Document RBZadZZ0YjdEXeYOORQwgXra

ABD00282810 VINYL - D. W. Hollis/M. L. Nathan Safety The Vinyl and Yard Departments operated without an injury in April. Shift safety meeting topics for the month included "High and Low Pressure Gas Systems". Discussions included potential hazards of each type of system and safety procedures. 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 April 36.8 1228.0 890.0 29.7 93.7 10,090.5 63.4 30 Y.T.D. (Fisc 245.6 1158.9 5967.0 28.2 91.2 10,283.3 59.7 212 Vinyl Department production for April was 36.8MM pounds. Reactors The reactor stream factor for April was 93.7%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 55.4% of the total downtime and was due to reactor scheduling conflicts, no place to dump reactor slurry, and downtime due to severe weather conditions. 2) Maintenance Service Downtime: Accounted for 3.3% 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 41.3% of the total downtime and was due to four reactor valve changeouts, agitator seal replacements on 500, 742 and 744 reactors, and cooling water jacket repairs on 700, 742 and 743. Dryers The dryer stream factor for April was 63.4%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 85.6% of the total down time. Dryers were shut down when possible for energy conservation purposes. 2) Operational Downtime: Accounted for 11.7% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning, transfer activator problems, and downtime due to power outages.  'ABD0b2828ff VINYL - Continued Dryers - continued 3) Maintenance Repair/Revision Downtime? Accounted for 2.7% of the total downtime and was due to activator, centrifuge and screener repairs. A new centrifuge chute was installed on number 4 dryer during the month. Product Quality Summary Resin Type Prime "BC" "HM % of Total Production 5265 5305 5385 5425 5465 Sifter Overflow Pond Resin Total 6,428,915 2,906,237 18,440,889 6,493,127 2,468,805 - 36,737,973 --- -- -- - 122,832 ( 20,240) - 102,592 17.5 7.9 50.1 17.6 6.7 0.3 ( 0.1) 100.0 Quality performance for April was 99.7% customer grade with 0.3% "H" grade production. A total of ten railcars were shipped as "B" grade during the month which represented 8.3% of the 120 total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 2/29/85 1/23/85 3/06/85 3/18/85 2/24/85 3/15/85 3/28/85 4/18/85 3/29/85 4/06/85 4/08/85 4/15/85 4/15/85 4/15/85 4/16/85 4/18/85 4/24/85 4/30/85 4/30/85 4/30/85 PLCX 43310 PTLX 42303 PLCX 42973 PTLX 41604 VIPX 45293 ERLX 6217 PLCX 43731 PTLX 41646 PTLX 42253 VIPX 45872 Shawnee 5385 Wexford 5425 Osterman Pond Resin Extrusion Debox Tech. Vulcan Debox Wexford Pond Resin Osterman Pond Resin Silverline Debox Silverline Debox Grifco Debox Derail Mat*l Derail Mat'l Quality Quality Quality Quality Quality Quality Quality Quality The vinyl area received twelve short lead time emergency type orders comprising 5.9% of the 202 Aberdeen resin shipments in April. Monthly Variable Cost Performance Variable costs for the month were favorable $1251.6M with $1066.5M due to price and $185.1M due to efficiency. Resin variable cost for the month was 20.687 <?/lb. vs. the budgeted 24.103 c/lb. A ABD00282812 VINYL - Continued Monthly Variable Cost Performance - continued The $1066.5M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $987.4M; VCM freight, $27.4M; process additives, $38.0M; and utilities, $13.7M. The $185.1M favorable efficiency variance can be attributed to lower than budgeted VCM efficiency, $71.2M; process additives, $43.5M; utilities area, $44.3M; and off-grade production, $29.7M. VCM efficiency for the month was 0.99561 lbs. VCM/lb. PVC versus the budgeted 1.00500 lbs. VCM/lb. PVC. Year-to-date efficiency is 0.9992. Year-to-date variable cost efficiency variances in the Vinyl Department totaled $602.4M favorable. Energy Performance/Progress 1. Plant energy consumption for the month totaled a record low of 2339 BTU/lbi , The previous low was 2411 BTU/lb. in July, 1983. 2. A total of four steam leaks and two steam traps were repaired during the month. General 1. Packaging for the month totaled 821,982 pounds. 2. Resin raw material in the 744 account totaled $177.7M at month end.