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T. H. Huffman From: Date: Subject: D. C. Skokna March 23, 1992 1992 VIS1A There was one OSHA recordable (HTO) injury reported during February. A mechanic suffered a laceration on his forehead when he was struck by a bearing race* At month end, the plant's employees have worked 4,622 days (6,184,610 employee hours) since the last lost time Injury. FVC Production, 101 Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M Feb. 36.7 89.6 96.2 1.0393 4.4 94.4 1.5 96.4 1.5 78.8 14.8> 120.1 51.2 XJLJL. 169.4 80.8 96.7 1.0345 25.4 96.3 9.9 97.1 7.4 77.7 < 17.4> < 185.1> < 448.5> Resin production was good during the month. Orders continue at a good rate in flexible compound causing the Line I and Line 111 schedules to be tight most of the month. Dry blend ran at low rates. The new dry blend sample line began operation. Costs Variable costs were near budget. Fixed costs were favorable due to no holiday and overtime lower than normal. VAB.0001189354 T. H. Huffman 03/23/92 Aberdeen Monthly Progress Report - February, 1992 Page 2 Sunbeam, a flexible compound customer, visited the plant for a tour and familiarization. Nibco, a resin customer, presented our employees the Nibco Certified Supplier Award. One NPDRS permit violation for high pH occurred when boiler blowdown overflowed to a storm sewer causing the pH at storm water outfall 003 to rise to 10.8 which exceeds the permit maximum of 9.0. D. C. Skokna Plant Superintendent rah VAB.0001189355 DISTRIBUTION COVER LETTER Houston J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblln C. R. Miller Aattfa! R L Poe H. J. Hall X H. D. Garrison LCVCM Plant P. D. Carrico LCCP Plant J. Friend LCLAB Plant J. V. Ware X Baltimore L. R. Bauer X Hammond J. Pavao X Premiere P. L. Foote Aberdeen RWS/DCS (File Copy), JBA, JEB, JME, SCH, DAB, DAM , JEN, JDO, BLT ENTIRE REPORT X X X X X X X X X X X X A VAB.0001189356 RAVKTY - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 0 jit 1 0 0 Fiscal 4 1 7 2 0 Fiscal Y.T.D. 1991 3 0 Vinyl Operations Compound Operations Maintenance Laboratory Rece iving/Warehouse Office Totals 001 033 147 000 000 & 1 Cuts and Abrasions Eye Injuries Burns Bruises S trains/Sprains Stings Other Totals 133 000 012 002 133 000 02 1 12 Lost Workday Cases Days Lost 1 4 First Aid Cases Medical Treatment Cases Lost Workday Cases 032 001 001 Safety Record Last lost time injury - 7/5/79 Days since - 4,622 Employee hours since - 6,184,610 On February 29, 1992, the employees of the Aberdeen plant completed 4,622 days with no lost time injury. 'IBS ih: i. VAB.0001189357 4 SAFETY - Continued The topic for plant safety meeting during the month was "Respirator Training". Routine dosimetry results for the month were: Chemical VGM Lead Total Particulates _________________________ Number 72 9 4 97.3 81.8 100.0 > PEL Number Percent 2 2.7 2 18.2 00 Maintenance Contusion and laceration of forehead. A VAB.0001189358 T. J. Arbtlter * All plant natural teams continue to work on proj ects and team A measures;. Some highlights for the month of February are: The Plant Manager's Natural Team established action steps to increase the use of SPC in vinyl and com pound production. m The Compound Operations Superintendent's Natural Team continued work on their project to reduce the amount of off-grade produced. A weekly quality meeting with Q.C. personnel has been established. The Compound Operations Supervisor's Natural Team is writing charge procedures. Fifteen procedures have been written to date. Compound D-Shift Natural Team is working to upgrade the central vacuum system. ; The Mechanical Department Natural Team is updating the weekend duty manual. m The Maintenance I&E Natural Team is preparing a presentation to management on their project to improve the lighting in V-ll dryer building. The Synergy Team is preparing their presentati* management on barriers to QMP and natural team ticipation. Sunbeam Home Comfort visited the Aberdeen Plant on February 11. The primary purpose of the visit was to give Sunbeam and Vista attendees a better tinderstanding of each other's companies, as well as afford the opportunity to discuss specific operational and business issues. Sunbeam purchases various flexible compounds for use in personal home products. Nibco, Inc. visited the Aberdeen Plant on February 20 to present the Nibco Certified Supplier Award to the Aberdeen employees. Nibco purchases various molecular weight resins for use in the manufacture of PVC fittings and valves. J Mk Jading _i -- i- VAB.0001189359 nmsr VABTAWCRS - D. C Variable Costs PVC Flexible Compound Rigid Compound Plasticizer Total <$ 12.7> 59.3 < 4.3> $.9, $ 51.2 <$569.3> < 81.6> < 35.2> <$670.2> <$582.0> < 22.3> < 39.5> 24.8 <$619.0> Efficiencies overall were near budget. Raw material use was below budget. Efficiencies were near budget. Plasticizer Efficiencies were near budget. Mates Erls* Variance - 8M VCM Resin to Flexible Compound Resin to Rigid Compound Plasticizers Off-Grade Resin Credit Pthallic Anhydride Natural Gas Other Total <$649.5> < 42.3> < 18.5> < 14.2> 21.2 26.3 36.4 < 29.6> <$670.2> Fixed Cost Variances Variance - $M Payroll and Benefits MM&C Miscellaneous TI&D Total $ 73.2 31.8 29.6 < 15.1> 0.6 $120.1 VAB.0001189360 Continued Overtime was low and there were no holidays during the month. MM&C Activity was below budgeted level. Variance - SK Outside Professional Service Unclassified Operating Supplies Rentals - Other Shipping Cost <$20.3> <$24.8> <$13.7> <$12.1> <$li.2> TI&D FIGA was $10M unfavorable. VAB.0001189361 lJ '! mm A VIHYL - J. D. Olson * D. K. Knittig Safety The Vinyl Department had no first aid case or OSHA recordable injuries during February. The nonthly safety meeting was "Respirator Training". 1. D-742's agitator shaft broke during the poly mode. Shift personnel did an excellent job of controlling the reaction. The shaft was replaced. The broken shaft was sent off for stress and corrosion analysis. 2. Seventy* five hours of operational downtime were due to "no place to dump". Fluid bed maintenance and product changes caused this downtime. 3. Software enhancements were installed in early Harch to elimi nate controller card failures that occurred in February. Changes to the software have reduced the peak and average load on the controller cards thus improving performance. Feb. Production, MM lbs. Dally Rate, M Ibs./C.D. Capacity Utilization Factor, % Total Reactor Charges Charges/C.D. Reactor Stream Factor, % Rotary Dryer Stream Factor (#4-#8), Fluid Bed Dryer Stream Factor, % Resin Quality, % Prime % 36.7 1263.9 95.4 865.0 29.8 89.6 94.2 95.1 96.2 Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts, and no blend tank space). Maintenance downtime (D-700 gearbox replacement, D-744 condenser cleaning, D-741 condenser cleaning, D-500 seal replacement, D-742 agitator shaft replacement, D-700 seal oil unit, D-700 rinse nozzle, D-745 rinse nozzle, D-741 steam stripping valve, FM D-744 gearbox, D-600 steam to jacket valve, D-741 temperature controller, and D-742 steam stripping valve). TTD 169.4 1113.9 84.1 4099.0 27.0 80.8 88.5 85.1 96.7 Hours 447.0 274.0 * VAB.0001189362 Continued % of Total Downtime Operational downtime (centrifuge plugs, dryer cleaning, flameouts) . 38.1 Maintenance downtime (activator problems, centrifuge repair). 27.1 Reactor limited production. 34.8 - J. B. Autrey/S. A. Truitt Reactor 500 seal failed after the seal oil pump failed. It was replaced and the seal was rebuilt for a spare. Reactor 700 gearbox and motor base were modified for a new style fluid coupling. While the reactor was down, the gearbox was rebuilt and the motor was sent out for preventive maintenance. Reactors 744 and 741 were isolated for condenser hydroblasting in an effort to improve quality control. * "A" vacuum pump and "B" compressor in the Old Unit were taken out of service and repaired. The west fan gearbox on cooling tower 4B developed an oil leak which is suspected to be due to high vibration. The tower was shut down for the gearbox oil seal to be replaced. Two control valves and one manual valve were changed out of service in the Vinyl unit. J - S. C. Hill--n. I. H. 8--ad A The Compound Department had no OSHA recordable injuries in February. General 4 Orders are tight on Line I and Line III. Close monitoring of dry blend product quality continues to cause higher than nor--1 downtime and slower than nor--1 rates. Sample production began on the new dry blend sample line this month. Operating Month. Awtt./BtT Line I 29 Line III 29 Line V 9 Total % Prime Capacity Utilization Factor 1418 2757 253 4428 94.38 56.02 49 95 28 153 Downtime Hours 7676 16025 1735 25436 96.34 64.84 - Product Changes > One Dicer Offline - Miscellaneous Maintenance - Quality 98 89 56 15 - Product Changes - One Dicer Offline - Miscellaneous Maintenance - Quality Line V - Product Changes - Quality 73 22 28 31 24 10 VAB.0001189364 CQMTOTOD - Continued Operating Month Rigid Compound 24 % Prime Capacity Utilization Factor 1478 96.40 28.53 62 9940 97.05 37.31 Hours - Product Changes One tfelex (Half Rates) - Miscellaneous Maintenance - Quality - Waiting on Raw Materials 93 60 25 48 7 Operating Month Plasticizer 27 1503 Prime 78.83 Capacity Utilization Factor 60.14 56 7427 77.72 58.54 J. B. Autrey, S. A. Truitt The north nitrogen blower in the P-1 building was replaced. The blower was leaking by the flights. A leak in R-l reactor coil was patched. The agitator seal on R-l had to be replaced after the blades were sheared off the agitator. The resulting imbalance ruined the seal. The Schenk filter was broken down and re-assembled for cleaning. The spare lab mill was rebuilt for a spare. The MAM blender gearbox was pulled out of service to aid in troubleshooting. As it turned out, the motor was all that needed repair. The Line 1 Banbury gate switch was relocated to enhance tempera ture sensing. Compound quality teams requested the RPM Indicator on Line III FGM be replaced and Line III speed indicators be calibrated. These items were completed. VAB.0001189365 f COMPOUND - CONTINUED - Continued Bolien controls were relocated to the new control room The lagoon acid tanks were decommissioned for removal. The west biodisc pump was rebuilt. The #5 pond aerator gearbox and motor were rebuilt repairs were required on the flotation structure. Major A VAB.0001189366 KBCTWKKITWG - J. K. Hlckerson, M. R. Kane, M. L. Garter 4 t The semi-bulk lead system was tested using supersacks of lead after the initial successful test using Atomite (a filler). The test was stopped before the supersack was emptied because the scale controller microprocessor was operating erratically. A low quality power source was found to be the cause. The controller has subsequently been connected to the UPS system which feeds the dry blend silos. This power source is of much higher quality and reliability. The test will be completed when the production schedule allows. Baseline drying capacity of the rotary dryers is being determined by doing a series of tests. It seems that there are two issues currently. One is the air supply to the activators causing send times to be long (on some dryers), and the other is the ability to maintain stable feed to the dryer inlet. The study to measure plant steam usage has begun. Construction is progressing well with a startup date targeted for mid-May. The operating manual has been written and will be Issued for review In late March with training still scheduled for April. One startup Issue to be resolved is where the startup water will be routed. The most likely location, with preliminary approval by the State DEQt is the stormwater outfall. Work is continuing to identify the startup plan as the startup phase will most likely be longer than a month. Sampling and modeling of the wastewater system continues. R&D has spent a week at the plant helping Identify and quantify the capabil ities and shortfalls of the system. A theory which is being proposed at this point is that ponds 5 and 6 add some BOD to the stream, although they do take out more than they add. The BOD contribution comes from the biological species (algae and plankton) in the last two ponds. Staffing Current engineer staffing level is 8. One offer is still out standing. Steve Carroll, an experienced hire, will begin in late March. Debbie Johnson will transfer to LCVCM in mid-March. Plasticiser Expansion Work is continuing on the Plasticizer Expansion Project. Scope of the project is to add a steam stripping column to increase capacity. Stripping alcohol outside the reactor reduces reactor cycle time. Column design is being optimized using computer simulations. VAB.0001189367 M.L. CARTER FEBRUARY REPORT Month 2nd Qtr. YTD ACTUAL 410.3 716.3 1935.3 BUDGET 488.0 1190.0 2571.0 VARIANCE MS - 77.7 % -15.9% - 473.7 -39.8% - 635.7 -24.7% - Expenditures in February were $77.7M less than the plant's budgeted expenditure forecast approved in the Second Quarter Budget submitted in November FY92. Rainy weather and equipment delays on the Hater Plant Project accounted for 95% of the underrun. - Current Quarter Expe and approved for the current quarter as submitted budgets. Total of current and previous quarter approved - The current approved quarter calls for 2nd quarter expenditures of $1190.0M. VAB.0001189368 OaC/>f (A 0CM 1 ca ui A APPROVED CAPITAL PROJECT STATU tu ini S? 8 tmu o oUI 8S III ooo ft! <A UooI oo u ui Uoi mm Ui 'O in o in VA.0001189369 ) 1 ft A APPROVED CAPITAL PROJECT STATUS ui dS ac g UJ u a UI oc oc UI oc uj oc u- o at uj g 5 o Ui o o CM CM OI in fO in VXB.0001f89370 <> 1 (O CO oo o U11J1 833 3 S APPROVED CAPITAL PROJECT STATUS Ui u lil CO CO uUJ o MMMNM H 8 8: N8M H H <5 8 C--O NH HHHHtKNl 8 8 N 8 H H UMIMNUHI It IlMIi N VAB.0001189371 iPITAL PROJECT STATUS 4 *A $ s O o u. s8 2 i up m A VAB.0001189372 * K. G. AMw Wmtmr There was one NPDES permit violation during the month of February. We exceeded the permit limitation for pH on February 19th for stormwater outfall 003 due to a wastewater bypass. Boiler blowdown overflowed to a storm sewer raising the pH to 10.8. Our permitted maximum dH is 9. The annual NPDES Inspection was conducted by the MDEQ on February 18th-19th. During the audit, the MDEQ informed us that our two existing permitted stormwater outfalls were sufficient and that no further work on stormwater .testing/permitting was necessary. The MDEQ indicated the majority of pollutants that they would reasonably expect to find should be contained in our two existing outfalls. The MDEQ said we should identify other stormwater outfalls during our next permit renewal in 1996 and they would decide then if additional permitting is required. We held a meeting with the Aberdeen-South Monroe County Chamber of Commerce, City of Aberdeen, and Monroe County officials on February 10th to discuss the results of the Superfund site sampling. We also discussed the upcoming drum removal and remediation project to be conducted by ENSR. This is scheduled to begin by early March. The .third topic of discussion was the removal and recycling of resin from pond 2 also scheduled to begin in early March. yte Waste shipments during the month Included: A bulk shipment of empty lead/antimony bags to Chemical Waste Management in Emelle, AL. A bulk shipment of API sludge to Chemical Waste Management in Emelle, AL. VAB.0001189373 * > mmtGY COHSEEVATIQB - J. R. Game Fiscal Y.T.D. A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU < 17.6%> < 14.8%> 3054.0 128.5 < 19.8%> < 17.4%> 3063.0 657.3 A No. 1 No. 2 No. 3 83.9% 83.5% 83.7% 83.2% 83.1% 82.7% Conversion of ell three boilers to the new control systems was completed during February. mmmmmm mm mmm T VAB.0001189374 mm p inrPT.nvioniT None. mPM aw nanmmR PBUrtPi1 FEBRUARY. 1992 E. Beall Daniel E. Johnson - Lead Project Engineer transferred and promoted to Senior Project Engineer at the Lake Charles Chemical Plant. > *i*' >" * David S. Cox - Manufacturing Chemist transferred to Research Chemist at R6D, Austin. Michael R. Kane - Operations Engineer, Compound transferred to Senior Process Engineer. Rory H. Sneed - Process Engineer transferred to Operations Engineer, Compound replacing Mike Kane. *. Linda A. Michels - Production Scheduler promoted to Customer Service Representative (new position). * Jeffery Shields - Vinyl Lead Operator promoted to Vinyl Chief Operator. None. None. None. OF ABBBECB VAB.0001189375 A REPORT Salaried Hourly Temporary SUB TOTAL LaO< A* TOTAL 76 161 2 239 1 240 DEPARTMENTS WAREHOUSE EMPLOYEES 15 K 9 r+ 0 GENERAL PLANT 11 50 MAINTENANCE * LABORATORY 36 8 0 24 5 2 COMPOUND 38 23' 1 VINYL 32 10 1 PLASTICIZER 5 z0 SUB TOTAL 161 62 4 SALARIED 76 7 18 NEW HIRES Salaried/Transfer Hourly Temporary TOTAL HO 0 0 0 0 EX 0 0 0 0 %M %F 60% 45% 22.2% 20.8% 60.5% 31.2% 40% 38.5% 9.2% 0 0 0 8.3% 2.6% 3.1% 0 2.5% 23.7% DEPARTMENT TURNOVER MO. FYD 00 00 02 00 00 00 00 ANN.% 0 0 13.3% 0 0 0 0 Month FYD Minority Female UsLl 0 0 0 0 1 0 0 0 0 WM1.I Hourly Month FYD Salaried Month FYD No 1 00 2 3.0% 00 1 3.2% VAB.0001189376 4 / 0 0 *0 0 0 *0 Ul I o 3 * *9# a. o 9 u fi Is 8 1 [ hrr '' m: ' * i * 1 b 8 8 8 ' * 0 .0 0 1 2 .0 0 1 8-1 * O I 3 s u CA U<Al Ul s8- i til 3 2 8 S 3 U3SCl (A Ul g Ul #* r.""j SO JDt II An tNa 8 8I 8 u 5 H >S * VAB.OOOl189377 VAB.OOOl189378 /Printed 3/04 92 8 8 - * i 'O i8 o* DEPARTMENTAL SUMMARY HOURS REPORT ........... MONTHLY ............. A iry Duty 0 .0 0 * 4 0 .0 0 0 .0 0 0 0 *0 0 0 *0 0 0 *0 0 0 *0 0 0 *0 B J o (4 IJI C _^ *11hi ;?S L O fl at T otal Aba X o f S/T 0 .0 0 B 4 0 .0 0 2 .2 9 4 - D. A. Barclay There were no reportable safety Instances this month. All teams met during February to review progress on their projects. FT92 Processed Invoices Working Fund Checks Written Cost Savings Through Md Process Raw Material Purchase Orders Issued MRO/AFE Purchase Orders Issued Spare Parts Purchase Orders Issued 1222 10 $2132.37 90 198 190 5638 88 $17885.59 451 977 940 (Decrease) Compound "A* Grade PLENSX Compound Off-Grade (BC) Compound Off-Grade (H) Mi Userap Dry Blend "A" Grade Dry Blend Offgrade Resin Type I Resin Type "BC" Vacuum Dust Total Packaged W/house 4,509,544 141,628 285,721 261,448 184,310 643,221 564,966 1,055,035 100 7,727,498 4,291,913 129,476 420,012 159,135 210,612 709,511 269,678 1,131,050 13P 7,433,572 <217,631> < 21,152> 134,291 <102,313> 26,302 66,290 <295,288> 76,015 0 <293,926> < 4.83> < 8.58> 47.00 < 39.13> 14.27 10.31 < 52.27> 7.20 0 37.49 < 3.80> b Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade Total Jew. 1,667,658 0 2,661,679 959,860 13,531,633 1^17. asp 20,638,680 Feb. *92 1,438,084 0 2,431,602* 790,510 12,685,666 1.982.750 19,328,612 (Decrease) < 229,574> 0 < 230,077> < 169,350> < 845,967> 164.900 <1,310,068> % <13.77> 0.00 < 8.64> <17.64> < 6.25> 9.07 < 6.35> Includes deferred sales (consignment) of 517,350. VAB.0001189379 f 4 A m m PI PYI OFF-GRADE FFR '91 THRU FFR *92 mm 1600 1400 T*1 1200 1000 800 600 400 200 0 02/81 04/91 06/91 06/91 10/91 12/91 02/92 03/91 OS/91 07/91 09/91 11/91 01/92 PKG'D PRODUCTS INVENTORY VAB.0001189380 ABERDEEN CHEMICAL PLANT SNIPPING ANALYSIS FEBRUARY 1992 -SHIPMENTS BY PRODUCTS- PU8LIC MONTH IPT/ITC EXCH/TOLL PUBLIC YTD IPT/ITC 04:13 PM 13-Mr-92 EXCH/TOLL RESIN-BULK RESIN-PACKAGED 19,583,950 19,175,210 397,600 219,250 0 0 90,865,360 . 77,757,890 2,219,706 1,049,500 0 0 FLEXIBLE COMPOUND-BULK 174,420 FLEXIBLE COMPOUND-PACKAGED 3,059,905 1,608,250 17,164 0 0 875,600 13,981,421 9,965,600 189,175 0 0 NEW BUSINESS 40,204 00 78,716 00 RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED RIGID COMPOUND-PELLETS 732,500 210,083 0 665,650 169,350 0 0 0 0 3,628,910 2,052,888 0 3,625,350 175,850 0 0 0 TOLLING - BULK TOLLING - PACKAGED PLASTICIZER 00 00 0 807,290 0 0 0 0 0 81,300 0 0 2,625,040 0 0 917,400 TOTAL 24,198,662 22,662,164 0 113,783,901 95,388,405 917,400 -SHIPMENTS BY MODE BULK: *FEBRUARY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER RAILCAR 171 9 6 4 CUSTOMER PICKUP COMMON CARRIER 17 27 0 7 1 12 02 TOTAL 215 16 19 6 TOTAL FEBRUARY *YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 190 18 48 ft 750 69 200 58 0 28 31 3 54 17 0 11 256 1,019 86 88 28 TOTAL YTD 856 72 293 1.221 PACKAGED: FEBRUARY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER CUSTOMS! PICKUP 1 23 0 0 COMMON CARRIER 22 75 12 0 TQFC AIR/UPS 00 00 00 00 AIR/UPS 1 2 0 0 TOTAL 24 100 12 0 TOTAL FEBRUARY 24 109 0 0 3 136 *YTO* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 13 97 0 0 111 376 0 0 9 58 0 0 0 000 1 8 1 0 111 495 68 0 TOTAL YTD 133 531 BRI888tmm8SBBIlGtmi II N II II N II H 00 10 8SS8BBKat ftmessessessesss: I snuuua 674 CC: DA8,TLC,AEV,JRF VAB.0001189381 AV Sea m fn mSm mm mem nMn g $ & (A K wmmmmmmmmmm 2| U. Ifc (A CA % NN MMIMiHpil VAB.0001189382 J. M. Edvards Safety There were no safety Incidents In the Laboratory during February. There were four customer contacts in February. Sunbeam Home Comfort representatives visited the plant to tour and learn about our testing and processes. Representatives from Nlbco visited the plant to give us a quality supplier award and tour our facilities. Jim Edwards and Eric Stouder visited Huls in New Jersey to introduce our resin product line and answer any technical questions about our resin. Jim Edwards and Eric Stouder also visited American Mirrex to update them on quality improvement issues and obtain feed back on Vista resin performance. The customer complained that boxes of different products in a truck were randomly loaded rather than grouped by product. 2/10 The customer complained that ceramic beads were plugging their screen paks. Austin Analytical discovered that the beads were Zirconium which was traced to a grinding operation in one of their other raw material suppliers. 2/12 Twltchell. Dothan. AL Due to a lab error, a car of 5395 was shipped without a second check on a compartment that was suspected to be high in moisture. Twltchell reported that the compartment in question analyzed to be dry and free flowing. LABORATORY - Continued Continued 02/14 The customer complained that a railcar of 442 delivered in September will not unload. Vycom said there was a hard crust on top of each compartment. 02/18 The customer complained that 57121 Water Clear Lot 11P11 ran rough. Good and bad samples were sent to analytical in Austin to find out the difference between the two. 02/11 The customer complained of brown paper contamination plugging screen paks using 38931 compound. Opera tions is investigating. 02/21 Merlon. VA The customer complained of a high level of fines In two railcars of 5305. Further investigation shows a difference between Vista's and Harley's sieves. Marley has ordered a new set of lab sieves. More samples will be swapped for analysis. ffMHWPig Formtech Product RP-91 WHT 110 Color 92^ 2 H/T E. RVCM of In-Process Samples The following is a summary of residual VCM results on in- process samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of February, 1992. Reactor Number of Samples Average RVCM, ppm Drier 5265 5305 46 0.255 27 0.165 F The following is a summary of the residual VGH analysis of shipment samples for the month of February, 1992. 5225 5265 5305 5325 5385 5395 5415 5416 5465 Debox Pond Dry Blend 4 75 43 0 38 13 70 0 0 26 0 4 0.169 0.083 0.045 0.077 0.142 0.066 0.141 0.034 5225 5265 5305 5385 5395 5415 Bulk Density Inherent Viscosity (vs. 0.64 - 0.67) (vs. 0.715 - 0.744) "L" Color "a" Color "b" Color % on Pan (vs. 2% max.) % thru 140 Hard Particles, Average 5 Minutes 7 Minutes Mets I.R. (vs. 95% of Control) Average Particle Size, Microns 2.53 0.11 --- 2.19 3.00 2.33 2.67 3.71 0.95 0.88 0.19 -------------- 3.89 3.67 6.00 2.60 2.79 0.95 1.33 ---- 1.27 3.08 4.17 3.17 1.54 2.20 0.89 0.41 ------- 2.13 ---- 1.67 1.86 2.07 1.36 0.37 ---* ---- 2.20 ---- 2.00 1.17 1.97 1.04 0.6 -------------- ---- 3.17 --- 3.00 2.00 0.33 4.22 ----- -- -- -- 22.00--------------- 7.00 ---- ---* 6.00 2.00 1.91 6.00 1.00 4.80 2.30 162 148 148 172 165 177 i VAB.0001189385 Continued Hardness Color Hard Particles Ha*t Stability Dispersion Dicing Cross Contamination Streamers Mischarge METS I.R. Tensile Strength Totals AdjjftSfiM&lcjft M Lbs. 40.0 <0.83> 15.0 <0.31> 55.0 <1.14> Rejections M lii. (%3 ----- 57.5 20.6 18.4 13.3 7.6 6.1 4.1 180.8 14.5 8.0 330.92 ----- <1.19> <0.43> <0.38> <0.27> <0.16> <0.13> <0.08> <3.73> <0.30> <0.17> <6.84> There were no rejections for this month. VAB.0001189386 SAMPLE SHPMENTS FEBRUARY 199B iRESfrl 02/04/92 02107/92. 02/12/92 02/12/92 02/13/92 02/24/92 5465 5415 5305 5415 5415 5 lbs 3X1 lb. Z5 lbs. 2.5 Ibe. 2.5 lbs. 200 Ibe 10 Ibe. SamaN Mode UPS Holm Industries Airborne MULANOVICH REPRESENTACIONE Airborne QALJJN TRADNG WC American Thermopiaetio Ext Ryko Ptaetice Airborne UPS AIR Airborne COMPOUND Date 02/03/92 Product 46562 BLK 02/2\/92 02/21/92 6085 BLK 462-121B1 BLK 462-34B1 BLK Amount 100 Ibe. 50 lbs. 100 lbs 100 lbs Customer Automotive Plastics & Tubing Co Vista - RAD Austin Premier Polymers Mode UPS UPS UPS DRYBLEND 02/14(92 02/26/92 Product RP442WHT110 480-167 WHT140 Amount 1500 foe. 056 lbs. Customer Vista - RAD Austin Dayton Extruded Plastics Ship Mode CC CC VAB.0001189387 NUMBER OF INJURIES A AS0ND88M M J S NJ'89M M J S NJ'90M M J S NJ'91M M J S NJ'92 TOTAL INJURIES -**- OSHA RECORDABLE I VAB.0001189388 MONTH -------- 12 MONTH AVERAGE ABERDEEN ENERGY CONSUMPTION BTU/LB CM CXI < L cn (7> < O cn O CTi < cn 00 cn oo < oo oo oo oo < r*oo oo < o o rO rO o o CM rO O O 1*0 o o o rO O O cn CM O O 00 CM O O r*' CM o o to CM O O lO CM O o CM O O rO CM O o CM CM MONTHLY a~i/ns VAB.0001189389