Module All scope items are complete except for the installation of the bag filter on the fluid bed dryer. Installation is planned for the week of 9-19 in conjunction with the reactor module outages. AFE A698 - Roof Upgrade Phase III Coating of the main office building and V-ll dryer building roofs is complete. Installation of the new membrane roof for the compound/dryblend area is in progress and scheduled for completion by mid-September. The V-ll recovery building and the administrative services roofs are planned for completion by 11-1. AFE A728 - Recovery System Compressor The compressor has been placed on order with delivery scheduled for mid-November. AFE C558 - Dry Calcium Stearate Addition Installation of the feeders and transfer piping is essentially complete. I/E installation is planned to commence by mid-September with completion by 11-1. AFE C738 - Plasticizer reactor Condenser The condenser has been placed on order with delivery scheduled for 1-1. AFE C748 - Resin Railcar Cleaning System Design is 20% complete and in progress. Quotes have been requested on the transfer system. Design is scheduled for completion by 10-15 and installation complete by 2-1. A m 'ii- v-'ik >.|->4^|-. VAB.0001190789 ............... V s MECHANICAL ENGINEERING - Continued A AFE P618 - Vinyl Valve Limit Switches Phase III Installation is in progress in both reactor modules. A total of 18 of the 77 valves have been modified to date. Modification of valves in the new reactor module will be coordinated with the 9-19 outage. MISCELLANEOUS ITEMS Printing of the new VCM/chem wash piping specifications has been completed. It will be Issued to the plant in early September. Development of specifications for reactor bolted joints is in progress. Completion is planned for 10-1. Capital expenditures for the year are $2.8MM ex-RQIP projects which is 97% of the target for the year. VAB.0001190790 I J|U -'+*! |'i* >f) | h rn-T-TT1:- -- ~riii>iiiirrnf inniTi nim hi m u . . I. . _:r : .. PROCESS ENGINEERING - V. E. Messick Resin Quality Improvement Project Flushing and commissioning of all equipment and piping in the new Suspending Agents/Kill make-up module were completed. Test batches of Methocel solutions were made and centrifuged. Operator Training classes will be held in early September. Start-up of the unit is scheduled for mid-September. Low Molecular Wt. Resin Expansion Initiator heat release data is being gathered by PED. information is being given on an "as needed" basis. Field Dry Blend Orbitran Replacement Univox Operator Training is now complete. and debugging were also done in August. software revisions are being planned. Configuration revisions Some additional minor Plasticizer Improvements Samples of waste-water produced by the plasticizer unit have been sent to R & D for analysis. Test-runs continue in the unit. Alternate Compressor Installation The class "A" design for this project was issued for review. This project will install a Siemans compressor for testing as an alternative to Nash compressors. Continuous Hardness Meter The class "A" design for this project was issued for review. This design will provide continuous monitoring and alarm capabilities for boiler feedwater hardness. Boiler Feedwater Treatment The revised class "A" design for this project was issued. This design provides bulk storage for boiler feedwater treatment chemicals. Capital Budget The 1989 Capital Budget was prepared and issued. A ~n'?rr -reuHlitilih..'. i:t . .-.i .'in-' VAB.0001190791 11IM!- trWir. . :-.i i( -tlS+lV =L. t-.fT M-: .ill.. . !d +!: i..1> J - -r-, ^ * HUMAN RESOURCE REPORT PERSONNEL - J. E. Beall EMPLOYMENT David A. Moore, New Hire Bruce L. Trego, New Hire PROMOTIONS/TRANS FERS William Earnest promoted from Compound Utility to Compound Operator. Keith Fogg promoted and transferred to Safety Director LCCP. Bernard Garth promoted from Compound Operator to Plasticizer Operator. Steve Hillman promoted from Compound Operations Engineer to Senior Process Engineer. Michael Johnson promoted from Compound Utility to Compound Operator. George Phillips promoted from Compound Utility to Compound Operator. Willie Rowe promoted from Compound Operator to Compounder. Gary Sanders from General Helper to Compound Utility. Pat Wells promoted from Compound Production Scheduler to Stores Supervisor. RETIREMENTS None TERMINATIONS/RESIGNATIONS Fred Davis Deborah L. Tollison TO/FROM LEAVE OF ABSENCE None A p. I-!.*! i: 'I -IK-4 i V-p-w^- ---1i- * - dr.-*| :|.|||i|f l' 4, B|l Mill I Mil ' ' !"hl: =" VAB.0001190792 - I'- : :i II : . :J p.HH ti:. . u p m h 4. Aberdeen* Mississippi Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound Vinyl Plasticizer PAR 16 13 40 24 40 32 5 76* 170 246 AUGUST, 1988___________ MONTHLY PERSONNEL REPORT Minority Employees Salaried Hourly Total 7 67 74 % 9% 39% 30% 0 Hourly Min. Hired 0 0 % Min. Hired 0 Hourly Min. Term. 0 % Min. Term. 0 # EMPLOYEES MIN. EMP. % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD 16 7 44 0 0000 0 16 7 44 0 8000 0 38 9 24 0 0000 0 24 6 25 0 0000 0 39 26 67 0 0000 0 32 10 31 0 0000 0 5 2 40 0 0000 0 Number of Applicants: Hires (Hourly): Month ______0_______ Year to Date 35 Month 0 Year to Date 8 APPLICANT BREAKDOWN: Terminations (Hourly): # Minority Q % Minority ______ 0 Month 1 Year to Date 4 # Female Q % Female ______ Q Overall Turnover ,6% Projected Annual Turnover 3.5% * Includes 1 temporary employee and 2 Co-op Engineers. . I ..1 J. U ' ........... *** * -|'l- *|" r-rf1: -Si -.i+t .J-l :l VAB.0001190793 I . - . >. *>- T 0 hO n 00 33 1 rr on 1 O a rr 03 O ro 03 cr ? <t ft 2 rt) 3 i ft h** 3 ft 03 t 0 < OJ ft 1 0 <3 ft ft 1 rr ft 3H* X n ft 3 CL a c h*- ft 3 OO 0 < t ft 011 1 X3 030 ft CL 1c ocrt ft c H-* 03 *1 c 0 *1 9? H* 3 ao 1ft 00 3 03 1 CL o 03 3i1 CO 0) 3o CL 3 < 03 o 1 3* pr o M* 3 H* 00 CL 03 i ft OO 03 33 H* CL 03 O 1 c pr 3 H* -t 3 03 00 o rr 3 cr ft rr 3" 03 ft H4* X cn (-- HU 3* X rr CL 3* 03 CL 03 3 H* O 3 "O m O -o 03 ft r-r 1 H* 03 c rr 3 cn O4 3 cn c 1 cn o 3 to tn 13 >m i-1 tr 2M H m f co OH h- r>4 r* H LH n 13 at csj >r O m 50 H r*i ?a n o H< > >c 00 as H 50 cxn cn o zZ a Z> x CO n cn w o ft 03 3fft rt 3 LJ h-1 o 00 Ln f--^ H-* 1--^ 00 Ol oo ro O ho vO 4>* cr H-1 LJ vO Ln CP Ln LO 4> LJ LJ LJ ho cr hO Ln cr LJ 'O cr ft o Ln O ro o Ln Ln ho ho o o o o Ln Ln O O Ln Ln o CO o rr 3 1 0) Cft 70 s: or o rr rt H t-^ft 3 ft A -fr- Ln Jh o> o N3 ho 00 OO cr vO O o OO > LJ vO 00 cr vo Ln O o o Ln o o o Ln Ln O oo hO Ln Ln ^0 ( t1 1 1 11 1 11 l1 l1l\ 11 1 1 1 1 1 1 11 1 1 1111 ( t1 \ 1 1 \1 \ 1 1 1 1 \ 1 11 1 1 111 1 i1 1 1 1 111 11 1 1 \ 1 1 1 no 3 rt 1 O < QJ ft cr *1 ft 3 ro x c c 0 3 103 1 a 00 31 rr X- 1 ro O Cl 03 cr L-* ft ro OO Ml < ft H-* --* -O vJ o ft ft H* 1--* |--l O oj * X cr X * ft ot 1 rr rr 1 Hu Ln vJ O' H-* VO Ln hJ cr -*L ro Ln O wTI CO X JT 03 3 Hu rt 020T 03 rr cn 03 H* 3 ft h-1 LJ I--1 <r LJ t-- cr NJ hJ Ln vO *--* OO O 00 O Ch ro o Ln > cr cn F* ft O3 cn n rr rt X o 3 1 pcan X m crzno L" d rn co LJ Ln hJ cr. <r ro Ln (S3 G 00 o vO ro O > O o o to vO vD O o CA 3 ft ft 03 n3 cn rt 03 00 o O cr o o H-* ITM1 iTM* 03 cr NJ o vO o O 03 vO LJ CO M ho rt 3"S i H-* -O Ln 4 ft LJ ft ft "O 00 LJ j--* ft ft 4^ hJ o ro <T <r o ro o O o '-j vO Ln o ro 0 H o CO rr rr 03 1 03 t-u 13 (CTQ LJ Hu *ft ft ro LJ LO Ln >--* LO ro ft ft ft ft a ] ftho vD cr o Ln o LJ ro Ln cr 00 00 O' 1--* O) ro O ft H '3 VAB.0001190794 *..:> "j n-fU-l: :i: : ,d|4_h:-L' $ i-?i -Hr1 Hlcftft-:/n-rfc" T 1 - is-..- .TE-n Ji-rlialft: -|K<Hv*rr1irzi(wHt]mvrmi:uj.MKU *i:4-Hrfpr.nii.4|-cLMU(t4mH4ll^a'4'ai^''r<<f!-!-!i ^t-i-ii--m.iHriMM'E .i.-:.-.rn-""S!!-!"t!.k.-j i _=: . .:-i.ti - n.,:- ENERGY CONSERVATION - D. A. Moore I. Plant Operations Total energy consumption for August was 127.315 MMM BTUs. Energy consumption decreased to 2448 BTU/lb. from 2570 BTU/lb. in July. An adjusted CMA reduction of 52.1% was obtained for the month. The adjusted CMA reduction for fiscal 1988 is 51.9%. II. Plant Energy Conservation Program Maintenance There were eighteen energy related items completed in August. Seventeen of these items were steam leak repairs. The remaining one was a steam trap repairs. III. Boiler Operation Boilers Ccnbustion Efficiency % Aug, 1988 Aug, 1987 No. 1 No. 2 No. 3 83.5 (2) 83.3 83.4 (1) 83.3 Note: (1) Boiler nunber two was not used during the month. (2) Boiler nunber two was operated one day during the month. I -SsiSs-r:!*:- I: - -I :: i VAB.0001190795 iltfJ:*l |i" O CPi CM 00 BTU/LB LTJ * o >in Q '/i g -3 i** u K -? in 3 jEo 2 !5 < o' > uj 113 in j cr u < u. >UJ ^ to , 1& Jt > ENERGY USAGE i Monthly 12-Month Moving Average VAB.0001190796 ::: a-*** i- ..................................................................." -*>**!** ^ *; i-MMWntt1-'ft V L--i.!-^JNH -n ww -n:-p, jjnfrp v.lv-.m .J;s .-wn r rfi ihr-i!, t >' ! I Month ENERGY CONSERVATION DATA 1988 August Production, Ml lbs. Resin Dry Blend Compound Plasticizer TOTAL 39.1 5.0 6.7 1.2 52.0 Natural Gas Consumption, MSCF Conversion, KEU/SCF Energy Consumption, Mil BTU Energy Consumption, BlU/lb. 64.971 1020 66270 1274 Electricity Consumption, Ml KWH. Conversion, BTU/KWH Energy Consumption, MM BTU Ehergy Consumption, BTU/lb. 6.104 10000 61044 1174 Propane Consumption, M Gal. Conversion, BTU/Gal.1 Energy Consumption, MM BTU Ehergy Consumption, BTU/lb. 0 92000 0 0 Total Energy Consumption, BTU/lb. 2448 Energy Consumption, Mil BTU Actual Unadjusted Actual Adjusted 1972 Base Period 127.315 105.454 220.431 CMA Reduction (%) Adjusted Unadjusted Fiscal 1988 Year-to-Date Performance 51.9% Adjusted 42.2% Unadjusted 52.1 42.2 1987 August 32.3 4.7 5.6 1.7 44.3 50.271 1020 51,276 1157 5.0828 10000 50,828 1147 0 92000 0 0 2304 102.104 81.933 185.916 55.9 45.0 A VAB.0001190797 :,|-,vnn.-ic i 1-i.iiri 1?-| 3t: Ifcl-'i I .. >. - . r-L-f *' U>* T ' ) I - ' II ' l. -l ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were within NPDES limits in August. Simiannual Bioassay testing was completed in August. No toxicity was found by the test. The test was conducted by TAI Environmentatl Sciences Inc. of Mobile, AL. Waste Management August Waste Shipments included: First load of Lead and Antimony contaminated bags to the hazardous waste landfill 0 Two loads of Separater oil to Stauffer One load of reactor culls to Sun Polymers Visited alternate source for emply 55 gallon drums - Buckner Barrel in Birmingham, AL. Misc. Trained in Houston with environmental and legal departments. A VAB.0001190798 TABLE I WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. Jan. - Ave. Max. F&>. - Ave. Max. Mar. - Ave. Max. Apr. - Ave. Max. May - Ave. Max. June - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Plow GEM 1229 1264 1222 1430 1083 1146 1326 1431 1521 1562 1208 1507 1076 1312 757 882 611 722 642 697 BOD PEM lb./dy. 5 77 7 100 15 212 22 378 8 106 12 155 19 311 25 426 11 201 14 262 12 179 15 211 6 80 9 112 9 81 11 116 7 56 11 85 4 32 6 50 00D PEM lb./dy. 28 433 39 553 43 607 65 1117 35 468 51 659 68 1111 87 1476 45 818 51 955 55 824 75 1052 38 508 53 662 42 379 52 550 33 263 48 373 35 272 54 410 Sus* Solids PEM LB./DY. 10 147 15 215 22 310 25 370 14 191 20 264 13 213 18 307 12 228 16 295 23 342 34 473 18 237 27 336 17 152 18 175 15 122 23 174 11 83 14 114 NFDES Penult Limits - December 1 through April 30 Ave. Max. -- 32 431 -- 43 800 -- 1462 -- 2713 NPDES Permit limits - May 1 through Novenber 30 Ave. Max. -- 26 357 -- 40 744 -- 1212 -- 2523 -- 674 -- 13% -- 674 -- 13% Dlss. 0Z 8.4 8.6 7.4 7.9 7.6 8.2 7.5 7.7 8.4 8.8 7.8 8.8 8.3 8.8 8.0 8.7 7.9 8.8 7.2 7.6 NIL LB./DY. 1.8 2.9 1.4 1.7 9.5 17.6 2.0 2.8 3.3 5.6 7.2 21.8 5.1 6.2 9.4 15.9 1.2 2.6 .75 .84 pH 7.5 7.9 7.5 7.8 7.6 7.8 7.5 7.7 7.5 7.7 7.5 7.8 7.7 7.7 7.5 7.7 7.6 8.0 7.5 7.8 6.0 13 6.0 - 9.0 28 6.0 13 6.0 - 9.0 28 I- irKt.*.*-^. , --r ?: * . :l..,-- tic; -M,-!-'l-i'-::i-H-i:^httir ; .-.i: - Hi: ' -ip- I!# H* 4 1.m ' d |St jh^tU1 HYHftV tt * t> id Iif< ITI'F ~1* ''<11 T f- lJ iTllif- J lA'T." V 11` ~l " '- : VAB.0001190799 h,-..- .. tw~i , ,-i ::::,fji' r':.'u- . :: . - i n r -ni- K1 1. .ill' ti. . 1 LABORATORY - H. G. Colenran A. Safety The Laboratory operated injury-free this month. The safety meeting topic was a film on burns, "It Happened to Me, It Could Happen to You." B. Customer Relations Customer Contacts 8/2-B. J. Harrison made a technical service call at Vinyl Building .Products to discuss a burning/streaking problem with 290-61 WHT 121 8/31-H. G. Coleman visited Klockner to discuss contamination and graininess of 5305. Requests for Corrective Action There were no RCA's received in August. Customer Problem Reports Date Customer Product Reason 8/8/88 U--Brand -Upper Sandusky, OH 90172D Dryblend line scale STATUS: No resolution; typical line scale. 8/8/88 Poly-Tex -Oakmont, PA 269-185 WHT144 Rubber balls from Gump. STATUS: Post-Gump screens installed. RESOLVED 8/19/88 Flexible Technologies -Abbeville, SC 17121WTR CLR Contaminationresin "Lumps" STATUS: Problem isolated to several boxes; rest of run looks good. 8/24/88 Donnelly Corp. 48451 BLK -Midland, MI Stringers STATUS: Typical stringer problem that got by quality control. VAB.0001190800 i- i j .v .r. *,-.t ' I- ( "-J'l-- 1- i;- >. .-It I'.PI ".................. /irib.%. a p1 1 1 1 ip --1 'll* i ' ir . n;-*1 'liu-i- . * * if ij --ri':. : I .................................... - .| r i^ABORATOFOr - Continued Customer Problem Reports - continued Date Customer Product 8/29/88 Klockner 5305 -Gordonsville, VA Contamination in 3 compartments of 2 R/C's STATUS: Downgrade 2<?/lb; team formed to address Klockner quality issues. Waivers Issued Customer Product Reason No. Essex Essex PVC Conpounders Southwire 5415 5415 5415 5415 Bulk Density Particle Size Static Flew Bulk Density 1 RC 1 HT 1 HT 1 RC C. RVCM Sunmary RVCM of In-Process Samples The following is a summary of residual VCM results on in-process samples. None of the reactor daily averages exceeded 400 ppm during the month of August, 1988. Reactor ________ Dryer Slurries5265 5305 Number of Samples Average, RVCM 932 147 25 0.7 73 0.7 RVCM of Shipment Samples The following is a sunmary of the residual VCM analysis of shipment samples for the month of August, 1988. Product 5265 5305 5385 5415 5465 Dry Blend Pond Debax No. of Sanples 43 121 26 65 0 Average RVCM, ppm 0.1 0.1 0.1 0.0 21 0 27 0.0 0.1 Resin Process Capabilities 5265 5305 5385 5415 Bulk Density 1.07 0.33 0.82 0.38 Inherent Viscosity 0.44 0.78 0.50 0.60 ,*L" Color Value 4.33 6.33 6.67 6.83 "A" Color Value 2.83 7.00 "B" Color Value 2.00 1.83 2.33 2.67 % on Pan (vs. 2% max.) 4.22 3.25 2.13 3.00 (0.50) VAB.0001190801 .j, ........ . \ f| g. sM:MMMVH--b 'f-r'K-tt-pL--.il|f j-rrp !!h|| I i n:n-i;hff>n|flyN^|S|ii,*, 'rilh^ l = iTtr1*4!'<<' ' r hT'- ' Mvi.'t" i* (ifipi: -nr if t- . ci^ ' :. LAB - Continued D. Resin Process Capabilities - continued 5265 5305 5385 5415 % thru 14CM 0.76 1.02 1.23 2.46 Drytime 0.83 1.00 Mets I.R. (vs. 95% of Control) 0.73 (0.37) Hard Particles (%> 10) ------ 1.5 0 E. Compound Quality Summary Hardness Specific Gravity Color/Clarity Hard Particles Cross Contamination Dicing Streamers Metal Contamination Total F. Dry Blend Quality Summary Adjustments M Lbs. (%) 48.0 (0.72) 7.0 (0.10) 29.0 (0.43) ------------------------ ------------------------ 84.0 (1.25) Rejections M lbsi. (%> 53.7 384.6 9.7 18.6 1.5 7.5 475.6 (0.80) (5.73) (0.14) (0.28) (0.02) (0.11) (7.09) Color Color/Kheometry 40 Mesh Partial Bex Torque Rejections MIbs. (%) 32.1 9.8 2.6 1.7 2.8 (0.64) (0.20) (0.05) (0.03) (0.06) Total 49.0 (0.98) G. Quality Management Process 1. The quarterly REACT meeting was held in Oklahoma City on August 17. 2. Compound test results on two control conpounds (38401 and 35031), which began in July, continued this month. SPC charts are being generated on hardness, specific gravity, hard particles, oven temperature, and mill temperature. Control limits are given below: * EMr? :prh-|shttH4l ICJ r*i;l =rM *! I' ^ |, L' .. .1 U | VAB.0001190802 : ,T,,i>L- -ir-f.t.-.-ii.-i- t <* j:" .-i-i . i LABORATORY - continued Compound SPC Testing 38401 - Hardness Spec. Gravity Hard Particles (20") 35031 - Hardness Spec. Gravity Hard Particles 15' Over Tenperature Mill Tenperature nX 61 80.1 61 1.377 61 22.4 61 49.0 61 1.37 61 5.1 All readings 204C h 61 323.9 30 0.78 0.009 8.3 0.70 0.012 2.7 6.0 h VAB.0001190803 >"' -- ' *! ! ' -N' - .1 . L! |.|H... . *, : I-1-41. irl -* LABORATORY - Continued 5415 Control Resin (Lot 04169) Testing A n X 3<r Moisture Dry Time Particle Size - 601 - 801 - 1001 - 1201 - 1401 - 2001 Pan Bulk Density Color - L A B Flow Time Hard Particles, 7 Min. Inherent Viscosity 62 0.166 .030 33 4.98 .39 45 1.94 .61 45 28.33 4.15 62 33.92 1.89 62 21.48 2.61 62 7.59 1.57 62 5.27 1.64 62 1.23 .54 31 .5053 .0064 61 100.614 .269 61 -0.111 .351 61 2.167 .775 31 7.59 1.29 62 4.89 3.05 26 1.0111 .0129 H. Miscellaneous 1. NSF performed an unannounced inspection of our dry blend operation on August 11* The only point for which we were cited was lack of seed-annual cell class testing. A program has since been established to accomplish this testing. 2. D. S. Cox wrote entry programs for the compound/dry blend database project. The system will be initiated in September. 3. Brian Harrison completed an analysis of 290-61 WHT 121 for Vinyl Building Products. No problems were found. 4. Ttoo production runs using the prill form of Sunolite 160 were successful. 5. Blendex 28443 (KM-653 substitute) was trialed in 317-204 WHT 110. The performance was good except for a small number of rubbery clumps in the Gunp overs. 6. Brian Harrison completed color matches for Omega Plastics, Intek (2), Superior Rubber, Corelmex, Condutel, BRlntek, and Ccran/Scope. 7. The lab performed an experimental design on the effects of glycerol monostearate and impact modifier on torque rheemetry and blown film quality of a rigid 5305 formulation for Klockner. Both ingredients affected rheemetry; neither affected blown film quality. 8. Brian Harrison attended a technical meeting at Americhen on 8/23 to discuss colorants for FIX at Premier. ; r.ivtn diiur. -inn ; i- VAB.0001190804 'I'Hi -:?N :-i<: :l?- I If--y+H-i L rM.` h-[|P|: t- |.t # .t; -i j !- --1 ......... i l i .. > : RHSTM Ship Date 8/15/88 8/29/88 JUNE 1988 Product 5385-3S 5385 Amount 5 X 1 lb. 50 lbs. Customer Crane Plastics Carlew COMPOUND Ship Date 8/03/88 8/05/88 8/10/88 Product 48451 BLK 35852 NAT 17462 GRY 545 8/12/88 8/16/88 8/18/88 8/18/88 38601 NAT 44461 BLK 35852 NAT 15072 NAT Amount 1500 lbs. 150 lbs. 50 lbs. 1500 lbs. 50 lbs. 50 lbs. 100 lbs. Customer Excel Industries Prestolite Wire Corp Tubular Protection of America Pacific Electricord Quintex Chicago Magnet Wire Vytron OTHER Ship Date 8/17/88 Product VRP Plasticizer Amount 1 gal. Customer Dexter Plastics VAB.0001190805 - fy. < ^t*ii . ii-i.tur^.^sjit-hJ-^iijpsrr -4-1 u^, .jf^m r , . .............................-jr ,_7Jv-M-!iffr:!r4Rl tti I SHIPMENTS BY PRODUCT - M LBS RESIN PLASTICIZER DRYBLEND COMPOUND NUMBER OF SHIPMENTS BY MODE: AUGUST 1988 TOTAL 28,712 492 5,093 6,431 40,728 FISCAL YEAR-TO-DATE 320,264 7,288 56,497 76,119 460,168 h TOTAL OCT. NOV. DEC. JAN. FEB. MAR. APR. MAY JUNE JULY 48 136 51 145 61 142 85 161 77 139 68 168 82 160 58 141 62 149 71 134 48 154 4 480 1 499 499 1 528 3 512 563 538 6 483 1 483 463 5 474 i! ; "ivin* * .............................................. tipjttK1#!"''- i VAB.0001190806 fcnipj s *n . i . hi- |n-*Wlim-rrrrtssri!j. I- - ! ' r ' '! >' r- 1r"5 .:'M! Iil#..! .!f "1 ------ MM POUNDS V. MONTHLY ABERDEEN PLANT PRODUCTION 10/01/87 - 09/30/88 MM POUNDS CUMULATIVE _450 400 350 300 250 200 150 100 r0 2 1 ------------------------4----------------------------------------------------------------------------------f----,--------------------i * * - -t 0^ f i t ---""-------------i iy t* y Oct. Nov. iDec, ............................ . .-L-________________________ Jan. Feb. ! liar. Apr.i May ... .i__________________ 19 87^80 1 1 \ |June i | 1 '- i July i t i * f ! Aug. * 1 ; SepU ---------------------- Budget Actual Cumulative 25 20 15 10 i 1 ) ; : VAB.0001190807 | . . i i 1^(71 r.'t -- Hr*^ -a, SlC . '.Ilf 1 >' i i ! --:L-- < < -1: 1.020 1.015 1.010 1.005 1.000 0.995 ABERDEEN PLANT EFFICIENCY 10/01/87 - 09/30/88 POUNDS OF RAW MATERIAL/POUNDS OF PRODUCT 1.020 1.010 1.000 .990 1.200 1.150 1.190 1.050 VAB.0001190808 -f iT-"hx: : fif v,ir i POUNDS PRIME ABERDEEN PLANT INVENTORIES 10/01/87 - 09/30/38 * 0.8 0.6 0.4 0.2 0 .............. + ........ 1 i 10.0 3.0 6.0 --f :L tl t - It saei 1 \ r i f1 i ii Oct h*-- ii 4 d i- 4 4 \ i T t * 1 t* J I & T 4 \ It 4 i II + A j VAB.0001190809 i:. rnir j' i . 4 ; f;1 : ji 1- :.ri i'-=tjh -'S icviPr^"J Hi: 6.0 5.0 4.0 3.0 2.0 1.0 0 of /O OFF-GRADE ABERDEEN PLANT QUALITY PERFORMANCE 10/01/87 - 09/30/88 K i 4.0 3.0 A 1 t i J i i i 11 i 2.0 1.0 0 i t> 1 * p l + -*- rj j. i i. |` IT ......................................................................................... j h * Oct. ! Nov.' p f T Dec.1 i + t 4-- f 4 t -1 j Jan. - + + * > . ' ' ' 1i . .1 Feb. \ t -- - t -i > ! i la r. Apr.! nay isoim r < ; * < i June t i + | :July \i i !1| i4 ^ T > t i ji > Auq.iSept.i i . ' ----- ' r : \ | : *- -s-.n.i.ir ii r i ~rr lit i iin rawg> tu*. ii^i : h- i ^unu- rp-4;b-.`i;.ii ^-*pj\NP: h* l J I VAB.OOOl190810 H- if a- i `v I!--* I Kf.' I .. I ; .i .-.igj, `A V - I 'ikj X.'h A SEPTEMBER 1988 REBIN Ship Date Product Amount 9/16/83 5415 50 lbs. 9/23/88 Sifter Overflow 2 lbs. COMPOUND Ship Date Product Amount 9/06/88 16851 CB 50 27251 BLK 200 lbs. 200 lbs. 9/08/88 34311 NAT 34501 NAT 200 lbs. 200 lbs. 9/09/88 38551 NAT 50 lbs. 9/09/83 14331 CB 50 50 lbs. 9/14/88 240-147D NAT (BC) 5 lbs. 39012 BGE 11 1 lb. 9/22/88 87-006A BLK 1500 lbs. 9/26/38 48451 BLK 1500 lbs. 9/28/88 151-150A WHT 151-150B WHT 151-150C WHT 151-150D WHT 151-150E BLK 300 lbs. 300 lbs. 300 lbs. 300 lbs. 2500 lbs. 9/28/88 852 NAT 87-006A NAT 2 lbs. 2 lbs. 9/28/88 9/29/88 240-147D NAT (BC) 240-128B GRY 50 lbs. 100 lbs. 9/30/88 17121 WAT CL 18031 CB 50 5 lbs. 5 lbs . Customer Gencorp Polymers H. Heller Co. Customer Donnelly Corp. Superior Optics BRIntec Corp. Proto Mold Ron Walker Communication Cable Dott Manufacturing ITW Corporation Blane Polymers Ron Walker Carlon (Via Premier) Vista - Ponca City *R*1 :l=- ................I.|. > 'I VAB.0001190811 l|4,ra,44tyn,H u: nH-g'i-zi.^S ;;-if , ., - j. ( .t=. r- -IH-i;1 r1'' itivfiijs p+:-.-i.--d,-i.ii.f,|..-i*.,. SHIPMENTS BY PRODUCT - M LBS. RESIN PLASTICIZER DRYBLEND COMPOUND Sept. 1988 26,394 650 5,786 6,947 FISCAL YEAR-TO-DATE 346,658 7,938 62,283 83,066 TOTAL 39,777 499,945 NUMBER OF SHIPMENTS BY MODE: RESIN-Bulk '' RAILCAR 121 Package VISTA TRUCK TRAILER ON 1 COMMON CUSTOMER BULK f VAN A FLAT CAR CARRIER PICK-UP CONTAINER TOTAL 38 2 63 224 1 38 12 Export | 1 PLAST.-Bulk 3 3 1 7 Package| DRYBLEND-Bulk Package 27 13 | ... 1 5 15 6 46 20 Export COMPOUND-Bulk Package Export TOTAL SEPT. 11 4 162 . 58 43 2 51 40 46 21 63 123 15 129 4 457 OCT. 1987 182 62 56 2 51 145 1 499 NOV. 1987 173 72 50 1 61 142 499 DEC. 1987 154 88 38 1 85 161 1 528 JAN. 1988 155 88 45 5 77 139 3 512 FEB. 1988 178 97 50 2 68 168 563 MAR. 1988 211 46 37 2 82 160 538 APR. 1988 170 63 44 1 58 141 6 483 MAY 1988 159 61 51 62 149 1 483 JUNE 1988 141 65 50 2 71 134 463 JULY 1988 152 66 46 3 48 154 5 474 AUG. 1988 158 71 60 3 48 136 4 480 A VAB.0001190812 i'rf|: *\ ./.uf. -<Li: K-t+Mttt"- r I' H Al-J"+!l l{ L- s,c" 'kM- J+'J'1 ..........: +............................... ' -i-'+i - - a.b- '\ + f J:l rrf , i f' Pjiu'.nT". t- i 'f --- J iti" i' -i.1 : I-"if li.frM'-i-h- p*:: i.. - ..:i . -i. t . ..At-..............- i,-- ..............r- --;ir^T -/if"-:- MM POUNDS MONTHLY ABERDEEN PLANT PRODUCTION 10/01/87 - 09/30/88 A MM POUNDS CUMULATIVE 450 10 1 1 *- t ^ * -4 ; Pi f- > tl jp i i- - K - +t * r \i 1 't ! * * ! r1 t - *f Y tP | > -- 05^ 1 |---------------------------------- 1---------------------------------- ;--------------------------------------------------------------------- 1---------------------------------- 11 !Oct. iNov. ;Dec, iJan. Feb* 1_______________........................... .............................. .............................. ........ .__________ ____ -___ __J^ Mar. Apr.i May ;June July Aug. Sept* ______ .________________-_______________________*____ -______ ._____ ____ IQ 8//88 Budget Actual Cumulative VAB.OOOl190813 i:4#' 'J Itt* WJ#pi**wT-l => r : 'l'1 s*TMfc T"'-? tt": |r-r.ifr!i^l- *. :>*'r-tV-'-l-PW- I-- : ' -' * *'-** I Ur ^'^lllpUs-irJ 'Mi-. -- tw 1 .......................--'.pc:- I--------------- . -- ; r.iu- I 1.020 1.015 1.010 1.005 1.000 0.995 1.030 1.025 1.020 1.015 1.010 1.005 1.000 ABERDEEN PLANT EFFICIENCY 10/01/87 - 09/30/88 POUNDS OF RAW MATERIAL/POUNDS OF PRODUCT /A A 1.200 1.150 1.190 1.050 Apr.1 Hav 87/88 fli ; i! . J. LL it In I t VAB.0001190814 j. -ih.-H+p. ; t| * "i .LJ_V? IT 4v "i iirr ii - i. -f ip i -uij |-\... . ti i_j. ;$#*'i*-. i^-:h<1 ii ..i a-^*h.\ .-> MM POUNDS PRIME 20 0,,8 0,,6 0o4 0.2 0 ABERDEEN PLANT INVENTORIES _________________ _ --W 10/01/87 - 09/30/88 A r fr *<|-n i-lT-T-ttttfXlfcHliii1 : u r* -iSTif - l-i tpM> -U- VAB.0001190815 i--.rirth-. irEtB.'&uii .'i ;M .Lrii; m ci.u jJ|;.:-: j..<..:..i.Jlta 'Mrfp i - nrfiT y - *il ':! ABERDEEN PLANT QUALITY PERFORMANCE 10/01/87 - 09/30/88 A 6.0 5.0 4.0 3.0 2.0 [ 1.0 0 Of fo OFF-GRADE 1.00 .75 ,50 .25 0 4.0 3.0 2.0 V &\ 1.0 0 r r Oct. 1* ** I l :* i: f ! Nov. I *H4 Dec.* * f t Jan.i -> ' 1 V1-->-X t -* -+ * Feb.l -- 1 t ! > *i * h 1 k h 1 i h -f * t - -- i H I t A >'1 f; Mar. Apr. Hay iJune July j Auq.iSent.i 1 o37/8G L ; .......................................................................................................... . .! -:i. iJK-t-rMiiflt'-.tr*-rri> *1 ' i fm i*#4- g n^ip4"lii n i Vt d:- - .>r.f VAB.0001190816 "'* fci Ihf;.'..VI-- : Pit- 1-! '*. :i*tvl h jrH i