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To T. H. Huffman ^a**: Svty** D. C. Skokna October 20, 1989 ABERDEEN MONTHLY PROGRESS REPORT SEPTEMBER, 1909 There were no injuries reported during the month. For FY1989, there were nine recordable and fifteen first aid injuries reported. As of September 30, the plant's employees completed 3,740 days (4,947,570 manhours) since the last lost time injury. PVC Production, MM Lbs.^ Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M 39.25 94.4 94.5 1.01225 5.71 96.8 3.61 100.0 1.33 96.2 0.4 <115.9> < 41.1> 454-r5 89.9 95.6 1.0055 72.1) 96.9 58.6 99.7 *. 18.3 92.0 < 3.8> < 236,7> 1675.5 Variable costs were essentially at budget. Fixed costs were unfavorable due to some turnaround charges, yearend accruals, and above normal purchases of operating supplies. 1. The 5415 Decontamination Team Investigated causes of and solutions to the variability of product contamination. The process, sampling and analysis contribute equally to the variability. Several changes were made to reduce both the level of contamination and variability. A nested design was used to determine the sources of variation. 2. The BPA kill 5305 trial railcar failed the "graininess" test at Klockner. Two new theories have been proposed (calcium from water and fast fusion times versus the competition). These will be evaluated. t T. H. Huffman 10/20/89 Aberdeen Monthly Progress Report - September, 1989 Page 2 OMP - continued 3. Sixty-one percent of the plant's natural teams met during the month; seven teams have mission state ments . 4. The second Quality Appreciation Day was held to recognize the accomplishments of seven project 5. The Maintenance Supervisors' Natural Team made its presentation to Management for improving small tool control. 6. The second round of SPC Expert training was completed. Environmental 1. Alabama banned shipments of hazardous waste from Mississippi as well as from other states, effective 9/14/89. Currently, we are seeking approval to dispose of the plant's landfilled hazardous wastes at other sites. Also, plant management met with local state senators and representatives to discuss this issue. Alabama says it will lift the ban once Mississippi has or plans to have "adequate" hazardous waste disposal capacity. Short term, there is minimal plant impact. The last PCB transformer was reclassified to be non-PCB. No other plant equipment is considered " PCB Contaminated". D. C. Skokna Plant Superintendent rah VAB.0001190339 U t- Jn Hous ton Austin Haimnnrf Blane J. D. Burns R. T. Ferrell T. H. Huffman X X C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin S. E. McGuire R. L. Poe H. J. Hall X H. G. Garrison R. A. Conrad J. Friend J. W. Ware X L. R. Bauer J. B. Maher X X C. R. Miller P. L. Foote RWS/DCS (File Copy), PJK, JEN, MRK, DAM JEB, HGC, JEL, REP, BLT. RBN. SCH X X X X X X X X X X X X X X X m mm VAB.0001190340 mmmm - B. L. Trego, J. V. Uptain First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 0 0 0 0 0 Fiscal 15 9 24 3 0 * Fiscal 13 6 19 1 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 02 04 0 14 01 01 0 0 24 5 3 9 1 0 19 Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains S tings Other Totals 06 02 06 04 04 00 G 0 24 7 0 6 2 1 0 19 Lost Workday Cases Days Lost 2 4 13 15 57 272 Last lost time injury - 7/5/79 Days since - 3740 Employee hours since - 4,947,570 On September 30, 1989, the employees of the Aberdeen plant completed days with no lost time injury. The topic for plant safety Training. during the month was Annual A Safety Review Team has been organized to establish a new plant review program in the plant, It will set up a program which reviews the normal audit items as well system safety items. VAB.0001190341 1 SA#kTV - Continued Another new team, the Safety Meeting Improvement Team, was formed to evaluate our present safety training meetings and seek improvement in them* Among the items discussed were meeting times and locations as well as resources to be made available. Routine dosimetry results for the month were: Wumhft-r VCM Lead Total Particulates 77 97.5 5 100.0 0 ------- 2 0 0 2.5 0.0 One of the VCM overexposures was without benefit of respiratory protection. BSiuXmOmBaKrIv^ There were no injuries reported. VAB.0001190342 >' f M. R. Kan * * 4 The second Quality Appreciation Day (QAD II) was held September 7 to recognize the efforts of seven teams. The teams provided displays of their completed work while plant employees enjoyed hors d'oeuvres. Each team was presented with a plaque that they will display in a plant location of their choosing. Rick Smith, Product Manager - Resin, was present and addressed the attendees about the need for continued effort improving and maintaining product quality. The second group of SPC Experts completed their training. The group totaled about thirty bringing the numbers trained to forty-two out of two hundred fifty. Improvement in identification of assignable causes has been noted as a result of training. The natural team scores for the second round of data showed an improve: from an average of 0.67 to an average of 1.13. Fifty percent of the plant's natural teams are meeting on a regular (monthly) basis. The Maintenance Superintendent's Natural Team met with plant management to present the toolroom mechanic need and justification. The plan was approved and the remaining meetings for the month concerned development of toolroom mechanic job description/duties and selection of the mechanic. The process engineering 5415 Contamination Team presented the results of their nested experimental design. The conclusions were that the three components of contamination variance (process, sampling, measurement) contributed equally to the overall variance. VAB.0001190343 4I D. C. Skokna At Total FVC Flexible Compound Rigid Compound Plasticizer $150.4 < 79.7> < 60.7> < 51.1> <$ 41.1> $2188.0 326.1 279.6 $2853.7 $2338.4 246.4 218.9 $2812.6 FVC - Lover than standard raw material consumption, and variance due to product mix caused the favorable variance. The primary cause of the variance was product mix. The primary cause of the variance was product mix. Raw material use was above budgeted levels and "VRP" production was low - these factors caused the unfavorable variance. - VCM - FVC Resin to Rigid Compound - FVC Resin to Flexible Compound - Alfol* - Purchased Plasticizers - Alfol* 810AI - TiOa - Other Price Variances Total $2185.4 283.4 276.1 42.7 38.6 13.4 <11.1> 25.2 $2853.7 - Payroll andBenefits - MM&C - Miscellaneous TI&D - Clearances Total <$ 8.2> < 57.2> < 41.5> < 6.0> < 0.5> <$113.4> VAB.0001190344 i t fe J- Continued - This category was essentially at budget. Year-end accruals were the primary cause of this variance. - <$9.0M> - due to VCSM related training costs. - <$23.5M> - cooling water chemicals, turnaround related supplies, and office supplies were purchased at above budget levels. VAB.0001190345 P. J. Kober, D. A. Miller, J. E. Nickerson The Operations and. Mechanical Departments did not have any first aid or OSHA recordable injuries during the month of September. The topic of the monthly safety meetings was the annual "Respirator Use Training". vmaooi190346 VINYL - P. J. Kober, K. V. Birck 1. The new baghouse on dryer #8 was checked for leaks. Several were identified and repaired. Baghouse performance improved significantly once the leaks were plugged. Each baghouse will be similarly tested prior to startup. 2. Installation of the second dryer baghouse on dryer #7 was completed during the month as part of the dryer baghouse project. Longer than expected installation and startup problems resulted in delayed 5415 resin railcar shipments. Customer resin needs were satisfied during the delays through truck shipments and increased 5415 production once dryer #7 was restarted. 3. The 5415 Decontamination Team continued its investigation into the sources of and solutions to 5415 contamination. The main focus this month was on railcar loading, sampling and testing. Their study concluded that each area contributed equally to product variability. Several new methods have been adopted in an attempt to provide the lowest ever/levels of contamination. 4. Annual rupture disc replacement was completed for the Old Module reactors. 5. A new antistat (Pationic ASZZ) was tested on 5415 resin during the month. The purpose of this test was to evaluate ASZZ both for its antistat abilities and as a way of reducing centrifuge torque (load). The test showed that at a 2500 ppm addition level there was a 34% reduction in centrifuge torque but that Mets IR was adversely affected. 6. The resin raw materials in the 744 account were valued at $411.3M. - Production, MM Lbs. - Daily Rate, M Lbs./C.D. - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime % 39.3 1308.4 934 31.1 94.4 69.4 98.8 94.5 454.5 1245.2 10728 29.4 89.9 72.1 94.0 95.6 * VAB.0001190347 VINYL - Continued Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks, New Module rinse/charge water conflicts, waiting on Q.C. data before charging, no place to dump and inclement weather). Maintenance downtime (drill condensers D700 and 0745, wash out New Unit recovery condensers, replace rupture discs D400, D500, D500, repair Old Module rinse pump, replace Old Module recovery compressor and New Module recovery compressor, and miscellaneous Instrument and valve repairs). Reactor limited production. 74.5 Operational downtime (centrifuge plugs, clean dryers, activator transfer problems, checking dust collector socks, power outages (4), plugged lines, and flameouts) . 9.5 Maintenance downtime (repair centrifuges (4) and motors (2), sparge pipes, shear pins, repair screeners, washout dryers and various other activator and centrifuge repairs). 4.9 Other (dryer #7 downtime due to the baghouse replacement project). 11.1 .ntenance Work - J. B. Autrey, J. B. Hegwood The west incinerator was shut down for repairs to its downcomer tank. A new downcomer pipe, tank liner and refractor were installed. A flange section was also replaced on the burner section during this time. Reactors 700 and 745 were shut down during the month for hydroblasting and condenser drilling as part of the ongoing contamination control program. Numbers 5, 7 and 8 Birds were rebuilt during the month. These repairs were made due to worn bushings and bearings. Numbers 7 and 8 Birds were also sent out for balancing because of bad vibration problems during startup. The motors on #7 and #8 Birds were replaced also. These motors were replaced due to bad windings and bearings. VINYL - Continued continued The rupture discs were changed out on reactors 400, 500 and 600 as part of the annual rupture disc program. Number 7 dryer was shutdown during the month for repairs to its Trunion. The Trunlon was frozen up and would not rotate. Several new style cameras were installed in the vinyl unit for testing purposes. If accepted, these new cameras will replace the existing cameras. There were nine major valves changed out in the vinyl area during the month. ii VAB.0001190349 COMPOUND - J. E. Nickerson, K. G. Akins All flexible compound lines returned to their normal operating schedules in September. This was a result of the strong demand for our flexible compounds which began late in August and continued throughout September. Most material produced was required just to meet orders. Little or no compound was made for inventory. Finished flexible compound inventory dropped from 4.8MM pounds in September to 3.9MM pounds. This type of scheduling results in shorter, less efficient production runs with higher than normal downtime for product changes. Demand for rigid compound continued to be weak in September. The dry blend unit was down several days this month due to lack of orders for rigid compound. A new condenser was installed on plasticizer reactor R-l this month. This completes the plasticizer reactor condenser replacement project. A low-smoke, low-flame compound was produced on Line I for a cable jacketing application. A sample was sent to Superior Optics for evaluation as cable jacketing on their duplex optic fiber cable. Line I Line III Line V Total % Prime Operating Month Avg./pav 26 26 20.5 1725 3117 865 5707 96.8 66 120 42 23177 38641 10323 72141 96.9 * - Product Changes - Quality Problems A Control - Dicer Problems & Maintenance - Miscellaneous Maintenance - Product Changes - Miscellaneous Maintenance - Dicer Problems & Maintenance Line V - Product Changes - We lex Problems & - W-P Maintenance - Quality Problems - Startup/Shutdown Maintenance & Control tP 125 17 8 12 97 14 3 52 44 14 6 9 mmm VAB.Q001190350 ! COMPOUND - Continued Operating _______ Davs Month Rigid Compound 21 % Prime 3613 100 172. 58588 99.7 Downtime - Product Changes - Quality Problems & Control - Miscellaneous Maintenance Operating __Davs Month Plasticizer 23 % Prime 1382 96.2 Hours 50 15 30 Avg./Dav 60 19935 92.0 J. B. Autrey, J. B. Hegwood The Line V twin screw extruder was shut down for repairs to its gearbox during the month. The bearings were replaced in the gearbox and put back in service. The gearbox will be overhauled as soon as the needed parts arrive. The west cooling tower pump, which was sent out for repairs, was put back in service. This completes the repairs to the three compound cooling tower pumps. The dry blend topaz unit was shut down for repairs due to a defective board. VAB.0001190351 UTILITIES - J. B. Autrey, J. B. Hegwood The Pall air dryer was shut down for repairs due to a poor dewpoint reading. The desiccant was changed and the inlet threeway valve was repaired. Numbers 1 and 2 boilers were shut down during the month for their annual PH. During this time, several piping revisions were to both boilers as part of a capital project to improve access and maintainability of control valves. The number 1 vinyl cooling tower was taken out of service The tower was dismantled and the water re-routed to #2 tower. This was done because of the deteriorating condition of #1 cooling tower. The fire pumps in the north pump house were shut down and new antifreeze and several preventive maintenance items were performed on each pump in order to maintain their integrity. VAB.OOai190352 t- Pp* * - R. E. Polk, S. C. Hillman, C. J. McDonald Installation of #7 dryer dust collector was completed. Stack sampling was delayed until October to allow the system to line out before testing. The team studying 5415 contamination completed their investigation and made recommendations which will reduce contamination. The recommendations Include: More frequent dryer cleaning, modifications to dryer #5 internals, modifications to dryers #4 and #5 feeders, and improvements to railcar cleaning procedures. An experimental design showed variation in contamination is due equally to process variation, getting a representative sample from a railcar and lab testing. A railcar of 5305 with no Isonox failed in a trial at Klockner. Efforts continue to find the source of graininess. Two new theories have been proposed: One idea suggests calcium from the water as the culprit while the other suggests faster fusion times than the competition may be the issue. A test run to reduce dry antistat dusting from the fluid bed dryer scrubber was successfully completed. The test involved adding surfactant and a foam control agent to the scrubber water so that the antistat can be removed from the air stream by the scrubber water. - I.E. PHI, S.C. HUIMNf C.J. NcMOTtl gIwgl MMMUMRMK F7I4/F357 C73T 1319 M4V Mff - tF^-h Cflf Nil MOT MOT 1741 I7OT WT foot rm tm I7!f ninff Mit (uPtO*Ti NS4f MOT H72f H7W HN9 . rt' >>H NBOT (JH9 flgMMt NMT mVninmil MUrMliflfLi nMBuHEirtals wmbtoescmptiw mm JOIN MUTT INFWPPTTrtOJETTI OLIMITt mM. Ml roam njnmzut Mem iwi mat ^FMRtUHWMK>*WBMMinMHf9tNRlpMtliV MMSLlWvftKMrUWIWmMK--fht TMwrUHVgUSMG'R--RUEItCI-YCLE MmMKNftBBHB. - PUR? AffflttQL VMI nmEWmmi Mil IWMBIHIBB NKBJMNMttfrNBIFlttyfnR MU ^ umL m Mmarm PNKMrllVMftMl KUNE SY8TEH _____ ITSTER HUH MFtlV KVIflONS UM HNOUH Ml IHMB8KBUCTIM MMRb*AMMb AfMnBOtTtMlBr *f*f*l vH*BIMm i? Mum BlBftBHKlNt C8MMMKMIIM RftMETt fumob nua nt lines 1,3. in a UK ft HK RKTSnXES fi HBHMHKmr min bfumw ' oaaun iiT. mi m wtircinir cmNm HHiimsmi IMRtftll SEMBfBM PUNT BIB MCICLE HTCTIIKM OPtOTL PROJECTS < MSN OTC AftKTU KMK.KPUCBENT PUWT WI HBB gnsiunn mirums ^^Nr^Wb- imtMm- f<t aruluM*' iMMnUvmft MTK M OFFICE EOUIFIOT nUnMmli iIBV rnitmU OruNtmm>4- umujiiK 11iMm kin cavunw in ocibb. If OVUM[MJtBBUKLB MB IP FfflJ n ra ffnmk m n 1-- w fMiniB n "' OHMKII0IIftMKilt:D(Mf-BlftttLtfT nBK1K flMJKMttl K CUB TV FtQJ OttHB-DI 0CTHEI. ranUKlK It CMUTL TH MBT ULILUB10 HEU CNUB ft iNn. TWIM' IIVflrBBMotBf-4 *I*t- WMBUTMOKBVR*- MIMB BHitUI KKNCUIBBMBtflwfft tPfMIVU1 oMtwRIABIMfll'DftI AwfHWBRHMK*- WTO iCHFLE"Ti I M"s l IN PMK:t K. PROTECT CMLETIH n PUMO FOR XCBBR.' - If IBirilK NOTH II MW NK cwkiuk HKj *k Kim*. mmunoN n pumpr jrnrrt. U MU. K CUB 7ft FIELD CNMB IN OCTMT BEpBBBlipt FW MtWU' EMSBBftiSlN 'flCOTMi* msmutm n in rnmn mo rnwiiiH homo tu ffum iy a MIKNK'M^IMMLIftlK CMLBUi II *"fff '-HIHM MB aB^an rVJMKVB r*K ^tftBBOU mGmPmWMBImmp fIt ViiMGBMMUii**iTiVi mBBBibM imm IfSBMBiBRBRBRRMBMPR-W't* ^^tKVi'*rBMMHMi^MRB-<m*w' GMBCInBCtTVQtVtl RMJMHMB^LrNMRB' MftM - HOIK a CMIEIL samii K MroftOTB. BB II CBVIftTE. OIK ML K KHMB K 0C1KK*- n- iIBt BnBtRBMflflBpIMBi-VBMBWtmVT:* CMBBBMBBCTTtIBMt ' ifvt ' BRlMMMPttB* TMIBB IMBERBnnBBEBK* tmtmatm tt n nMtviiMBfiiJMRnr. KfUHftfKMMRT, - t/'- -rv* - ,J4k L E + M '4 ^ ' ' r.L**. I* DfllKI.' rMBB* vftMMIBBBBVtLkL MOTfeOL MOnUtlUN I BIN 111 HI B i IIM II m^Wft itUl nVUnH rlJNO nB QCIwQli JMR9tItBitRt Hv* mHbRmMmUnB tIbt MBVBnIIr tIRt kBPbVmMmBBmB*- EMNMMi tt CMfKCnKIS IN iNmuttm imsm funiN ntfliifimlMtfMI' iVtV 9o*tHmHlIt KiMHftin FUMim cttVLsrm NKKB OVtlm. NK MRNVMft NMK KB WCO OI MB VI1H KUVOT 9CHENLB FttHttKKB, m iBiiKK no Murumm mm bw bukw kkmb m ocibb, lmim cwm KflMftaJicFcaricnK n RMMBiiainB. fIHWff AVMpHpMptf^fci^t'Eisft' ^Ml VOT^^^^WMinOT VOT flRb ______ IB MIMT KfIMMKT WOT." mmm^mmmmmk k cumm rau ORKUniR It 9K CBfttnt NB M PttlOKII. CttfUTtW IIAJMO FOR KCOttB ML . -- .. ri- B,a" . - P.# IBI- r . ^ Hrw ^ x:'. 't4 f . 1 .. ^i. ^ i - ^ * SP u , 4 -h. rr` ; t 11 p- ?!tH- -- JT- d- w'.ftai' s.-1-' K' - 't- 1L, T'j.^r i< ' +' _r"^ r n 2 ' rOTf. t f . d- _.-* > !* > >* ^\ N1 p f -fc.-' j It #^r -* 1 1 4 P ^c kmMBRB *B RMBM tMMMHMRPMMBBMiMRHRPPmMMMMpMVIVBPI t F. G. Jeanson All wastewater discharge parameters were met for the month of September. i Vaste shipments included: - One bulk load of floor sweep to Chemical Vaste Management. - One bulk load of separator oil; to Systech in Demopolis, Alabama. Alabama's ban on hazardous waste from Mississippi took effect on September 14, 1989. No more hazardous waste from the plant can be shipped to the Chemical Waste Management facility in Ensile, Alabama. We are currently in the process of getting our hazardous waste streams approved at the Lake Charles Chemical Waste Management facility. We have also applied to the Mississippi DEQ for an extension to store hazardous waste an additional 30-60 days above the ninety-day storage limitation. This was done in case we have any trouble getting our wastes approved at another site. i. Plant management met with our local State senators and representatives to discuss the hazardous waste disposal issue. i Samples of API sludge and pit #1 sludge were analyzed for EP toxicity. Both of these materials were found to be non-hazardous. The Mississippi DEQ was here to do an audit/inspection of all air emission points this month. We received all zeros on this visual inspection. I set up a meeting for October 12 with Mississippi DEQ to discuss permitting issues for the VCSM Project. A NESHAP authorization will have to be obtained and reduction from a major pollution source to a minor source will' be requested. The Quarterly NESHAP Report was issued to the Mississippi DEQ. SARA The Aberdeen video and brochure will be updated. Scripts were reviewed and revised to include the 1988 SARA 313 emissions. I attended the annual Vinyl Chloride Safety Association (VCSA) meeting and the Vinyl Institute (VI) Safety, Health and Environmental Committee Meeting this month. I gave a presentation on fugitive emission bagging at the VI meeting. ---v VAB.0001190355 Continued I attended the annual Mississippi Manufacturers Association Environmental meeting. A neighborhood complaint was received this month on PVC dust. This complaint was followed up with a couple of visits with literature on PVC and VCMt and an explanation of what we are currently doing about PVC particulate emissions. The neighbor was satisfied with our effort and no additional work will be necessary. I attended a workshop on in-plant spill response. The one remaining PCB transformer we had at the plant was reclassified this month to be non-PCB. No other equipment in the plant is considered PCB contaminated. The report from Tufts University written about Vista's response to SARA 313 was reviewed. Comments will be returned to Tufts. "IK r*_ "Vi VAB.OQ01190356 D. A. Moore A. Unadjusted EUI B. Adjusted EUI C. BTTJ/Ub. Product D. Total Energy Consumption MMM BTU 0.58% 0.40% 2505.21 125.16 This corresponds to an adjusted CMA of 53.23% and an unadjusted CMA of 41.91% -2.80% -3.75 2525.51 1528.20 51.89% 40.36% There were forty-two energy related items completed in September, 1989. Thirty-six of these items were steam leak repairs. The remaining six were steam trap repairs. The survey for vinyl and plasticizer areas identified no steam trap items for repair. No. 1 No. 2 No. 3 83.31% 83.48% 83.03% 83.65% 83.48% 83.12% VAB.0001190357 ii Pttionnal - J. E. Beall Todd M. Haley, Rehlre Vemeta Young promoted from Utility to Operator. Jerry Crosby . Lisa A. Varnock Thomas A. Madigan m - . x1 it' h Ralph D. Flippo temporary absence to take care of International Union Business. ABERDEEN, MISSISSIPPI -p Salaried Enployttf Hourly Employsos Total Employees MONTHLY 79* 172 251 REPORT Minority Employees #, % Sslarled 7 Hourly 66 381 Total 73 29Z Nsv Employees 0 Hourly Min. Hired 0 0 % Min. Hired 0 Hourly Min. Term 0 % Min. Term. 0 PEVARTMEMTS QgMFtOTggS MIN. EMP. %MIN. NEW BTRES YTD TERM. YTD. TPRHOVER YTDV Warehouse 16 Gen. Plant 13 Maintenance 41 Laboratory 24 Compound Vinyl Plasticizer ii 23 5 _ 39____________26_ --LG___ n n n a a a a a a a a Number of Applicants: Month 0 Year To Date 21 APPLICANT BREAKDOWN # Minority 0 % Minority 0 # P le n % Female * Includes 2 Co-op Engineers .p a leMSumuieiwiin H,- . 'k--K Hires (Hourly) Month Year To Date Terminations (Hourly): Z Month To Date Overall Turnover 0 2 Projected Annual Turnover ]--21 1I V M-h m I* i i. p VAB.0001190359 *F % C3 W ft! imI VllOj z\ Ul ilSI *1 *U{ *<Q1|;tJn. i cn ** ao uo oo om s 8 a. vo vO0 c*4J 0o0 CM .00 oo m N<r so om oCM n in CM - o in vr% m 0 * * m -T m CM K r-* cn n vn n C"> cn O* CM vO CM N h * t t b u9 s om m jn r* CM m m r* * + * +* 0 0 N 00 CM vO cn m o00 o CM cn m ON s vO vO m N vO 94 cn vO m r*Cfr 9 MMM i -- *v r w* r1' " 11 VAB.0001190360 t mmm jn- 9 r-i ti * J. E. Little There were no safety instances this month. Savings due to competitive bidding were $1370 for the September, and $124,369 for FY1989. Savings due to prompt payment discounts were $2281 for the September, and $25,716 for FY1989. Warehouse - Finished Total packaged inventories are continually decreasing; offgrade inventories remain a serious problem. however, (M Lbs.) Flexible Compound Rigid Compound Resin Total FY1988 Total Offgrade Total 5667.5 555.8 364.7 6588.0 142.7 49.7 28,6 221.0 3306.6 651.7 643.1 4601.4 477.0 64.4 _&3,,7 625.1 9/07/89 QAD II presentations - Administrative Services personnel were involved in three project teams: Stores Team, Office Equipment and Carrier Performance. 9/20/89 Natural Teams met to discuss mission statements. 9/28/89 A meeting was held to review AT&T audit scheduled for October 10 and 11. 9/29/89 Operations and intemal/extemal auditors met to discuss year-end audit. VAB.0001190361 h fI l1 I I mtHIl CUBICAL PLAIT SUITIN'HUMS SIPTNN! 1919 -SHUNTS IT P8098CTS- FOLIC 80ITI IPT/ITC I1CUI6I 1ISII-WLI miMACIIfili 21,838,130 19,665,229 553,878 0 0 0 FLS1IBLI COKPO8I0-I9LI 163,916 tUIIIU CC6M0WHCU8ID 4,760,299 1 inn comm-Mii 3,772,090 lien cunm-nouD 252,749 899,556 16,Ml 1 0 0 0 0 0 FUSIICIIII 175,440 333,156 0 TO I08UC IPT/ITC IICUNI 225,391.230 124,456,799 5)2,)S) 8 15,498,450 13,834,190 48,551,557 1.211.040 9 0 41,214,1)0 3,002,050 5,598,508 1,551,121 0 2,232,130 2,241,400 3,296,559 * total 32,217,095 11,984,526 0 347,159,369 147,738,106 3,298,55 -SIIPII0TS IT 8001' BOLL: i*s*uipInHOnIiKit* mu ILUIBLI COBPOVflB 11011 COONO PLASTICIZIt IlllOI 154 9 19 2 CQST088! CONN TISTA PICHP CAtllll 9 33 73 0 04 0 65 0 04 TOTAL 268 513 * 30 * | :V TOTAL A0G9ST 184 0 39 86 - 309 - Wit mu ILUIBLI CO8PO0ID non comm PLASTICIZE! 1,613 447 836 172 155 27 0 17 261 66 44 14 31 15 6 38 3,008 199 385 84 TOTAL TTD P1CU6I1: tfitprantH mu ILUIBLI COHPO9I0 IUI0 CO8POM0 PLASTICIZIt TOTAL AUNT 2,060 TISTA 0 0 6 9 0 555 869 241 CISTWII COHN PICKIP cittin T0IC CM2I1II1 5 11 9 43 84 9 0 90 0 00 AAA ^a ^A 46 104 9 6 0 0 0 9 AII/NS 10 7 1 0 18 3,736 TOTAL 26 M- 134 - 190A f ^ 179 * Wit mu nilllLK CO8POI80 11019 CO8FOW0 flasticizki 122 0 577 1 135 0 30 0 59 3 27 25 00 -Vrt. TOTAL m 637 --i 1 001190362. LABORATORY - H. G. Coleman A. Safefv - There were no safety Incidences In the Laboratory this month. The monthly safety meeting was the annual respirator training provided by the Safety Department. Additionally, our Q.C. technicians and supervisor attended an eight-hour first aid course taught by Ginny Belk. There were no customer contacts or RCA's received this month, nor were any Customer Problems Reports recorded. September. There no product waivers issued in The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of September, 1989* Reactor Number of Samples Average RVCM, ppm 930 36 55 136 1.506 1.220 The following is a summary of the residual VCM analysis of shipment samples for the month of September, 1989. 5265 5305 5385 5395 5415 5465 Dry Blend Debox Pond Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2% pmax.) 44 0.285 68 0.606 65 0.194 0 63 0.090 00 46 0.119 20 0.172 5 0.138 (based on dryer regulars") 5265 5305 5385 1.60 0.79 -------' 3.05 5.33 5.33 1.43 1.15 0.58 0.27 1.57 3.33 2.33 1.08 . -~ ~ ' 1.90 0.56 .... 4.22 *- - 2.67 2.07 1.33 0.61 *-* 4.44 *__ 6.33 2.75 0.25 Continued E. . (based on dryer "regulars "> - 5265 5305 5385 HU % thru 140 Mesh Drytime Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) 0.58 -- -- -- Average particle microns 137 F. 0.65 -- -*--- ** 138 2.48 2.67 -- --- 0.9 167 2.48 2.67 2.05 1.27 1.8 170 Hardness Color/Clarity Hard Particles Dicing Metals Totals G* Adjustments M Lbs. (%) 39.0 (0.68) 39.0 (0.68) 12.1 78.5 20.7 16.3 9.0 138.7 (0.21) (1.38) (0.36) (0.29) (0.16) (0.041 (2.43) Contamination Total 1*1 (0.10) 3.6 (0.10) Flexible 38401 - Hardness - A Scale - Specific Gravity - Hard Particles - 20 sec. D 26 26 26 i 83.88 1.377 20.69 35031 - Hardness - D Scale - Specific Gravity - Hard Particles - 2 min. 26 26 26 49.85 1.377 5.50 Mill Temperature, F Oven Temperature, C 26 325.4 All Readings 2SL___ 0.61 0.015 4.71 0.61 0.009 2.76 1.02 204C. A VAB.0001190364 LABORATORY - Continued f Moisture Drytime Particle Size - 60 mesh - 80 mesh - 100 mesh - 120 mesh - 140 mesh - 200 mesh Pan Bulk Density Color - L A. B Flow Time , sec. Hard Particles, 5 min. Hard Particles, 7 min. Inherent Viscosity J. R 2 22____ 37 0.155 0.041 60 4.74 0.21 60 2.14 0.67 61 40.50 2.99 60 26.25 0.57 59 17.07 1.54 60 8.68 1.06 60 4.03 1.23 60 1.33 0.46 30 0.5011 0.0027 27 100.57 0.19 29 0.09 0.14 25 1.66 0.23 30 7.05 0.45 60 37.1 7.9 60 6.1 2.5 26 1.0102 0.0059 1. We changed our retain storage container to a smaller one and re-arranged our retain shelf space. The result is that we now have six-month storage capacity for shipment retains! .2 Repeatability and reproducibility studies were performed this month on the resin contamination test (Syntron). While the results are somewhat inconclusive, there is much variability (mostly repeatability error) apparent in the test - as much as +/-10 on a group of samples averaging 13 contaminants. A separate report will be issued as more data is collected. 3. D. S. Cox performed a precision study on slurry RVGM. The 3a control limits were +/-30 ppm on 20 repetitious of a sample that averaged 45 ppm. The observed variation is sample error rather than instrument variation. 4. Raw material specification sheets were updated this month; distribution will be done in October. 5. A sample of Occi 160, a very low molecular weight resin used in injection molding applications, was received from Premiere Polymers and tested for I.V. in duplicate at 0.490 and 0.488. VAB.0001190365 RESIN Ship Date 9/01/89 9/01/89 9/01/89 9/06/89 9/07/89 9/12/89 9/13/89 9/13/89 9/18/89 9/18/89 9/19/89 9/27/89 9/27/89 9/28/89 SAMPLE SHIPMENTS SEPTEMBER 1989 Product Pond Resin Pond Resin Pond Resin 5 385 Pond Resin 5385 5415 5415 5385 Pond. Resin 5415 5305 5305 Pond Resin 5415 Amount 50 lbs. 50 lbs. 50 lbs. 2 lbs 5 lbs. 100 lbs. 100 lbs. 100 lbs. 250 lbs. 2 lbs. 100 lbs. 300 lbs. 50 lbs. 100 lbs. 10 lbs. Customer FABRICA DE SANDALIAS BLUE STAR PANIMEX GRAVINIL, S. A. Huls America Lastique Int'l. Corp. OSCAR FERNANDEZ Rubbermaid OMAR SANTOS ESCAMILLA Carlon Dayton Extruded Plastics BASF AKTIENGESELLSCHAFT SEMBODJA HOLLAND B.V. IFER DOMINICANA C.A. Huls America A COMPOUND Ship Date Product 9/01/89 34431 NAT 34643 NAT 9/06/89 17462 BLK 18162 BLK 9/07/89 36451 NAT 9/13/89 9-712 9-746 9-803 9-856 9/13/89 MSP-90 p WUMMMP Amount 50 lbs. 50 lbs. 100 lbs. 100 lbs. 100 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 4 1500 lbs. (WPWOTMMWMMPm Customer & BICC (CARIBBEAN) LTD. i i. Superior Metal Products Tandy Wire Conex of Georgia . OMAR SANTOS ESCAMILLA VAB.0001190366 J, *- H ' "f *1 '111i*p mmmrn iiiiitftiipi COMPOUND (Cont.) Ship Date Product 9/15/89 16851 CB 50 9/18/89 240-128B GRY 568 9/21/89 48562 BLK Amount 100 lbs. 2150 lbs 50 lbs. -^ Sample Shipments/Sept 1989 2 Customer ABC Plastics Carlon Co. Mytox Manufacturing DRYBLEND Ship Date 9/27/89 Product 90172D WHT 110 Amount 50 lbs. Customer SEMBODJA HOLLAND B.V. PLASTICIZER Ship Date Product 9/01/89 108P Amount 1 gallon Customer Aristech Chemical Corp. ,-|s i. . .. .:_!... '/v ,..; i. iMI- 1 *-. h, -*- =*'i in i**~ .Y . - .^.^l^.t*. .. lc! VAB.00Q1190367 , # -1 p , , _ _- -ml * '"'.' .i 4 ' V*t> r" 1 L, J f :a!^:!f` 4* NUMBER OF NJURIES * A ABERDEEN CHEMICAL PLANT INJURIES fTneMe Month Running Totals) ri w* J*87F M A M J JASON OJ'BBF MAMJJASQN DJ'SF M A M J J A S TOTAL INJURIES 4 OSHA RECORDABLE 'mmmmmm imm m VAB.00Q1190368 m ***** mmmmm A i- ^ , .j li. . . '-r* -k" BTU/LB VAB.0001190369 ABERDEEN ENERGY CONSUMPTION B T U /L B 12 MONTH AVERAGE