Document ZnEQz04Qo3Gd2gE01v6prj0EY

o,r,ccMU4 <WM) INTER. CONFIDENTIAL memo TENNECO CHEMICALS, INC. TO M, W. Williams at Piscataway Prom H. B. Carr at Flemington Subject QUALITY ASSURANCE AND TESTING SERVICES MONTHLY REPORT - JULY, 1971 Date August j5 , 1971 Copy to W. E, Beckman W. C. Champion E. Farber J. C. Fisher P. Gawason H. R. Horton E. J. Hourihan C. W. Johnston F. W. Kanzler I. 0. Kenen R. Roe M. C. Spalding W. D. Wesely File ----- RESIN PLANTS Raw Materials 1. Dow Methocel A meeting was held in Piscataway on 7/22/71 with Dow repre sentatives to review Methocel specifications with particular attention to the presence of discreet metallic particles. Our complaint at Columbia Records was reviewed and Dow was presented with the claim. An answer on corrective measures that Dow will institute as well as the Columbia claim is expected during August. 2. Shell VCM A meeting was held in Piscataway on 7/22/71 with Mr. Chick Scoggin of Shell and M. W. Williams, G. I. Rozand and C. W. Johnston of Tenneco. Nitrogen specifications were stressed and our requirement for a thousand ppm max. was reviewed with Mr. Scoggin. Mr. Scoggin assured us that Shell will make every effort to comply with this spec requirement. Arrangements also were made to receive Shell tank cars (26 M gallons) in Burlington the latter part of August for which process performance and testing correlation will be established. In-Process Testing Latex Bactericide Study During the plant shutdown, iodophors were successfully used to prevent souring in stored latex. An apparent detrimental effect on clarity will be further assessed, however, the use of Iodophors will prove significant should we have to store latex in the future for any reason. COLORITE 014353 M, W. Williams 2- - August 3, 1971 Finished Rosin 1. Control Chart Review - Flemington On 7/13/71? a control chart review was conducted with P.E. and Flemington production management. The plant in general exhibited good control with particle size being the main area requring attention at this time. Arrangements were made through Purchasing to have outside VCM shipments arrive in blocks since an apparent relationship exists between particle size control and VCM quality level. Block ship ments will provide a better basis for study and for correc tion. 2. Improved Metallic Test Based on the Columbia 150 resin complaint and the metallic particles discovered in Methocel, a significantly improved Q.C. Syntron test utilizing a ca. 5,000 gauss magnet" was established. General 1. Primex Support J. C. Hahn visited Burlington during the period with a sample of Mexican monomer. Light and heavy end G.C. analyses were performed on the sample such that it may serve as a control for Prominsa's new gas chromatograph. Additionally, a sample of Burlington recovered copolymer monomer was analyzed and this will serve as a control for Prominsa for this G.C. analysis. 2. Mercury Analyses A program established to define our control of mercury emission in plant effluent streams has been continuing over the past several months. A report will issue during August summarizing data obtained thus far with the main conclusion being that we are in good shape - iess than 1 ppb in both Flemington and Burlington. COMPOUND PLANT 1. Color Standards The establishment of Bight and dark limits for Compound Plant standard products was completed 100/ during July. COLORITE 014354 M. W. Williams -3- August 3, 1971 2. Industrial J?lastics Complaint Further analytical confirmation was obtained during July that the "eyes" in 3164, Gray 83 weather stripping compound were caused by fibrous contaminants (June report). These fibers appear now to be introduced at the customer's plant. A&E 1. Training Program for Nixon Q.C. Personnel During the Nixon plant shutdown, all Nixon Q.C. personnel not on vacation came to Flemington for training to upgrade their laboratory skills. The program consisted of brief lectures on theoretical aspects of vinyl technology followed by laboratory work in which the Nixon Q.C. staff worked closely with the A&E group. 2. Analyses of Latices Two latices were analyzed at the request of CSL for resin type and thickening agent. Both were vinyl acrylic latices and the thickener in each case was ammonium salt of straight chain organic acids,' 3- Geon 8830 Natural Compound Two different lots of Geon 8830 Natural and a sample of Blane 2120 Natural were analyzed as part of a program to develop a switchboard wire insulation compound. Of sig nificance was the fact that the two Geon samples had widely different lead levels, 40,000 vs. 1,000 ppm. This differ ence possibly indicates either an incorrect compounding of a lot at Geon or a Geon formulation change. To be sure that this was not an analytical error, the results were confirmed by retesting. 4. July Time Allotment Shown below is A&EJ s July time allotment versus the May and June levels. May, 1971, % June, 1971, % July, 1971," j, CSL P.D. Nixon Q.C. P, R. Safety General Foam 16.3 30.1 45-4* 1.4 0.7 6. i 100.0 27.8 31.5 29.2 7.7 0.7 3.1 100.0 17.9 27.6 38.9 7-3 0.8 4.5 3.4 100.0 COLORITE 014355 M. W. Williams -4 August 3, 1971 NIXON 1. Color Group During July, 9 sample color matches, 2 production color matches and 3 dual strip color matches were completed. Two new pigments were evaluated during .July; a pyrozolone red and a Harmon black. Both pigments were found to be suitable replacements for our current sources and will be added to our list of approved suppliers. 2. Dow Saranex A severe bubble problem occurred recently when a Saranex/ Surlyn structure was mated in line with MCFD-1025 sheet. The problem has been traced analytically to a release agent on the Saranex surface. A meeting was held with Dow on 7/20/71 to discuss the problem and possible solutions. Dow's reply should be received during August. 3. Surlyn Nixon has experienced severe contamination problems with Surlyn film from Consolidated Thermoplastics and Pierson. Since both of these companies purchase their Surlyn pellets from du Pont, du Pont's process is the apparent cause of the contamination. A meeting was held with representatives from Consolidated and du Pont on 7/9/71 to define the problem and to explore possible solutions. Du Pont has agreed as a control measure to make film from its pellets and look for contamination rather than doing so in the pellet stage. All agreed that a contamination specification for the Surlyn film is required and this will be established as soon as sufficient data is available. 4. Personnel --------------------------------------------- - j During July, Mr. Fred Hitchcock and Mr. Ken Langbauer joined the Nixon Q.C. group as line technicians. Mr. M. C. Spalding attended a management seminar sponsored by Leadership Development Associates from July 11-17, 1971- COLORXTE 014356 M. W. Williams -5 August 3, 1971 5 July Time Allotment Shown below is Nixon Q.C.'s July time allotment versus the May and June levels. May, 1971, % Q.C. Plant Eng. Prod. Eng. Proc. Eng. Prod. Dev. Tech/Serv. & Marketing 86.0 2..0 5-1 2.3 1.6 3.0 100.0 June, 1971, % 85.6 4.2 5-9 1.2 1.9 1.2 100.0 July, 1971 60.5 3.9 8.9 11.2 8.5 7-0 100.0 HBC:em H. B. Carr COLORXTE 014357