Document aJQagp35yezB6Qo8J6yLn5rnY

TINMCOJ POLYMERS, INC. ICON^ANY, INTEROFFICE COMMUNICATi TO: Pasadena FOR. F. Koslosky FROM. D. Hersh Rt. MONTHLY HIGHLIGHT REPORT FLEMINGT0N PLANT - SEPTEMBER 198$ DATE: October 2, 1985 I. SAFETY A. STATISTICS Month Y-T-D Goa 1 Total Year Y-T-D Incidence Rate 1ncidence Rate Goal Total Year First Aid 0 0 6 Minor 22 1 Restricted Duty 0 0 1 Lost Time 0 0 0 Total Record. 2 2 2 0 3.6 0 0 3.6 Incidence goals are based upon 1^5,000 exposure hours. Total exposure hours for September is 13,3200. Total exposure hours year-to-date is 110,37^* Last lost time injury occurred on October 2, 1982. Total exposure hours since last lost time injury is kk3,k07> 8.3 1 - * 1 .k 0.0 2.8 B. GENERAL 1. The plant sustained two (2) recordable injuries during September. In one instance a mechanic fractured a finger when the pneumatic wrench he was operating slipped thus creating a pinch point. The second incident resulted when a Polymerization Supervisor pulled a leg muscle while rapidly descending a flight of stairs during response to an emergency situation involving a monomer leak. The monomer leak resulted from a gasket^fai1ure in a slurry transfer line. In the emergency situation noted above, the same Polymerization Supervisor may have been exposed to a concentration of VCM exceed ing 100 ppm. The employee was given medical surveillance as per VCM Standard 1910.1017- 2. The safety training subject for the month was a review of fire prevention techniques. 3. .Twenty four (2k) employees were monitored during the month for VCM exposure using the charcoal tube method. None exceeded the permis5able exposure level of 1.0 ppm. k. As of October 2, 1985 the Plant has now worked three years without experiencing a lost time injury. TEN-FLEM 20004 TEN 4406 Monthly Highlight Report Flemington - September 1985 Page 2 I I. STATISTICS A. Product ion Summary B. Product ion Loss Report C. Qua 1it y D. Headcount E. Overtime Attachment 1 Attachment 1 1 Attachment 1 1 Attachment IV Attachment V III. PERSONNEL A. STATISTICS Prod. RD Sept. Y-T-C MedlcaI; Personne1: Pre Reemployment Exams Annual Semi-Annual Exams Accident Treatment 0 5 2 Employment Applications Logged 5 Employment Interviews 0 Insurance Claims 38 Employed Oriented Terminations/Retirement Transfer In Transfer Out Promotions 0 0 0 2 1 00 3 7 12 111 02 3 27 00 0 38 139 18 3^3 00 11 00 02 01 6 15 o; 2 3 B. GENERAL I. Meetings were conducted with all plant personnel on September 12 to announce the cessation of manufacturing operations at the Flemington site effective November 17, 1985. Plans have been imple mented for the transfer of a small number of personnel to other Tenneco locations, and outplacement service has been initiated for the remainder of the plant complement. 2. Initial discussions were conducted with~the ICWU and IU0E on September 19 to review severance benefits. The next discussion session has been scheduled for October 8. 3. Meetings were held with all salaried employees on September 12 and 13 to discuss their severance benefits. P. Cravey and W. Rivers met with several of the salaried employees to provide them with requested information concerning pension and benefits. TEN 4407 Monthly Highlight Report Flemington - September 198$ Page 3 IV. COSTS Conversion cost for September is estimated favorable as compared to budget primarily resulting from: 1. Above budget production volume 2. Cost savings resulting from operations without use of mechani cal refrigeration. V. MAJOR PROJECTS AND ON-GOING PROGRAMS A plan has been initiated to safely shut down, purge, and secure all plant operating areas prior to the November 17 shutdown date. Pro duction operations are scheduled to be curtailed October 31. Purging and securing operations will be completed during the period from Nov ember 1 through November 17. During the month of September, two of the four underground monomer storage tanks were removed from service and are being purged and se cured in preparation for the shutdown. VI. CAPITAL Approved 9/30/85 Committed 9/30/85 Est. Spending 9/30/85 Est. Spending 1985 $M 195 185 185 195 V! I. ENVIRONMENTAL A. RCRA Reclassification The NJDEP has again requested additional information before granting a change in status from TSD to Generator. With the now announced cessa tion of manufacturing operations the regulations must be reviewed to determine small quantity generator requirements. Recognition of the site as a generator only is still of prime importance as it strongly impacts on future closure and reporting requirements. TEN 4408 Monthly Highlight Report Flemington - September 198$ Page 4 B. Discharge to Groundwater PermIt/Discharge to POTW Permit The draft for this permit was received from the NJDEP on September 17. There is a forty five (1*5) day comment period prior to scheduling a public hearing. During this comment period, we will submit our reply detailing certain conditions we believe should be modified. C. ECRA Contact was made with the NJDEP regarding the applicability of the Environmental Cleanup Responsibility Act (ECRA) to the Flemington site. After a study of the ECRA regulations, it is our opinion that it does not apply to the ceasing of resin production at the site. After discussion with NJDEP officials, we submitted a letter detailing our reasoning and submitted it to the Bureau of Site Evaluation for an official determination. D. 1nspections A general stack inspection was conducted by the Bureau of Air Pollu tion Control. All areas were found to be in compliance. E. Genera 1 1. The proposed penalty assessment by the NJDEP for late filing of a TSD report has been rescinded. The NJDEP agreed that a misunderstand ing created the problem. 2. To avoid the potential for problems as a result of recent Leaking Underground Storage Tank (LUST) legislation, we are planning to remove the four underground VCM storage tanks and two other underground tanks before the end of the year. VIII.OPPORTUNITIES 1. The plant was able to produce 5.6 MM lbs. of COP in September using only well water for Reactor Building cooling requirements. 2. Early removal from service of the underground monomer storage tanks will expedite plant purging and securing requirements. IX. VULNERABILITIES Nothing to report. X. INDUSTRY TRENDS Sales demand continues to run below budget. TEN 4409 Monthly Highlight Report Flemington - September 1985 Page 5 XI. GENERAL COMMENTS Notification to the community, press and government officials of the cessation of Flemington manufacturing operations was performed in a most favorable and timely manner. Our corporate Public Affairs, Governmental Affairs and Personnel departments are to be complimented for the professional and able assistance which they provided. DMH:ms $ 77). D. M. Hersh cc: H. R. Bowers G. E. D i s c h D. H. Hunter R. R. Neugold TEN 4410 Attachment I PRODUCTION SUMMARY Past Month Actual Budget Year-To-Date Actual Budget Next Month Est. Production, M Lbs. Variable Cost Est., $/Lb. Fixed Cost Est. , $M Conversion Cost Est., $/Lb. VCM/VAM Yield, % RFT, % Non-Offgrade, Total Overtime, % ^ntrollable Overtime, % Reactor Utilization, % Shipment, M Lbs. Ending Inventory, M Lbs. 5601 .0328 453 .1137 97.5 81.3 100 6.1 5.8 84.8 4979 5225 .0402 483 . 1320 97-5 -99.3 13.0 10.2 --- 40318 .0407 4091 . 1423 97.7 82.9 100 9.8 8.6 66.8 42792 6520 47025 .0402 4347 .1320 97.5 -- 99.3 13.0 10.2 --- 5600 .0329 453 . 1138 97.5 85.O 100 9.0 9.0 67.1 5600 6520 Product Mix, 314 315 318-5 390 391 400 % 26.9 8.9 23.2 30.3 -- 10.7 27.0 30.2 -- 30.2 0.7 11.9 21.0 12.4 36.3 15.8 0.5 14.0 27.0 30.2 -30.2 0.7 11.9 17.9 14.3 -- 32.1 7.1 28.6 TEN 4411 PRODUCTION LOSS SUMMARY Reactor Capacity Product Mix Penalty Reactor Capacity g Actual Mix Actual Monthly Production Reactor Capacity Efficiency Reasons for Losses Reduced Running Mode 8899 795 8104 5601 69-1? 2503 Attachment TEN 4412 September, 1985 Product E Grade M Lbs. QUALITY Off-Grade M Lbs Attachment III RFT Non-Off Grade %% 315 390 400 Total 0.00 527.00 0.00 527.00 0.00 0.00 0.00 0.00 100.00 68.33 100.00 81.34 100.00 100.00 100.00 100.00 1. NOG for September was 100%. 2. RFT for September was 81.3 % * 3. There were two truck load shipments of COP 314 rejected by Kentile, Brooklyn this report period for failing the pencil test. One load was aerated, returned to them at a later date, and accepted. The second rejected load will be treated in the same manner. 4. Seven lots of COP 314 were produced under LOP this report period. Although there was some movement in the +80 mesh range, it is trending back to the coarse side again. 5. Six lots of COP 318-5 were produced this report period. All were within target specifications. TEN 4413 Exempt Non-Exempt Hour ly HEADCOUNT Approved 23 6 44 73 Attachment IV Actua1 21* 6 it3** 70 * Raymond Donovan to Chalmette effective September I, 1985 Mark Druyos resignation effective October 1, 1985 **Resignation of one shift mechanic. TEN 4414 CONTROLLABLE OVERTIME >385 BY CAUSE Attachment V ^^enteeism % of Total Jan. 194 .20.3 Feb. Mar. 96 144 9.2. 18.2 Apr. Mav 7.2 143 J2.3L 21.6 Training X of Total 0 0 00 0 0.0 0.0 0.0 0.0 0.0 Vaca. Cov. % of Total 30&2^ 251 31.4 24.0 192 24.2 108 224 18.5 33*9 June Julv Aug. Sept. 8 112 6.5 28.5 78 10.4 23 5.5 00 0 0 0.0 0.0 .JUL. 0.0 48 132 369 118 39.0 33.6 49.2 28.3 Oct. Nov. Dec. Sixth Day % of Total 168 17.6 160 15.2 232 192 224 29.3 32.9 33.9 48 88 208 184 39-0 22.4 27.7 44.1 t Rest. Duty % of Total 0 0 00 0 00 0 0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Extra Work % of Total 25^ 49p` 123 .26.3 47.4 15.5 163 28.0 42 6.4 12 48 9.8 12.2 67 8.9 56 13.5 Misc. % of total 42 44 .olv 48 28 7 13 29 36 4.4 4.2 12.8 8.2 4.2 5.7 3-3 3-8 8.6 JgffAL I^Pf Bade 956 13-6 1048 14.8 792 8.8 583 661 8.1 7.3 123 393 750 417 2.4 7.1 8.3 5.8' T Base Hours 7040 7080 9000 7200 9000 5160 5560 9000 7200 NOTES (1) Includes 179 hours of maintenance work on Waste Water Stripper and freeze up related problems. (2) Total high due to unavailability of Relief Operator. (3) Total high due to additional mechanical work performed during maintenance shutdown and unanticipated collector bag change on start-up. (4) Includes 64 hours of coverage due to job vacancy. TEN 4415 FLENIHGTOH PLANT SAFETY PERFORMANCE 1985 RESTRICTED DUTY CftSES vs. 1985 GOALS T98<( Actual Cases - Zero 1985 Goal (one case)-------- 9 I9B5 Actual Cases-------------- A JIH.V MffiiiRI tfnrMAFB 'r'rru u^.fnwB r*r>*e NUMBER O f CASES fin v Aimitr r-ff H*inpn - "tn p^-.-.T'-urr -......... .. FIEHINGTOH PLAHT SAFETY PERFORHAHCE 1985 HIHOR CASES vs. 1965 GOALS ' 1984 Actual Cases Zero 1985 Goal (one case)-------- 0 1985 Actual Cases------------A l -r--* FLEHIHGTON PLANT ENVIRONMENTAL PERFO REACTOR OPENING EXCURSIONS - 1985 Goat (Three Cases) --------- 0 1985 Actual Cases --------------------- A HUMBER OF CASES 00