Document XzLgbNnxxvgg14zX6Vmy825Gg

1984 ANNUAL REVIEW ABERDEEN CHEMICAL PLANT APRIL 9, 1984 IDRK I. SAFETY II. CASH FLOW PROGRAM III. ENERGY CONSERVATION IV. NEW PRODUCTS V. MANUFACTURING IMPROVEMENTS c VI. MAINTENANCE IMPROVEMENT PRESENTED BY AL SATHER C. R. MILLER VELDON MESSICK PAUL KOBER PETE MARKEY RICK SNOWDEN DTH 000099925 DTH 000099926 r 70-1 -INJURY .DATA ABERDEEN CHEMICAL PLANT NUMBER OF INJURIES -4-- H- -I 1976 1977 1978 1979 1980 1981 1982 1983 YEAR DTH 000099927 ABERDEEN CHEMICAL PLANT INJURY PERFORMANCE 1ST.QTR. FIRST AID OSHA RECORDABLE RESTRICTED LOST TIME 1981 1982 38 30 36 03 _GL __L 1983 28 4 1 0 1984 7 O 0 0 TOTAL 41 36 32 LAST LOST TIME INJURY - JULY 5, 1979 INJURY FREQUENCY x 1 0 0 FREQUENCY 12 MONTH ROLLING AVERAGE OF INJURIES (FA OR OSHA) TOTAL EMPLOYEES DTH 000099928 SAFETY 1983 HIGHLIGHTS DECREASED INJURIES 4 YEARS - NO LOST TIME INJURY FIRE PROTECTION IMPROVEMENTS SAFETY EMPHASIS SHIFT FROM STAFF TO LINE DTH 000099929 SAFETY PROGRAM IMPROVEMENTS PROGRAM ANALYSIS - LINE INVOLVEMENT - DEPARTMENTAL PROGRAM CONCEPT - SAFETY MEETINGS / SUPERVISORY LEADERSHIP - SAFETY COMMITTEE EMPLOYEE INVOLVEMENT - ESAR PROGRAM - TEAM INVESTIGATIONS - PROJECT FIELD REVIEWS DTH 000099930 SAFETY 1984 PLANS LINE MANAGEMENT RESFONSIBILTY / EMPLOYEE INVOLVEMENT SAFETY CONTROL SYSTEMS IMPROVEMENT CONTRACTOR PROGRAM IMPLEMENTATION EXPANSION OF EMERGENCY SYSTEMS PM PROGRAM DTH 000099931 PERSONNEL DOSIMETRY SUMMARY % OF SAMPLES GREATER THAN PEL %> PEL WITHOUT RESPIRATORY PROTECTION VCM 1982 1983 LEAD 1982 1983 TOTAL PARTICULATES 1982 1983 10.0 6.0 4.7 5.5 2.0 1.8 5.4 1.3 0.0 0.6 0.0 0.0 DTH 000099932 1983 VCM OVEREXPOSURE % OF PERSONNEL DOSIMETERS -o*IoOCoo*Oo1Oo>o^Oo9o<0oO o m a DTH 000099933 o<0 INDUSTRIAL HYGIENE PROGRAM HIGHLIGHTS EMPHASIS ON IMMEDIATE LEAK RESPONSE ELIMINATION OF NEGATIVE PRESSURE RESPIRATORS IMPLEMENTATION OF IMPROVED VCM DOSIMETERS DTH 000099934 DTH 000099935 CASH FLOW IMPROVEMENT PROGRAM CAPITAL EXPENDITURES - 1983 1983 PROFIT OBJECTIVE ACTUAL CAPITAL EXPENDITURES CASH FLOW IMPROVEMENT $5779M $2995M $2784M PR0dEGtLJNllEBIWNS^AS~fiC3aggREl^ MAJOR PROJECT EXPENDITURE DEFERRALS LINE I MODERNIZATION BULK CTA STORAGE AND HANDLING MAJOR PROJECT DELETIONS LINE V SURGE BLENDER 6-10 TM STORAGE FACILITIES BULK LEAD STABILIZER ADDITION BOTTLE COMPOUND PRODUCTION $1769M $ 135M * iK $ 230M $ 120M $ 300M $ 200M $ 850M DTH 000099936 1983 CASH FLOW IMPROVEMENT PROGRAM FIXED COSTS VARIABLE EFFICIENCIES INVENTORY CONTROLS CAPITAL EXPENDITURES VARIANCE FROM PROFIT OBJECTIVES (OVER)/UNDER TARGET ACTUAL $200M $458M $ 1786M $45781* - $403M $2200M S2784M TOTAL S4186M $8223M DTH 000099937 CASH FLOW IMPROVEMENT PROGRAM FIXED COSTS - 1983 ACTUAL VARIAMCE PAYROLL AND BENEFITS $404M MAINTENANCE MATERIALS AND CONTRACTS ($ 70M) TAXES , INSURANCE AND DEPRECIATION $ 62M MISCELLANEOUS S 62M TOTAL S4S8M DTH 000099938 CASH FLOW IMPROVEMENT PROGRAM VARIABLE COST EFFICIENCY VARIANCE 1983 RAW MATERIAL/OFF-GRADE PRODUCT MIX UTILITIES TOTAL $979M $2970M $629M $4578M DTH 000099939 CASH FLOW IMPROVEMENT PROGRAM MATERIALS AND SUPPLIES INVENTORIES 1983 1 2/83 TARGET BOOK AVAILABLE 0739 WAREHOUSE $ 1500M $ 1580M $ 1579M SUPPLIES (PARTS) 0744 PROCESSING $1100M $ 617M $ 832M SUPPLIES TOTAL INVENTORIES S2600M S2197M $2411M IMPROVEMENT $ 403M DTH 000099940 CASH FLOW IMPROVEMENT PROGRAM CAPITAL EXPENDITURES - 1983 1983 PROFIT OBJECTIVE ACTUAL CAPITAL EXPENDITURES CASH FLOW IMPROVEMENT $5779M $2995111 $2784M MAJOR PROJECT EXPENDITURE DEFERRALS LINE 1 MODERNIZATION BULK CTA STORAGE AND HANDLING TOTAL MAJOR PROJECT DELETIONS LINE 5 SURGE BLENDER 6-10 TM STORAGE FACILITIES BULK LEAD STABILIZER ADDITION BOTTLE COMPOUND PRODUCTION DTH 000099941 $1769M $ 135M $1904M $ 230M $ 120M $ 300M $ 200M $ 850M 1984 CASH FLOW IMPROVEMENT PROGRAM INVENTORY CONTROL OPERATING PLAN RESIN COST STUDY FIXED COST VARIABLE EFFICIENCY COST INVENTORY REDUCTION CAPITAL EXPENDITURES DTH 000099942 1984 CAPITAL EXPENDITURES PROFIT OBJECTIVE REFORECAST 2/10/84 REFORECAST (VISTA) $MM 4.2 4.2 2.4 VISTA BASIS LIMIT ABERDEEN EXPENDITURES TO $2MM DEFERRAL OF PROJECTS DELAYED CONSTRUCTION PROJECT DELETION DTH 000099943 DTH 000099944 ENERGY PERFORMANCE ABERDEEN CHEMICAL PLANT I 1983 PERFORMANCE vs BUDGET ABERDEEN CHEMICAL PLANT INCREMENTAL MMM btu/yr _3L 1983 BUDGEtED ENERGY PERFORMANCE (2/2/83) (PRODUCTION BASIS:493.4 MM lbs) PRODUCT MIX AND PRODUCTION LEVEL EFFECTS (2.3) 0.1 ^-11 CENTRATE HEAT RECOVERY COMPLETION DELAY 16.1 (0.7) INCREASED FLUID BED DRYER THROUGHPUT (23.9) 1.1 ADMINISTRATIVE PROGRAMS AND MISCELLANEOUS (143.7) (153.8) 6.5 7.0 % ADJ cma 44.1 1983 ACTUAL ENERGY PERFORMANCE (ACTUAL PR0DUCTI0N:481.8 MM lbs) 51.1 DTH 000099946 MONTHLY ENERGY PERFORMANCE 1982-1984 ABERDEEN ENERGY PROGRAM KEY ELEMENTS SUPERVISOR AND EMPLOYEE AWARENESS REDUCED RATE OPERATIONS PLAN BOILER OPERATIONS AIR CONSERVATION STEAM AND AIR LEAK PROGRAMS INSULATION AND STEAM TRAP PROGRAMS 1984 EMPHASIS ITEMS CONTINUED ROTARY DRYER UPGRADE PROJECT STEAM AND DRYER NATURAL GAS MONITORING PROJECTS V-11 CENTRATE HEAT RECOVERY DTH 000099948 1984 ENERGY CONSERVATION FORECAST INCREMENTAL MMM btu/yr % %ADJ QMA 1983 ENERGY REDUCTION vs 1972 (CMA ADJUSTED BASIS) 51.1 PRODUCT MIX EFFECT 13.3 (0.6) PRODUCTION LEVEL EFFECT (13.3) 0.6 ,--11 CENTRATE HEAT RECOVERY (9 MONTHS FULL OPERATION) (29.4) 1.3 OTHER PROJECTS & MISC. (17.4) (46.8) 0.8 2.1 1984 FORECASTED ENERGY REDUCTION 1984 BUDGETED ENERGY REDUCTION 53.2 49.5 DTH 000099949 DTH 000099950 NEW PRODUCTS ABERDEEN CHEMICAL PLANT 1984 NEW DRY BLEND APPLICATIONS COMPOUNDS AND PLASTICIZERS FITTINGS APPLICATIONS DTH 000099951 NEW DRY BLEND APPLICATIONS IMPACT MODIFIED PIPE BLEND SPECIAL APPLICATION-TRUSS PIPE 5426-42A ARMCO SHEET BLEND RP-420 RIGID PROFILE PRODUCTS TWIN SCREW BLEND-PVC WINDOWS SINGLE SCREW BLEND SPECIAL BLENDS FURNITURE PURGE DTH 000099952 COMPOUNDS AND PLASTICIZERS EXPERIMENTAL COMPOUNDS 34642 COMPOUND CABLE INSULATION LINEAR ALCOHOL PLASTICIZERS 610P 108P 810P DTH 000099953 FITTINGS PRODUCTS 5265 RESIN LOW MOLECULAR WEIGHT COMMERCIAL VALUE ADDED PRODUCTION CT A FITTINGS BLEND 90172B DTH 000099954 DTH 000099955 9NimL0Ydnn*( MANUFACTURING IMPROVEMENTS DOING A BETTER JOB WITH WHAT WE HAVE IMPROVING ADMINISTRATIVE CONTROLS PERFORMING OPTIMIZATION TEST RUNS DEVELOPING NEW PROCEDURES TRAINING OPERATORS DEVELOPING LOWER COST RAW MATERIAL SUBSTITUTES DTH 000099956 PRODUCTION,M M LBS ABERDEEN RESIN PRODUCTION MMlbs PVC/YR. 415MM plH 000099957 ABERDEEN VCM EFFICIENCY LBS.VCM/LBS.PVC 1.02072 DTH 000099958 ABERDEEN RESIN VARIABLE ENERGY COST 4/LB PVC (CONSTANT PRICING) 1.48287 DTH 000099959 ABERDEEN RESIN PRODUCTION % PRIME PRODUCT 97.1 TARGET 97.8 PRIME PRODUCT DTH 000099960 ABERDEEN PVC RESIN VARIABLE COST. <fc/LB (CONSTANT PRICING) 20.6429 PVC RESIN VAR IABLE CO ST, $ /L B 1980 1981 1982 1983 1984 DTH 000099961 MANUFACTURING RESIN IMPROVEMENTS PVC VARIABLE COST DIFFERENCES 1980 VS 1984 AT CURRENT PRICING & 1984 PRODUCTION VOLUME A $1.54MM MAJOR OPERATIONS IMPROVEMENTS DTH 000099962 CO M PLAINTS/YR ^ ABERDEEN PLANT JUSTIFIED RESIN COMPLAINTS 17 DTH 000099963 AVAILABLE RESIN RAW MATERIAL INVENTORY VALUES (EXCLUDING MONOMER) ($M) S26SM $26SM FUTURE MANUFACTURING IMPROVEMENT MTS OPERATOR TRAINING PROGRAM RESIN COST STUDY ADDITIONAL TECHNICAL SUPPORT FOR PROCESS OPTIMIZATION UTILIZE NEW PLANT COMPUTER - IMPROVE TIME MANAGEMENT - PROVIDE IMPROVED DATA MANAGEMENT FINE TUNE NEW AUTOMATED ADDITIVE ADDITION SYSTEM CONTINUE TO OPTIMIZE RAW MATERIAL & FINISHED PRODUCT INVENTORIES DTH 000099965 0V0))i JZ 0) i/> uLO J5* Q) JD O -w JCZO 3o >> (T3 2 JVQ0Ds)-) (0 (0 ><1/05. U 20) JZ -4-- VV0i CO ns-*--I JZ a H*## "Oco c00)) JD fO 5(0 DTH 000099966 DTH 000099967 MAINTENANCE IMPROVEMENT DTH 000099968 1983 MAJOR POINTS TRAINING I&E MECHANICAL OPERATIONS SUPERVISORY SKILLS CRAFT DELAY STUDY WORK ORDER PLANNING PREVENTIVE MAINTENANCE DTH 000099969 TRAINING I&E <'>2200 MANHOURS OF IN PLANT TRAINING MED INSTRUMENT TRAILER MECHANICAL PONCA CITY COURSES - SIX SUPERVISORS - SIX MECHANICS ALIGNMENT VENDOR - BOSTON GEAR BOX - RELIEF VALVES - RUPTURE DISCS OPERATIONS DTH 000099970 MED INSTRUMENT TRAILER SUPERVISORY SKILLS SUPERVISORS PLAN WORK ORDERS USEFUL WORK CONOCO AVERAGE-2.4 HOURS/DAY ABERDEEN BEFORE- 2.5 HOURS/DAY ABERDEEN AFTER- 3.1 HOURS/DAY DTH 000099971 PREVENTIVE MAINTENANCE AUTOMOTIVE FIRE PUMPS DTH 000099972 1984 PROGRAM SYSTEM RELIABILITY I&E MECHANICAL CRAFT PRODUCTIVITY DTH 000099973 SYSTEM RELIABILITY I&E CONTINUED TRAINING INTERLOCK/ALARM PM PROGRAM MINOR INSTRUMENT REPAIR LOGREPETITIVE REPAIRS MECHANICAL IDENTIFY TARGET EQUIPMENT - OPERATIONS - MAINTENANCE - ENGINEERING DEVELOP PH-1 PROGRAM TARGETED TRAINING MAINTENANCE ENGINEERING r DTH 000099974 CRAFT PRODUCTIVITY SUPERVISORY TRAINING TPG COURSE 100 HOURS PER/SUPERVISOR NUTS AND BOLTS "HOW TO' - PLANNING - SCHEDULING - WORKLOAD CREW MIX CROSS TRAINING CHANGING HISTORIC ROLES MIXING CREWS MAINTAINING THE BACKLOG OTH 000099975 THE EASIEST ORGANIZATION TO CHANGE IS SOMEBODY ELSE'S r DTH 000099976