Document Rp0kd5qbKGjDgQrLg9MKbY0VX

Faxed 3/02/84 Interoffice Communication To : R. D. Gamblin From : John Friend Date : March 2, 1984 Subject : 1984 OBJECTIVES Attached are proposed 1984 objectives for the Aberdeen Chemical Plant. rah attachments i J i f t VAB.0001183771 Part uantitative Goals Name John Friend SAFETY 1. Occupational Injuries a) Lost Time b) Medical Treatment 2. Improve VCM exposure for Vinyl and Maintenance Department employees exposed above the PEL without respiratory protection (% of per sonnel dosimeters). 3. Develop and implement |najor revisions to the safety control permit system which will provide a second level of approval for certain jobs by requiring involve ment of more plant personnel. 1.4% > PEL 1.0% > PEL July 1, 1984 PRODUCTION 1. Achieve the following 2/84 refore casted production levels (assumes no sales, transportation or raw material supply constraints): a) Resin b) Compound c) Dry Blend d) Plasticizer 2. After total upgrade of no, 7 resin dryer, demonstrate a 15% rate increase above the 1983 test rate. 3. Improve the stream day production rate on Compound Line I. 370MM Lbs. / 49MM Lbs. 50MM Lbs. 11.0MM Lbs. 7300 lbs./hr. of 5385-1 415MM Lbs. 53MM Lbs. 52MM Lbs. 14.4MM Lbs. 8400 lbs./hr. of 5385-1 60M lbs./day 63M lbs./day T VAB.0001183772 Name John Friend Part uantitative Goals Results 1983 Objective 1984 COST CONTROL 1. Reduce energy consumption per pound of production on an adjusted CMA basis. 51.1% Below 1972 53,2% Below 1972 2 Reduce overtime as a percent of straight time worked. 12.2% 10.5% 3 Improve the yield of prime grade resin (as a % of total resin pro duction ex pond resin). 97.1% 97. a% 4 Decrease compound mi11 scrap and H-grade production. 0.0189 lbs/lb. 0.0180 lbs/1b Achieve the budgeted variable cost efficiencies excluding product mix variances. $1.62MM Favorable Budget 6 Control costs to no greater than the fixed cost budget excluding depreciation variances. $312M Favorable Budget 7 Minimize the impact of severe cold 40 reactor-days 10 reactor-days weather by reduction of downtime downtime downtime due to freeze-pps. 8 Reduce resin sifter overflow pro duction. QUALITY CONTROL 0.0036 Ibs/lb . 0.0030 lbs/1b I1 I 1 Reduce the number of plant justified customer action requests. 13 * 2 Improve resin quality control and thereby reduce by 15% the percentage 6.1% Waived of resin shipments requiring waivers (ex bulk density waivers). 12 5.2% Waived IJ m mm Actual Results 1984 b1 VAB.0001183 Name John Friend a PSrt antitative ENVIRONMENTAL 1 Eliminate reportable VCM relief valve discharges. 2 Eliminate reportable waste water bypasses associated with pond resin reclaim operations. 3. Improve slurry stripping performance and reduce the number of days the slurry average is above 400 ppm VCM. 4. Make application and obtain approval for delisting the plant as a hazardous waste storage site under RCRA. 5. Develop a Superfund reporting protocol for the plant. Results 1983 2 Kr 3 6 days - - Objective 1984 0 0 4 days July 1, 1984 June 1 1984 OTHER 1 Achieve capital expenditure levels on a quarterly basis within +15% of the forecast (excludes unHerruns and projects placed on "hold"). 2 Identify a dollar value of 0739 inventory items which should be capitalized or obsolete rather than carried in spare parts in ventory. 3 Maintain current utilization of minorities in the hourly work force. -25% +15% $200M i 39% 39% * Actual Results 1984 1 1-a- A 11 VAB.0001183| k Name John Friend Potential rovements of Quantitative Factors Estimated Effect on Earnings Pre-Tax ft V * 1984 Results SAFETY two treatment PRODUCTION 1. Produce 425MM pounds of resin. 2. Produce 57MM pounds of compound COST CONTROL 1. Reduce energy consumption to 55% below 1972 on an ad.iusted CMA basis. .2 Reduce overtime to 9.0% of straight time hours worked. 3 Improve the yield of prime grade resin to 98.8% of total resin production ex pond resin 4 Improve variable cost efficiencies ex product mix. 5. Reduce fixed costs excluding depreciation variances. QUALITY CONTROL 1. Reduce the number of plant justified customer action requests by 23% from 1983 (10 RCA's). .2 Improve resin quality control and thereby reduce by 34% the percentage of resin ship ments requiring waivers (ex bulk density waivers) -- 4% waived. $225M $ 85M $120M $400M Favorable $250M Favorable VAB.00011 * Name John Friend Part C Special Projects To Be Accomplished During The Year (Non-Quantitative) PERSONNEL * 1. Take action on the highest priority problem in the vinyl resin area (.operator training) by developing justification for, gaining approval for and implementing the training program developed by MTS (consultant) for our vinyl unit personnel. 2. Continue and expand the maintenance improvement program on training by continuation of the weekly TPC training for I&E personnel and implementation of training in maintenance management skills for maintenance superivosrs, 3. Successfully negotiate a new labor agreement without incurring a strike, 4. Upon anticipated 1984 retirement(s), hire a qualified minority into the plant security guard force. r7 OPERATIONS 5. Assist R&D and PED to solve the compound fusion problem which is causing serious quality ^ concerns with major customers like Western Electric. o. Improve the knowledge of our resin cost structure by completing a major resin cost study which will identify costs by resin type. 7. Culminate the development of our high margin, low molecular weight resin by designing a system for and implementing use of a new chain transfer agent which minimizes con denser fouling in low molecular weight resin production, 8. Continue to work with R&E, Marketing and the Business Area in development of new high margin dry blends. In rigid profile dry blends, concentrate plant efforts on product consistency, production rate improvement and quality control techniques, 9. Identify steps to improve plasticizer yields and batch times in order to regain lost capacity resulting from the exclusive use of$ straight chain alcohols for feedstock. 10. Modernize warehouse operations by installation of the IBM System 36 computer and computerization of the spare parts, raw materials and finished goods warehouses. 11. Improve plant hazard control by developing an interlock PM program, 12. Design a system for minimizing the steam consumed for PVC reactor evacuation. n 13. Conduct a plant study to identify the steps required to reduce the increasing city water consumption rate. Improve emergency systems reliability by expanding the weekly fire system checks to include the new emergency generator and the emergency lighting system. VAB.0001183776 Name John Friend OTHER t 15. Investigate the possibility of reducing natural gas costs by securing a second supplier. 16. Develop and implement an emergency media communications plan. 17. *i . Evaluate and implement the use of new, more reliable VCM dosimeters. .r k' r * V- " P " ' *\ " \ J VAB.0001183777