Document by50LEp8n2w368K6nXEVOLobg

ABD00282825 VINYL - J. W. Ware/M. L. Nathan Safety The Vinyl and Yard Departments operated with one first aid injury in January. The injury involved a puncture wound from a piece of wire on a valve handle. Shift safety meeting topics for the month included "First Aid Training" and discussion of recent injuries and near-miss incidents in the Vinyl Department. Production .1 Production, MM Lbs. 2. Daily Production, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days January 37.9 1221.7 873.0 28.2 91.0 12768.0 49.8 31.0 Y.T..D. (Fiscal 1985) 141.4 1149.0 3400.0 27.6 91.1 10623.0 57.7 123.0 Production Vinyl Department productionfor January was a record 37.9MM pounds which was 102% of the Business Area's targeted production level of 37.0MM pounds. The new record of 37.9MM pounds outpaced the previous monthly productionrecord of 37.5MM pounds set in July, 1983. Reactors Major mechanical downtime during the month resulted from the following: 1. Agitator seal replacement on 500, 600, 700, 742 and 743. 2. Cooling water jacket repairs on 742 and 743. 3. Agitator motor replacement on 745. 4. Old module dump Sweco repair. The agitator seal failure on 700 was the direct result of an associated bearing failure. A majority of the remaining failures have been attributed to freeze-up of the seal flush systems during cold weather conditions. Appropriate revisions to improve winterization of the seal flush systems have been accomplished. Valve change-out and repairs accounted for a stream factor penalty of 1.0% during January. Operational downtime occurred as follows: Cause Stream Factor Penalty Recovery system scheduling conflicts No place to dump 3.0% 1.0% A ABD00282826 VINYL - Continued Dryers Production was essentially reactor limited during the month. Downtime in the dryer area occurred as follows: Cause Stream Factor Penalty Energy conservation Dryer cleaning Centrifuge pluggage Activator problems Mechanical problems 44.3% 1.2% 0.6% 1.5% 1.6% Product Quality Summary Resin Type Prime "BC" "H" % of Total Production 5265 5305 5385 5425 5465 Sifter Overflow Pond Resin Total 2,298,229 2,806,864 25,269,342 6,199,069 1,211,080 - - 37,784,584 -- -- -- -- - 73,884 - 12,800 - 86,684 6.1 7.4 66.7 16.4 3.2 0.2 - 100.0 Quality performance for January was 99.8% customer grade with 0.2% "H" grade production. A total of four railcars were shipped as "B" grade during the month which represented 2.6% of the 153 total resin hopper shipped. Ship Date Car No. Customer Product Reason 1/08/85 PTLX 41627 Wexford Resifted Sifter Overflow Quality 1/11/85 PLCX 43850 Wexford Pond Resin Quality 1/11/85 VIPX 45792 Osterman Resifted Sifter Overflow Quality 1/18/85 PLCX 43743 Vulcan Resifted Sifter Overflow Quality The vinyl area received 20 short lead time emergency-type orders comprising 7.1% of the 280 Aberdeen resin shipments in January. A ABD00282827 VINYL - Continued Monthly Variable Cost Performance Variable costs for the month were favorable $787.9M with $794.9M due to price and ($7.0M) due to efficiency. Resin variable cost for the month was 18.802 c/lb. vs. the budgeted 20.887 c/lb. The $794.9M favorable price variance was primarily attributed to lower than budgeted pricing for VCM $717.4M, lower than budgeted pricing for Lupersol 223 initiator $22.0M, and lower than budgeted pricing in the utilities area$30.5M. The ($7.0M) unfavorable efficiency variance can be mainly attributed to an unfavorable variance in VCM efficiency ($64.6M). Actual silo level measurements could not be made during end of month inventory period due to hazardous weather conditions. Estimates were used - which understated resin production and therefore overstated VCM consumption. VCM efficiency for the month was 1.01469 lbs. VCM/lb. PVC vs. the budgeted 1.00500 lbs. VCM/lb. PVC Y.T.D. efficiency was 1.00467. Y.T.D. variable cost efficiency variances in the Vinyl Department totaled $252.1M favorable. Energy Performance/Progress 1. Plant energy consumption was 2575 BTU/lb. 2. A total of seventy-eight steam leaks, two air leaks, and thirty-three steam trap repairs were made during the month. General 1. Packaging for the month totaled 576,884 pounds. 2. Resin raw material in the 744 account totaled $223.4M at month end.