Document VGkpjOZay1zw0ekx47LGOX96Z

CELANESE PLASTIC MATERIALS COMPANY Chemcel Plant Bishop, Texas TO: FROM: E. Munoz R. L. Bunkley RLB-46-79 August 20, 1979 Quality Control Monthly Report July, 1979 CC: Dr. R. A. Daniel - Chatham Mr. J. W. Beltz Mr. A. R. Kurkowski Mr. R. W. Murphy Mr. F. M. O'Neill Dr. M. L. Druin (6) - Summit Mr. C. Gottfried Dr. M. Meisters Mr, F. B. McAndrew Mr. W. L. Shearer Mr. M. M. Wilson , Mr. D. Zimmerman Summit Data Files te *?- Mr. A. C. Abshier - Bishop Mr. W. S. Allen Mr. C. A. Amond Mr. G. Artripe Dr. H. L. Davis Mr. J. C. Doedyns Mr. D. L. Dotson Mr. R. D. Fuchs Mr. C. L. Hammond Ms. A. R. Hancock Mr. L. N. Harvey Mr. H. P. Hohon Mr. J. L. Merian Mr. W. H. Meyer Mr. A. B. Milam Ms. P. J. Moede Mr. K. A. Rose Mr. R. G. Rothenberg Mr. J. D. Saladino Mr. A. G. Salinas Mr. P. N. Thomas Mr. D. Wallen Mr. E. D. Wendler ...... Mr. K. A. Wolf File: 3.017 301.014 501.009 Central Files (3) - CCCTC 003915 ! GENERAL SUMMARY: CeIcon product waivers totalled 44.3% of the month's production total of 8.3 MM lbs. Natural Finishing product waivers were the result of melt index out of specification, pellet quality problems and out of specification natural color. Quality waivers in Special Products were due mainly to out of specification melt index and tensile strength. Celanex quality waivers were low this month, with only 3.1% of the month's total production of 1.98 MM lbs. being out of specification production. Quality waivers were due to pellet contamination and unfilled pellets. Nylon product waivers amounted to 30.6% of the total production of 3.22 MM lbs. Waivers were due mainly to production out of specification on Relative Viscosity, high volatiles content and off size pellets. A lost time occurred on July 30 when Mr. John Kirchoff, Sr. Technician in the Color Lab, broke a finger when an extruder screw which he was cleaning slipped and rolled over on his hand. As a result of this accident, stands to hold the 2 1/2" screw will be fabricated and in place before the screw is pulled again. I.' CELCON A. Customer Complaints - Dotson/Tijerina/Hernandez 1. Capitol records complained (P-5533) that processing problems were experienced when using Celcon C-143 natural from lot 8122106. The lot of material involved had been released as specification material. Since the complaint also indicated that an RTS visit had resolved the processing problems the complaint was closed. (DLD-127-79) 2. A precautionary complaint (P-5534) was entered by Chicago Molded citing delivery of a shipment of Celcon M270-14 natural (lot 8121604) instead of the requested M270-04 natural. The customer also indicated they experienced parts failure when the product was used. Plant records showed the indicated lot to be specification M270-04 material and was so labeled prior to shipment.. .The discrepancy in labeling could not be resolved without additional information. The part failure problem was referred to RTS for further investigation. (DLD-128-79) 3. Hoffer Plastics entered a precautionary complaint P-5535 stating ^that half a shipment of Celcon color concentrate was labeled M90-07, CC-3063 K20, and half was labeled M90-07 CC-3093 K20. The customer used all the material as both materials produced the desired color match. Resolution of the labeling discrepancy could not be made as no lot number of the materials were indicated. Warehouse personnel, however, were made aware, of this complaint and the need for proper care in package labeling. (DLD-129-79) 003916 i RLB-46-79 -2- August 21, 1979 4. A complaint (P-5524) indicating excessive formaldehyde odor with a shipment of Celcon C-143 natural from lot 8122^51 was entered by Hult Molding Co. The material met all quality parameters upon release. RTS was re quested to investigate the customer's molding process and conditions. (DLD-138-79) 5. Nypro Inc. entered complaint P-5530 citing excessive black speck contamination in a shipment of C-155 natural, lot 9010901. An unopened 50 lb. bag was returned for evaluation. Plant records indicated this particular lot was waiver released due to the presence of black die drips. Examination of the return sample confirmed the presence of the black die drips. The customer's complaint was valid. (DLD-139-79) 6. Westlake United Corporation entered a precautionary complaint (P-5505) citing contamination of two lots (9010401 and 9010301) of U10-11 natural with excessively burnt pellets. A 50 lb. unopened bag of lot 9010301 was returned for evaluation. ' Plant records indicated both lots were released as - f. specification material and were free of burnt pellets Both plant retain samples and the customer's return ^ sample were found to be free of any burnt pellet contamination. (DLD-140-79) 7. Russel Hobbs (Britain) entered a precautionary complaint (P-5531) indicating that a lot of Celcon M90-34 white, lot 8120204 was rejected due to inadequate "heat stabilizers" as determined by the customer's internal methods. Plant records indicated the lot to be specification material. Further input from Amcel will be requested in an effort to resolve the problem. B. Manufacturing Support 1. .Melt Hydrolysis Support - Guthland All unit methods have been reviewed and updated. The unit TEA method calculation was found to be in error. Previous analytical results were found to be approximately 357o higher than actual. The method calculations have been corrected and all unit personnel made aware of the procedural change. A new method for determining the wt.% trioxane in the quench tank has been prepared. (DEG-11-79) 003917 r RLB-46-79 -3- August 21, 1979 2. SH-1 Kokneader Particle Size - Guthland . Initial results from a modification which increased the particle size exit the grinder in SH-1 have shown a 22% reduction in water carry over at the first centrifuge. Evaluation of the results on Westfalia operation and process methanol control are continuing. 3. Fluid Bed Drying Efficiency - Guthland A laboratory evaluation of particle size on drying efficiency revealed no significant differences in drying rate as a function of particle size. 4. Trioxane Reaction By-Products - Moede Increasing residence time and catalyst concentration were previously found to significantly increase total by-product formation. The effects on the conversions and distribution of each major by-product, methyl formate, formic acid and methanol, were further documented in a report (PJM-16-79). 5. Celcon U10-11 Production Problems - Allen |l- * w* Natural finishing experienced black specks, erratic MI control, and color problems during most of the recent U10-11 run. A check of unit polymer quality and finishing operations revealed the following: (1) U-10 polymer quality was normal but overall average MI was slightly higher than previous runs (1.0 versus 0.85). (2) An initial run of U10-11 on the KKCH had been unsuccessful, producing a large quantity of high color, high black speck count material for rerun. (3) Stabilizer feed addition on the 8" extruders was found to be highly variable (0.06% to 1.73%) as determined from spot samples. Subsequent to this finding, analysis of highly colored pellets revealed them to contain a higher stabilizer content than normal spec color pellets. The high variability in stabilizer levels and the quality or rerun is suspected to have been the major contributor to the black speck and high color problems. The high MI problem is thought to be the result of the initially higher feed MI. Work is in progress in Process Engineering and Quality Gontrol `to address each of the defined problem areas. 003918 RLB-46-79 -4- August 21, 1979 C. Analytical Development 1. Determination of Zn in Water - Saladino A method for determining the concentration of Zn in water (TO-2 cooling water) was developed. The water sample is diluted and analyzed by Atomic Absorption Spectrophotometer (AA), using a 0.50 ppm Zn standard A report will be issued. D. Routine Analytical Sample count, overtime hours, holiday overtime hours, and formaldehyde feed concentration for July are summarized in Table I. The sample count for July was 6183 compared to 5221 in June. The overtime hours for July were 509 compared to 418 in June. The sample count increase was due to a longer reporting period and a significant increase in sampling from Natural Finishing and SH-2. The overtime hours are as follows: Technician vacation Sick relief Nucleant Production Safety Training Scheduled Overtime PBT-IV Testing TO-1 & TO-2 Unit Support Coverage for vacancy on "C" Shift 72 8 74 18 120 25 8 184 ft Special Analytical Support was provided to the following projects: 1. K. H. Patel - PBT High IV. Trials Batch Numbers 8, 9, & 10. 2. F. Trevino - Special Nylon Trials - Wollastokup G 1100 Silane treated trial runs. ... H. CELANE2 A. Customer Complaints - Dotson/Tijerina/Hernandez 1. A precautionary complaint was entered by ADC claiming feeding problems with Celanex 3310 natural from lot 9042063 due to the erratic size and shapes of the pelletsi In addition, problems were experienced in coloring this material with Celanex color concentrates. The lot in question met all release parameters including pellet quality. Examination of the small return sample and our shipping lot retain revealed the pellet geometry and size to be typical of normal Celanex production material. 003919 RLB-46-79 -5- August 21, 1979 The secondary problem of coloration could not be resolved without additional information. RTS was requested to investigate the problem. (DLD-152-79) III. NYLON A. Customer Complaints - Dotson/Tijerina/Hernandez 1. Reynolds Metals Company entered a complaint (P-5507) stating that they could not produce gel free nylon film when using N-186 natural from lots 9012421 and 9011821. RTS confirmed the gel problem and noted that the gel problem did not occur on the equipment when Zytel resin was substituted. The complaint also indicated that the additional lots 9011721, 9011921 and 9012921 of N-186 were also rejected by the customer. All the lots indicated passed normal quality control tests prior to shipment. Since-our standard methods of analysis did not identify any problems with these materials, samples were sent to Summit for gel testing. This complaint will remain open pending the results of Summit's testing. 2. Two complaints P-5545 and P-5515 were entered by -- ` , Reynolds Metals Company indicating that excessive soft gels occurred when Nylon N-186 natural from lot 9011821 was processed into blown film. This complaint was identical to complaint P-5507 from Reynolds citing the same problem with the same lot of material. As indicated in that complaint reply (DLD-126-79) the lots in question have been sent to Summit for gel testing and resolution of the customer's problem. (DLD-137-79) 3. Reynolds Metals Company complained (P-5551) that they received three gaylords of N-186 natural that were badly damaged. The lot numbers of the damaged material were not provided. Our records indicated that the shipment left the plant without any damage. There was insufficient information provided in the complaint to resolve the possible source of the damage. Damage could have occurred through rough handling or during transit, or double stacking by the carrier after leaving the plant. The complaint was referred to Distribution and they were requested to notify the carrier of the damages. 4. Reynolds Metals Company complained (P-5552) that they found 11 gaylords out of 30 with poor heat seals on the liners. The material packaged was Nylon N-186 natural from lots 9060521, 9060321 and 9060421. 003920 RLB-46-79 -6- August 21, 1979 Investigation of the complaint indicated no sealing problems were evident during the packaging of these lots. A random check of other gaylord packaged products failed to find any liners with inadequate seals. All warehouse personnel have been made aware of this complaint and the necessity for insuring proper seals during packaging. 5. Plasco Inc. rejected three lots of Nylon 1503-2 natural as they did not meet their internal specifications for color. Complaint P-5539 was entered requesting credit for the shipment. The material met all Bishop quality parameters upon release. Marketing was requested to lot select future shipments to meet the customer's requirements. (DID-130-79) 6. Borg Warner complained of black speck contamination in Nylon 1503-2 natural from lot 9021092. A 50 lb. bag was returned for evaluation. This lot of material was waiver released due to the presence of black die drips. Examination of the return sample confirmed the original observation. The complaint was valid. (DLD-131-79) 7. A complaint (P-5519) was entered by Plasco Inc. sta.ti^, that a shipment of 1503-2 natural from lot 9021092 was ' contaminated with large chunks of glass. A 50 lb. unopened bag was returned for evaluation. Part of the indicated lot was originally found to contain undispersed glass and was to have been reprocessed. Examination of the return sample, however, disclosed the presence of undispersed glass in the pellets. It appears that a portion of the original production was packaged before being reprocessed. The customer's complaint is valid. (DLD-132-79) 8. Nypro Inc. entered complaint P-5543 stating black speck contamination of a shipment of Nylon 1000-4 natural from lot 9042684. The lot in question was released as specification material. Examination of the returned bag of material supported this conclusion. (DLD-133-79) 9. A complaint (P-5540) was entered by Saginaw Steering Gear stating that they rejected a shipment of Nylon 1503-2 black (lot no. 9030772) due to failure of the lot to meet their internal specifications on ash content and specific1 gravity. This particular lot was waiver released for a higher than normal ash content 37.5 wt.% versus a specification maxi mum of 35.0 wt.%. The customer's specification calls for an ash range of 31 - 35 wt.%. No specification was given for the required specific gravity limit. 003921 yj i RLB-46-79 -7- August 21, 1979 Marketing was requested to lot select future material for this customer to avoid product rejection. (DLD-134-79) 10. Heyman Manufacturing Company complained (P-5550) that gaylords of Nylon 1310-2 natural from various lots bulge on the sides when stacked. Photographs showing two such gaylords accompanied the complaint. Examination of the photographs indicated that the lids and not the sides were bulging arid adjacent gaylords of nylon did not exhibit the problem. Without additional information to preclude the possibility of rough handling or water damage to the boxes in question no further resolution of the complaint was possible. (DLD-135-79) 11. A complaint (P-5510) was entered on Wilde & Son claiming that out of 200 lbs. of Nylon 1000-1 natural one 50 lb. bag was contaminated with "black graphite" on and in the bag. The original shipment consisted of 150 lbs. of lot 8051182 and .50 lbs. of lot 7101104. No indication was given in the complaint as to which lot the contaminated bag originated. Both lots of material were free of contamination when released. Since the contaminated te material was opened and no other material involved the?', plant could not evaluate the contamination problem in : , more detail. v* Ark Less Switch Corp. entered a complaint P-5553 stating that black specks were found in a shipment of Nylon N-249 precompounded white from lot 9061131. A small envelope of approximately 12-15 pellets was returned with the complaint. Plant release records indicate the material was released as specification product. The lot did contain some biack specks but these were well within specification release limits. B. Manufacturing Support 1. High Volatiles in Unfilled Black Nylon - Saladino Off spec volatiles continues to be a problem with unfilled black Nylon (1310 and 1000). The problem can be related to the Neozapon with EVA carrier used as the black concentrate. Prior work has been done to show that the ethylene-vinyl acetate copolymer (EVA) added to unfilled black nylon as a dye carrier is causing high volatiles (WSA-10-78). Work will continue to further identify and resolve the problem. 003922 RLB-46-79 -8- August 21, 1979 2. Low RV Production Problem - Allen Use Of nylon salt which did not meet pH specifications is thought to be the cause of a short period of low RV production. Changes in unit SOC's and SOP's were recommended to prevent recurrence of this problem. A letter (WSA-22-79) was issued. 3. Nyl-on Packaging Studies - Allen Fifty bags of 1000-2 Nylon, packaged in 0.0005 inch foil lined gusseted bags were shipped to Polyplastics. Polyplastics will evaluate the moisture uptake of these bags and compare this information to a previous moisture uptake study on samples sent them in the Export bags a 0.00035 inch foil lined tube type bag. A potential savings of 21 cents/bag could be realized by switching to the gusseted bags with the thinner foil liner. A letter will be issued. 4. Contamination in Chemtron Nylon Black Concentrate - Allen Metal contamination in PPG's Chemtron nylon black concentrate remains a problem. A lot of concentrate, initially fe. rejected by Bishop Q.C., was "cleaned up" by Universal^1", Plastics and returned during the month. Metal in most drums of this lot was low. However, the level of contamination varied from drum to drum, causing minor problems in production. The search for an alternate supplier continues. 5. Nylon Nucleant Production - Saladino/Salinas The inventory status of the nylon nucleant production is summarized below: Inventory 7/1/79 Inventory 7/31/79 Nucleant Produced in July Nucleant in Process Inventory 7/31/79 (167. KF) Inventory 7/31/79 (23% CaAc2) 13 drums 11 drums 39 drums 14 drums 33 drums 21 drums C. Analytical Development 1. Nucleant Analysis - Allen A revised procedure for the analysis of nucleant (CaF2) in nylon by AA (CL-3-16) was published (WSA-20-79). 2. Nylon Salt Concentration by RI - Allen A tentative method for the determination of nylon salt concentration by refractive index (CL 1-97) was published (WSA-21-79). The method is similar to the Nylon Unit Method (UM-7) used for the same purpose. 003923 RLB-46-79 -9- August 21, 1979 3. Calibration Solution for On-Stream Analyzers - Allen A procedure for preparing the sugar solutions used in calibrating the nylon unit's on-stream salt analyzers was published (WSA-19-79). 4. Evaluation of the Nylon Volatile Test - Salinas An evaluation of the Bishop Method (CL 1-74) for deter mining the weight percent volatiles in nylon polymer was completed this month (AGS-6-79). The results of the lab study indicated the precision (2a) of the method to be * 0.0297o at the 0.185% level in unfilled natural and t 0.020% at the 0.190% level in glass filled nylon (AGS-6-79). IV. INDUSTRIAL HYGIENE - Hancock, Pritchard A. Formaldehyde Survey A formaldehyde survey in the SH1/T01 area has begun. Last year, a formaldehyde survey revealed exposures over the "action level" for the gauger job descriptions. Revisions^ have been made to the Units to reduce these exposures. -- The summer months prove to be the worst case for exposure : (especially in the tank farms). The survey will check ^ formaldehyde, exposures for the new process and provide a recheck for the summer months exposure. B. Dust Surveys The survey for nuisance dust in the Celanex Unit has been delayed. The survey was to be concentrated around the SEO production run. SEO production has been temporarily discontinued pending modification of the blending system. The survey will be resumed as soon as SEO production begins. C. Environmental T-30,000 and T-30;009 scrubber vents in SHI have been sampled for organic emissions to obtain an operating permit from TACB. A report was issued. The Century Organic Vapor Analyzer (OVA-128) is being set up to monitor for fugitive emissions in the SHI unit. TACB requires fugitive emissions monitoring at least monthly for all new processes. Practice samples were taken in SH2 to check"the field operation of the unit. Emissions from pump seals, valves, flanges, etc. were less than 10 ppm TOC. (EPA & TACB define a leak as one having a volatile organic compound (VOC) emission of 10,000 ppm.) High TOC concentra tions (greater than 1,000 ppm) were found around the Komline Sanderson filter. There were visible leaks (methanol) from the filter. Several area samples (specific for methanol) were taken. Results are not yet available. 003924 RLB-46-79 -10- August 21, 1979 The maximum range of the Century Detector is 1,000 ppm TOC. To*analyze for concentrations between 1,000 and 10,000 ppm, a diluter kit has been ordered. When this attachment arrives, it will be checked out and a procedure will be written for monitoring fugitive emissions. At this point the instrument will be turned over to Maintenance to begin the TACB monthly emission point monitoring. D. Method 'Development The NIOSH method of sampling and analyzing for methanol has been developed and is currently in use. Methanol vapors are trapped in silica gel tubes, desorbed with water and analyzed by G.C. A method for monitoring trioxane vapors is also being developed. E. Analytical Load The OSHA/Environmental analytical load, to date, is summarized below. SH1/T01 SH2/T02 MH2 Nat. Finishing Spec. Prod. Celanex Nylon Chemical Co. Month OSHA Environmental 37" 4' 4 10 18 0 00 50 70 00 00 OSHA 77 226 117 226 317 39 30 0 YTD Environmental" lfe . 1Ek\ 1' 2*-' 2 1 1 3 71 14 1,032 30 COLOR SERVICE - Artripe, Rothenberg, Harvey GENERAL SUMMARY: Color Service developed 32 color matches this month. The distribu tion of color match work for each market group was 22 Celcon, 5 Nylon, and 5 Celanex; of this 3 Celcon, 3 Nylon, and 2 Celanex were reworked from existing formulations. 360 pounds of products were extruded and shipped. A total of 300 chips were sent out in the process of filling 17 sample requests for chips only. We have scheduled 25 color matches for August, leaving our backlog of unscheduled work at 48. The backlog is for reformulation of existing formulas. Reformulation is necessary due to pigment obsolescence, reformulating Nylon vendor concentrates, and chip replenishment. There are no new marketing requests on backlog. 003925 RLB-46-79 -11- August 21, 1979 Fisher Body Claret WPH 4887 and Blue WPH 7310 have visual approval by fisher and are under UV testing at Fisher. We how have all colors approved at Chrysler through the 1981 model year. This month we produced 500 lbs. of white Nylon concentrates and 120 lbs. of Celanex concentrates on rush orders. Color Service work load remains very high, turnaround time per match was below last month.(24 vs. 34 days). 1. Method Update - Rothenberg Two physical property test methods were revised and issued during the month. The methods were : Determination of Flexural Properties (CL 2-23) and Determination of Notched Izod Impact (CL 2-19). 2. Celanex Color UL. Program - Rothenberg Celanex color information was provided to A. Serle for the planning of a program with UL to retain our all-color recognition by new UL standards, which'takes effect on January 1, 1980. Pi- ' Color formulations (in Celanex 2000, 2012, 3300 and 3310) Vith the highest level of organic pigment, inorganic pigment arid a combination of organic and inorganic pigments were identified. Information was based on Celanex color formulation tickets cross-referenced with the Bishop active Celanex color file. In all color formulations, each component was identified and the weight % pigment was given. 3. Deactivation of V-0 Celanex Colors - Artripe, Rothenberg For several months efforts have been made to obtain UL approval for three concentrates used in V-0 Celanex formula tions . This approval has not been forthcoming. In order to protect our all color approvals @ 1/32", Color Service has placed the following concentrate formulations on the inactive list: EL 3143-K20 (yellow) EN 3148-K20 (orange) ES 3144-K20 (red) Requests'for these colors will not be filled until approval is given^by A. Serle and Marketing (RGR-63-79, RGR-64-79). 4. Nylon Molding Conditions - Rothenberg t A study is underway to define optimum molding procedures for Nylon (all grades). All aspects of injection molding are being ' evaluated to insure that molded specimens reflect optimum physical test and color data. Results will be published when testing is completed. 003926 RLB-46-79 -12- August 21, 1979 5, Pigment Evaluation - Rothenberg Seven (7) new pigments have been received during this time period. Final evaluations on these colorants will be completed shortly. VI. STATUS OF LAB BUILDING CONSTRUCTION - Rose Initial plans have been made for modification of the exhaust system for the 2-story hood to achieve design flow velocities. Modifications to the system should be complete by mid-September. Recontouring of the hood floor to provide for proper drainage is still out on bid. This job will be scheduled to coincide with the hood duct work to minimize downtime. Many leaks are present in the lab roof. Significant repair will be necessary to make this tar paper roof watertight. Leakage of water into the color measurement room during rainy weather is jeopardizing critical equipment. Roof repair should be completed as soon as the 2-story hood traffic is off the roof. Condensate leakage persists above the solution prep room from the . A/C air handling unit. This problem creates a safety hazard from , having puddles of water on the floor. Two of the lab rooms have had the epoxy grout in the tile floors repaired, and there are two more rooms that have not been completed. This job needs to be wrapped up. A broken steam vent pipe above the ASTM room has not been repaired. During periods of high steam usage, condensate leaks into the ASTM room. Backs for the island bench sink units have not been received or installed. Addition of a methane gas outlet-to the Special Problems lab has not been completed (PER 9680, 4/11/79). VII. PERSONNEL David Guthland, Chemist assigned to the Polymer Units resigned July 31, Peggy Moede has temporarily assumed responsibility for the Polymer Units in addition to the Trioxane Production areas. William Lowe joined Celanese as a Lab Technician assigned to the Color Lab on-July 23. Bille Le-Blanc, `Color Lab Clerk, was accepted on bid for the Color Lab Technician position, effective August 1. Richard Rothenberg, Chemist assigned to the Color Lab was promoted to Process Chemist, effective August 1. 003927 RLB-46-79 -13- August 21, 1979 Cinda Alverado, Color Lab Technician was transferred to the Specification Lab, effective July 20. RLB:s lh Attachments R. L. Biinkley ft 003928 (A ll Types) (A ll Types) % o f Total T o ta l No. S pies. Nylon Non- Routine Routine T o ta l No. S pies. C elaneic Non- R outine Routine T o ta l St 00 VO V0 vo CM o rH CM o VO o\ 00 Ov in rH St o CO CM rH o o rH rH CM o rH O St St rS rH 00 00 rH o o OV o CO 00 CO St o vO rH VO ov CM CO oo CO m in <r vO ON CM rH rH CO rH rH VO OV OV CO CO CO CO rH rH CM CM 00 00 rH VO CM s CM CM r-s mm CM CM rH rH rH vO CM CM CM m in co VO OV CO o CO 00 00 o rH St VO m <--i0n> ' t<oD a, a, 0Efl03 h>--> fO < 0c1 oO3: 0) c301c c o rH co 00 in vo co in co CM >* /o o> H >* CO CO rH o >3 rl O <u Is a, 00 J~1 CM vo o >4 o co cm r- -s oo n n|o|o(o(o D P <f ri n o> CM ooc<yo> >- o: o3i:oo_ x-._oJ oo <D > < 0) > < 04,* <>: *o "O <u 0) a> <y u. L&. o a o X U oXo c u OV CO CM o 00 CO 4- rH r. rH o 00 vo oo rH CO m m vo ov r- VO o m CO P- 00 o st ao St rH oO Ov CM rH rH ooo OV CO CM o CO 00 m st o ov ov CM St V0 co m Ov aO m vO CO >3- St' o in vo m Ov 00 rH o o p^ Ov CM rH rH o 'O 00 CM CNJ oo </) CT -J e r +cJo c h- UO C/1 3 c/1 H* *T3 eo r W U. a. t~ 4-> CO S Uf* <U X CL 4J (iO. (0 a> c 4-> CO X CSJ CSJ f 43-i o <D to r-* fmOm Wl C o 0) X tO CL a; P* /VCO* o /O co 3o rS Q <>u Hfw Is pLl St 00 COCO CM CM CM CM m Q i-M st u-t Ho o o Hi co co vo CM CM Ajj 3o S i iS U Is <>D o oa\ o m a\ om s * H hJ . <M Js Jo H O cU o ,, EC <--l TJ H 3 *r4 OOr-l <U O ai X No. Spies. C e lco iP Non- Routine Routine T o ta l A re a _________ I ' Gross Production Total Packaged Off Specification Quality Waivers TABLE II Celcon Quality Summary M Lbs JULY. Percentage Year to Date M Lbs Percentage 8319.3 100.0 49164.6 100.0 4423.3 3685.3 53.2 44.3 14684.9 12091.9 29.9 24.6. TABLE III Celcon Experimental Products Product Production Releases C234A C243 C244 C251 166800 158650 " 132250 152400 166800 130400 132250 152400 003930 TABLE IV Analysis of Celcon Packaged Off Specification Natural Finishing -- JULY % of Quantity Total Defect Lots M Lbs. Natural YTD Lots Quantity M Lbs. Melt Index 25 2,312.0 Discolored Pellets 9 839.9 Black Specks 7 917.5 -Stabilizer Content 2 123.4 Ash Content 00 Natural Color 12 864.7 Ext. HCHO .0 0 10X Melt Index 2 37.0 Kd 0 0 Volatiles 2 37.6 Off Size Pellets 4 588.0 33.4 12.1 13.3 1.8 0 12.5 0 0.5 0 0.5 8.5 69 6,118.0 19 1,290.9 32 2,779.2 15 863.6 1 28.3 17 1,618.0 4 108.8 3 56.1 3 362.5 6 205.8 6 914.6 7. of Total Natural 16.1 3.4 7.2 2.2 0.1 4.2 0.3 0.1 0.9 0.5 2.4 Special Products -- JULY Quantity Defect Lots M Lbs. Melt Index Discolored Pellets Color Match Off Size Pellets Colored Pellets (Contamination) \/olatiles Stabilizer Content Kd Black Specks Tensile Strength Natural Color (Glass Filled) Ash Content 14 211.84 67.9 2 26.5 5 87.0 00 3 37.9 1 40.4 00 00 15 205.8 2 30.7 5 .38.4 % of Total S. P. 15.1 4.8 1.9 6.2 0 2.7 2.9 0 0 14.7 2.2 2.7 YTD Lots 73 16 16 43 5 10 12 19 1 20 16 5 Quantity M Lbs. 1,088.9 162.3 118.6 587.8 22.4 143.7 406.9 119.5 9.4 279.0 208.3 38.4 % of Total S. P, iofe ITS1,1' 5.5 0.2 1.3 3.8 1.1 0.1 2.6 1.9 0.3 003931 TABLE V Celcon Releases Formulation Reieases Quantity CM Lbs) Lots JULY YTD JULY YTD Quality Waivers Quantity (M Lbs) Lots JULY YTD JULY YTD M9000 Flake 0 M9001 Flake 142.6 M27000 Flake 0 M2501 Natural 207.3 M2504 Natural 705.5 M2514 Natural 0 M9004 Natural 4406.2 M9014 Natural 0 M90210 Natural 0 M14014 Natural 0 C143 Natural 0 M27004 Natural 0 M27014 Natural 0 U1011 Natural 345.3 M2501 Color 0 M2504 Color 56.0 M9004 Color 253.7 M9014 Color 0 M9008 Color 0 M9008 Natural 17.0 M9034 Color 0 M14014 Color 0 C143 Color 19.6 M27004 Color 0 M27008 Color 1.4 M2504 Black 52.1 M9004 Black 137.3 M9014 Black 64.4 C143 Black 0 M27004 Black 0 U1011 Black 44.3 GC25A Natural 1.2 GC25A Black 296.8 M9007 Color 16.5 M9007 Black 92.7 Salt & Peppers 182.6 C155C 0 C234A 166.8 C240A 0 C241 0 C243 130.4 C244 132.3 C251 152.4 C2S2 0 C254. 0 C255 0 C257 0 C267 0 C300 0 C301 0 TOTALS 71(,624.4 26.8 1005.3 24.9 881.1 1519.7 25.7 21864.6 2127.9 30.2 49.6 2179.5 1795.4 1188.3 489.6 21.8 56.0 1559.4 22.6 98.3 239.2 256.3 38.8 100.0 107.1 226.5 159.2 2388.7 468.0 133.4 263.4 65.2 441.3 1593.0 216.4 215.3 1039.7 124.7 901.9 502.6 64.7 435.4 2804.9 363.6 176.4 12.6 5.0 12.0 20.4 717.4 417.5 49,477.3 0 12 0 2 9 0 29 0 0 0 0 0 0 12 0 3 22 0 0 1 0 0 2 0 1 2 4 3 0 0 1 1 17 10 4 13 0 5 0 0 -------, i 4 1 0 0 0 0 0 0 0 159 3 84 2 17 26 1 177 17 1 1 28 14 23 18 2 3 141 4 9 15 14 3 14 10 32 15 70 24 8 10 5 36 70 59 10 75 5 31 4 4 -8 32 7 2 1 1 1 2 7 4 1,152 97.9 4li.l '565.1 1045.3 2082.6 6361.7 750.5 30.2 345.3 195.2 68.4 225.1 412.7 35.9 55.5 35.9 269.2 1.9 14.2 148.5 19.6 52.1 41.8 52.4 25.2 2.6 77.9 92.0 373.4 253.2 16.3 1.2 161.1 12.7 1 5 13 12 2 6 2 2 1 2' 1 43.2 130.4 9.9 152.4 85.3 143.0 93.8 18.2 162.2 319.5 285.6 1 1 1 1 3,685.3 12,091 .9 51 9 15 47 7 1 2 1 6 15 2 . 26 - 1 trel -iv. 8! , 4: '1 3 10 11 1 13 1 3 5 1 1 ... 2 5 4 212 X COLOR BLACK OTHER GLASS FILLED NATURAL CONCENTRATES MONTH 4.56 6.10 4.26 3.91 79.74 1.43 YTD 5.51 8.88 4.23 4.11 76.40 0.87 QUALITY WAIVERS MONTH YTD 48.3 24.4 003932 >. - Gross Production Total Packaged Off Specification Quality Waivers TABLE VI Celanex Quality Summary M Lbs JULY Percentage Year to Date M Lbs Percentage 1985.3 100.0 14180.7 100.0 85.0 62.7 4.3 1028.9 7.2 3.1 777.3 5.. 5 OO3933 1 TABLE VII Analysis of Celanex Packaged Off Specification Defect Flammability Discolored Pellets Ash Content Off Size Pellets Volatiles Contamination Color Match Unfilled Pellets Lots 0 0 0 0 0 2 0 2 JULY M Lbs 0 0 0 0 o- 22.3 0 62.7 % of Production 0 0 0 0 0 1.1 *0 3.2 o\| Year to Date % of Lots M Lbs Production 9 177.4 1.2 5 52.3 0.4 22 480.5 3.4 2 62.8 0.4 ' 1 39.4 fl, 0.3 4 73.5 U 0.5 7 95.3 0.7 2 62.7 0.4 003934 TABLE VIII Celanex Releases Formulation Releases Quantity (M Lbs) Lots JULY YTD JULY YTD Quality Waivers Quantity (M Lbs) Lots JULY YTD JULY YTD ""2000 Natural 2000-2 Natural 2002-2 Natural 2012 Natural 2012-2 Natural 3200-2 Natural 3210 Natural 3210-2 Natural 3211-2 Natural 3300 Natural 3300-2 Natural 3310 Natural 3310-2. Natural 3311 Natural 3311-2 Natural 3200 Black 3210 Black 3210-2 Black "300 Black J00-2 Black 3310 Black 3310-2 Black 3311-2 Black 3300 Color 3300-2 Color 3210-2 Color 3310 Color 3310-2 Color 3311-2 Color J225 J226 J227 J228 TOTALS 0 0 0 64.6 57.5 0 107.6 0 0 625.3 55.4 389.5 44.2 0 0 32.7 0 0 235.5 0 0 0 0 57.1 41.6 0 0 74.8 0 0 0 0 0 1785.8 25.9 326.2 18.4 150.9 133.6 38.9 801.6 217.8 39.5 3539.4 102.5 1651.1 414.7 15.0 47.0 298.0 224.5 102.2 3888.6 19.1 361.4 172.8 54.4 275.0 41.6 21.1 122.7 144.6 53.7 9.7 7.5 13.0 13.0 13345.4 0 2' 0 31 02 6 13 5 13 01 3 49 30.4 0 13 01 18 120 62.7 313.7 23 11 73 91.3 2 19 01 0 1 ** 19 * 0 12 19.5 05 25.5 3 52 194.2 01 0 21 34.7 0 11 20.4 02 5 22 47.6 33 01 08 59 04 0 1 -- 01 0 1 01 64 512 62.7 777.3 2 29 6 - te -.rtL 1 1 5 2 1. 4 ---- -- 2 31 QUALITY WAIVERS 3.5________ 5.8 Month YTD 003935 Gross Production Total Packaged Off Specification Quality Waivers TABLE IX Nylon Quality Summary JULY M Lbs Percentage Year to Date M Lbs Percentage 3215.5 100.0 18289.9 100.0 1346.3 982.9 41.9 30.6 6492.0 5319.7 35.5 29.1 TABLE X Nylon Experimental Products Product N224 N243 N269 N270 N355 N265 N277 Nat. N277 Black N276 Production 376,700 154,800 91,200 44,400 62,535 4,950 5,850 9,500 4,700 Releases 376,700 154,800 91,200 44,400 62,535 -- -- -- -- & 003936 i * # TABLE XI Analysis of Nylon Packaged Off Specification Defect Relative Viscosity Volatiles Ash Content Discolored Pellets Off Size Pellets Natural Color T od Impact Nucleant Copper Black Specks AEG Lots 26 26 0 2 25 0 0 4 0 0 1 JULY M Lbs 462.0 465.3 0 32.9 486.1 0 0 84.6 0 0 21.6 % of Production Year to Date i of Lots M Lbs Production 14.4 14.5 0 1.0 15.1 0 0 2.6 0 0 0.7 137 3129.7 17.1 107 2295.8 ' 12.6 12 228.0 1.2 10 96.2 - 0.5- 28 567.1 1.3.1 30 637.6 U 3.5 14 316.9 1.7 15 293.1 1.6 2 42.5 0.2 5 43.5 0.2 1 21.6 0.1 003937 0y4 11 TABLE XII Nylon Releases Formulation Releases Quantity CM Lbs) JULY YTD JULY Lots YTD Quality Waivers Quantity (M Lbs). JULY YTD Lots JULY YTD 1Q00-1 Natural 1000-2 Natural 1000-4 Natural 1003-1 Natural 1003-2 Natural 1200-1 Natural 1300-1 Natural 1310-1 Natural 1310-2 Natural 1310-4 Natural 1400-2 Natural 1403-2 Natural 1500-2 Natural 1503-1 Natural 1503-2 Natural 1600-2 Natural 1603-2 Natural 1000-2 Black 1003-2 Black ' 0-2 Black 1. 3-1 Black 1503-2 Black 1603-2 Black 1503-2 Color 1603-1 Color 1603-2 Co lor N181 N184 N186 N198 N224 N243 N245 N249 N269 N270 N273 N355 N357 TOTALS 273.9 668.8 120.9 0 0 168.5 0 22.0 611.0 285.6 0 0 37.6 0 0 0 0 0 0 344.1 0 549.8 0 0 13.4 0 0 0 0 0 376.7 154.8 0 0 91.2 44.4 0 62.5 0 3,825.2 628.3 2008.8 732.0 365.9 907.0 389.9 58.0 33.0 1528.3 616.9 ,, 63.0 32.9 357.7 284.3 1266.2 103.0 24.9 195.9 .348.3 590.5 39.2 2134.6 108.8 72.6 222.8 12.6 830.8 62.0 302.0 41.2 1586.1 782.4 175.6 17.0 433.2 192.5 147.5 867.4 315.6 s 18,878.7 13 34 6 0 0 16 0 1 28 .13 0 0 1 0 0 0 0 0 0 24 0 17 0 0 1 0 0 0 0 0 18 7 0 0 4 2 0 3 0 189 31 . 101 37 18 46 37 3 2 75 29 3 1 12 9 48 4 1 6 14 31 1 63 4 6 19 1 40 4 31 2 78 39 9 2 22 9 7 45 5 897 103.8 122.0 62.1 22.0 149.9 109.6 185.2 122.6 21.6 21.6 62.5 982.9 145.1 386.8 116.4 142.5 179.8 5 6- ... 6 22.0 228.2 207.0 1 7 5 7 20 6 7 17 1 11 10' 130.7 252.2 1072.7 74.7 134.3 266.4 370.4 39.2 726.3 42.9 * *~ /< 7* * 14 5 4 7 38 2 4 9 19 1 21 2 12.6 21.6 61.8 t 85.3 272.3 1 1 I 1 6 -4 14 290.1 38.4 5,319.7 3 - 15 1 54 228 QUALITY WAIVERS 25.7 HontE 28.2 YTU 003938