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To: T. H. Huffman Interoffice Communication From: Date: Subject: D. C. Skokna September 20, 1989 ABERDEEN MONTHLY PROGRESS REPORT AUGUST, 1989 There were two August 31, the ^ ing the month. As of 3,710 days (4,905,962 manhours) since the last lost time injury. Kev Statistical Information August Y.T.D. PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM L 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 39.93 91.7 94.8 0.9874 5.20 95.9 3.31 99.9 1.31 87.5 2.6 <93.4> 287.7 415.29 89.5 95.7 1.0049 66.44 96.9 54.97 99.7 17.1 91.7 < 4.1> < 64.7> 1716.6 Costs Fixed costs were unfavorable due to charges associated with the Old Module turnaround taken in July. Variable costs were favorable due to good VCM efficiencies. OMP The 5415 (resin) Decontamination Team investigated sources of contamination through the production A hopper car of 5305 (resin) was produced using BPA as the kill agent (versus Isonox) for a trial run at Klockner. This trial will test the theory that the current kill agent causes the "graininess" problem. Nibco (a 5265/5305 customer) performed a quality audit of the plant. The audit went well with the plant earning a score of 83.4% - the highest by any of Nibco's other raw material suppliers I VAB.0001190370 *r7-. :.i 'SV Iff1 T. H. Huffman 09/20/89 Aberdeen Monthly Progress Report Page 2 - August, 1989 OMP - continued Plant representatives visited AT&T to begin the process of becoming a certified supplier. AT&T (a 34862 compound customer) will perform a quality audit of the plant in October. Sixty-three percent of the plant's natural teams met during Augus t. Environmental The first of five new dryer baghouses was started up in the resin unit. Alabama banned all disposal of hazardous wastes from Mississippi in their state, effective 9/14/89. We plan to ship the plant's hazardous waste to Louisiana. Also, other options are being developed. The plant began recycling aluminum cans from break areas. D. C. Skokna Plant Superintendent rah VAB.0001190371 DISTRIBUTION louston J. D. Burns R. T. Ferrell T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith COVER LETTER X X ENTIRE REPORT X X X X X K. J. Eggers X R. H. Gerlach X R. D. Gamblin X Aus tin S. E. McGuire X R. L. Poe X H. J. Hall X Oklahoma Citv H. G. Garrison X LCVCM Plant R. A. Conrad X LCCP Plant J. Friend X LCIAB Plant J. W. Ware X Baltimore L. R. Bauer X Hammond J. B. Maher X Blane C. R. Miller X Premiere P. L. Foote X Aberdeen RWS/DCS (File Copy), PJK, JEN, MRK, DAM, JEB, HGC, JEL, REP, BLT, RBN, SCH A .I*. 4ii,: .1.. j!p.|, *| r . , i. - H- =t VAB.0001190372 fc. M>fl>prp-'-r ii'*H;...' I.i.h I'lHI' .-i .. .-. H1SH JJJV SAFETY - B. L. Trego, J. V. Uptain First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases August 2 0 2 0 0 Fiscal Y.T.D. 1989 Fiscal Y.T.D. 1988 10 __5 15 30 00 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 0 0 1 0 1 0 2 Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises S trains/Sprains Stings Other Totals 2 0 0 0 0 0 0 2 Non-Occupational Injuries Lost Workday Cases Days Lost 0 0 Safety Record Last lost time injury - 7/5/79 Days since - 3710 Employee hours since - 4,905,962 On August 31, 1989, the employees of the Aberdeen plant completed 3710 days with no lost time injury. Topics for the plant safety meetings during the month included: First Aid Training, Entry, and VCM/Lead/Noise Safety Training. Safety banquets were held to celebrate ten years without a lost time accident. Debs Gamblin and Tom Huffman were present to talk to attendees. DJ. . VAB.0001190373 1 ! HTM. I.-* -- 'Win SAFETY - Continued Routine dosimetry results for the month were: Chemical < PEL Number Percent > PEL Number Percent VCM Lead Total 78 98.7 5 100.0 1 100.0 1 0 0 1.3 0.0 0.0 The single overexposure to VCM was with benefit of respiratory protection. Monthly Iniurv Summary Iniurv Class Department Description Receiving/Warehouse Abrasion of right finger. Maintenance Cut on left finger. A H i.stlipf1^11*11*r.,i j-fcni;-: . J- ; -^s Nf j::. !H,T|!.1-.!.,f *p| irp : tfl'i'-TP: 'ii|- -l :l VAB.0001190374 "i!11 ^ -- : v.iiiL- .i . ' >i. .... -11!' ' .f . hioimv -I.j :-il--. QUALITY DEVELOPMENT Mike Kane and Harold Coleman, along with Business Area and Marketing visited AT&T in Omaha, Nebraska. The purpose of the visit was for AT&T to explain the process of becoming a certified vendor and gain Vista's agreement to proceed, We have agreed to take the next step which includes an intensive two-day audit of the Aberdeen facility quality systems. Representatives from Nibco visited the plant and performed an audit. The plant scored 83.4% and Nibco was pleased, for the most part, with what they saw. The corrective action steps which were committed to Prestolite Wire Corporation are 62% complete. An updated corrective plan was sent to Prestolite, along with an updated Line I and III FMEA. Plant Manager The Plant Manager's Natural Team met twice in August identification step in the process improvement strategy, customer, suppliers, products, services, and processes, a Quality Appreciation Day II for September 7 to team contributions to the quality effort in 1989. and completed the They defined their They also planned employees and Vinyl Department The Vinyl Natural Team focused their efforts on solving the contamination complaint that Southwire has voiced over the past two months. A detailed process investigation is being conducted in an effort to find causes and make improvements. The Operations Engineer visited Southwire in Carrollton, Georgia, to sample railcars and also compare testing techniques. Maintenance The Maintenance Superintendent's Natural Team began looking at ways to improve the Maintenance process and identified that damaged, missing, and unsafe tools was the biggest problem. The solution has been developed and includes placing one person in charge of the tool room. A set of procedures will be developed for the tool room. The solution has been presented to plant management and approved. Compound A meeting including Compound, Laboratory and Quality personnel was held to discuss the direction of SFC in the Compound Department. It was decided that verification of the correct weights of material in a batch is critical to making good compound. An overall control plan is being developed to show major unit operation with sample points, sample frequency, test method, and control strategy for each parameter. VAB.0001190375 UALITY DEVELOPMENT - continued 1:.. Administrative Services The Stores Team conducted its second training session this month. The Carrier Performance Team met to finalize the criteria and then met with Ergon and M.S. Carriers to explain the performance criteria and review August performance. ---*r-i I- i!. - - .J . " ' ' ........................ " 7 VAB.0001190376 ... w. ,r, ................................ ............. :1<1 ..........................rail!fh ^ >! j *! p "i- . . : ' !' -- -rVP :j* . U..J. ... ly. COST VARIANCES - D. C. Skokna Variable Costs Product PVC Flexible Compound Rigid Compound Plasticizer August. 1989 Variance. $M Efficiency Price Total $398.2 < 55.5> < 42.1> < 12.9> $287.7 $1580.4 124.3 158.9 45.6 $1909.2 $1978.6 68.8 116.8 32.7 $2196.9 PVC - VCM usage continues to be well below budget (0.9874 pound per pound versus the standard consumption of 1.0140 pound per pound). Also, there was a favorable product mix variance of $44.3M. Flexible Compound - The unfavorable variance was caused by product mix effects ($29.9M unfavorable) and high scrap rates ($17.4M unfavorable). Rigid Compound - An unfavorable product mix variance of $43 8M caused the unfavorable variance. Plasticizer - Consumption of AlfolR alcohols was above budget. Price Variances $M VCM Resin to Rigid Compound Resin to Flexible Compound AlfolR 610 AlfolR 810AI 610P Phthalic Anhydride DIDP Other Price Variances Total $1577.1 161.2 155.8 44.9 12.3 17.9 <18.9> <79.0> 37.9 $1909.2 Fixed Cost Variances - Payroll andBenefits - MM&C - Miscellaneous - TI&D - Clearances Total <$ 1.9> < 78.2> < 10.0> < 2.8> < 0.5> <$93.4> :k VAB.0001190377 COST VARIANCES - Continued Payroll and Benefits - Were essentially at budget. There was a favorable payroll variance of $18.7M offset by an unfavorable benefit variance of $20.6M. M, M. & C, - Costs associated with the Old Module turnaround caused the unfavorable variance in this category. Miscellaneous: - Moving/Home Assistance - Outside ProfessionalServices - Shipping Costs (Last month's in-plant switching charges cleared this month.) - Wastehauling (While repairing the sulfuric acid tank foundation, dirt with a low pH was excavated and had to be disposed of as hazardous waste.) $10.0M $11.5M $14.1M Favorable Favorable Unfavorable $33.0M UnFavorable A pv 4.1 -ifc qpnaiSM;ii-infill*-i= VAB.0001190378 nr irt v. t n j.^Lr _______________ AND MECHANICAL DEPARTMENTS P. J. Kober, Dan Miller, Ted Nickerson erations/Mechanical Safety Safety The Operations Departments did not have any first aid or OSHA recordable injuries during the month of August. The Mechanical Department had a single first aid injury and no OSHA recordable injuries. The first aid injury involved a mechanic who cut his finger while replacing a pressure safety disc. The topic of the safety meetings for the Operations and Mechanical Departments was the annual industrial hygiene training. VAB.0001190379 i" uniii-itfat I.U U-P--qk, Oh VINYL - P. J. Kober, K. W. Birck The 5415 (Resin) Decontamination Team investigated sources of contamination throughout the 5415 resin production system. This portion of the study concluded that during normal production with dryer cleaning, every third day, product con tamination will average a total of seven counts. Our production target for Southwire is thirteen counts average total contaminants. 2. Three batches of 5305 resin were killed with a solution of BPA and Ethanol instead of Isonox, the normal kill solution. This experimental material has been shipped to KlocknerPentaplast. It represents the Graininess Team's current "best guess" solution to the graininess problem that Klockner-Pentaplast is having with our 5305 resin. 3. The first dryer baghouse was installed on dryer #8 as part of the dryer baghouse replacement project. Startup problems prevented full utilization of the dryer during most of the month. 4. The resin raw materials in the 744 account were valued at $357.9M. August YTD - Production, MM Lbs. - Daily Rate, M Lbs./C.D. - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4-#8), % 39.9 1288 945 30.5 91.7 64.6 415.3 1243 9794 29.2 89.5 72.3 - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime 96.2 94.8 93.6 95.7 Reactor Downtime Hours Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks, New Module rinse/charge water conflicts, waiting on Q.C. data before charging, no place to dump and inclement weather). 261.2 Maintenance downtime (drill condensers D741, D742, D743, D744, D745, and D700, replaced D300 manway, heat treated chem wash lines, and miscellaneous instrument and valve reDairs). 255.9 A -Is -i s-.f-i, r [h . ;H - ..l ',H+ " ! - ..i JivIXSfEtoliwCt, h*r. -}#-< W+f - ^ l r- r..> h: ii M-l" VAB.0001190380 < MM VINYL - Continued Drver Downtime % of Total Downtime Reactor limited production. 67.1 Operational downtime (centrifuge plugs, clean dryers, activator transfer problems, checking dust collector socks, power outages, and flameouts). 8.9 Maintenance downtime (repair activator valves, replace centrifuge sparge pipes, pins, wash out dryers, and various other and centrifuge repairs). 4.4 Other (dryer #8 downtime due to the baghouse replacement project). 19.6 Key Maintenance Work - J. B. Autrey, J. B. Hegwood During the month, #1, #7, and #8 Birds were shut down for repairs. The gearbox and motor were replaced in #1 Bird. The bushings and bearings were replaced in #7 and #8 Birds. Reactor 300 was shut down during the month because of a broken agitator shaft. The shaft is being examined by Cindy Gross in Houston to determine the cause of the failure. The reactor seal was changed out because of this failure. During the month, reactors 700, 741, 742, 743, 744 and 745 were shut down for condenser drilling and hydroblasting. This was done as part of the contamination control program. Reactor 700 rupture discs were changed out during the month as part of the annual rupture disc program. The 904 recovery compressor was changed out during the month due to a seal failure. Number 7 dryer exhauster motor was changed out during the month because of bad bearings. There was one major valve changed out in the reactor area during the month. VAB.0001190381 COMPOUND - J. E. Nickerson, K. G. Akins A General All flexible compound lines continued to operate on a three-shift, five-day schedule in August due to light orders. However, orders began to increase late in the month. Problems with the plasticizer unit vacuum system were resolved with repairs completed in August. The repairs included work needed to start up the P-1 Eductor Water Recycle Project. This system, now in operation, is reducing plant water consumption by approximately 75 GPM. The dry blend unit was shut down on several occasions during the month to control inventory. Several experimental compounds were run in August. Samples for Prestolite were produced on Line I. A THHN wire compound was produced for Triangle Wire using their formulation. Samples of 46801 black compound were produced at three different temperatures for Flexible Technologies in an effort to resolve a processing problem at their facilities. Operating Comnound Production Davs Production ('M Lbs . ) Month Ave./Dav Fiscal Y.T.D. Line I Line III Line V Total % Prime 24.5 24.5 22 1609 2653 942 5204 95. 9 66 108 43 21452 35524 9459 66435 96.9 Downtime Hours Line I - Product Changes - Quality Problems 6c Control - Dicer Problems 6c Maintenance - Miscellaneous Maintenance - Mill Maintenance & Repair 71 13 12 12 5 Line III - Product Changes - Miscellaneous Maintenance - Star tup/Shutdown - Quality Problems 6c Control 48 28 13 10 Line V - Product Changes - Welex Problems & Maintenance - W-P Maintenance - Quality Problems 6c Control - Startup/Shutdown - Miscellaneous Maintenance 63 23 16 16 13 12 VAB.0001190382 .. . ': |,b - -.... ' ' %rr*'l- h F;..i-l-i-i-V+lrJF*-^jfc r+- H!rfS-'V.L <i < . ,:ni:r.iTJl^K; . l-fl*.: .* ii^l ^ hair- j4'i COMPOUND - Continued Operating *W Davs Rigid Compound 21.5 % Prime Month 3312 99.9 Production (M Lbs.) Ave./Dav Fiscal Y.T.D. 154 54975 99.7 Downtime Hours - Product Changes - Quality Problems 6c Control - Univox Problems & Maintenance - Miscellaneous Maintenance 41 22 20 20 Operating Davs Month Production m Lbs.) Ave./Day Fiscal Y.T.D. Plasticizer 26 % Prime 1501 87.5 58 18553 91.7 KeyMaintenance Work - J. B. Autrey, J. B. Hegwood Dry blend "D" blender was shut down during the month for repairs. The stub shaft on the drive end was removed and a new shaft and bearings were installed. The Line III mill was shut down during the month in order to change out the front mill roll hydro therm pump. The pump failed due to normal operational wear. VAB.0001190383 I-!. ! i r V "T- " UTILITIES - J. B, Autrey, J. B. Hegwood Number one boiler was shut down during the month for its annual inspection and preventive maintenance, during which time several piping revisions were made in order to upgrade its integrity. The east bio-disc pump was removed during the month for refurbishing. The pump had failed due to normal operational wear. The pump was removed, rebuilt and put back in service. The Deltech air dryer was shut down during the month because of continuing problems with the refrigeration system. It was determined that a leak had developed in the chiller vessel. The chiller vessel was removed and the leak repaired. A new chiller was placed on order to replace the faulty chiller. The repairs made should be adequate until the new vessel arrives. The propane vaporizers were shut down during the month for inspection. Several leaks were repaired and the venturies were set. Kits are on order to rebuild the regulators. The API separator was by-passed during the month so that it could be cleaned. i*' Irli i a* iT'vr: ; i|-rg ^-..,3- .-=4,. -*( -.-i . i l-ii.Jtx-Hf : ; Ji isip-umv ,.j j. i|.i f '*ir Hi-fi \X !i r i . -,-1 .k . ENGINEERING - R. E. Polk, S. C. Hillman, C. J. McDonald PROJECTS IN DEVELOPMENT - GENERAL VSCM Review of the process control diagrams was started by the VSCM Project Team. Rigid Calendering Resin Klockner and American Mirrex (formerly Hoechst-Celanes< to trial 5305 produced using only BPA as the kill Klockner car has already been produced and shipped. have agreed The Klockner recently used 5305 resin in a color sensitive application without reiections. Our resin "b" color currently averages 1.8. First Fiscal Quarter Capital Budget The First Fiscal Quarter 1990 Capital Budget and AFE's have been submitted to Houston for approval. Reactor Steam Stripping Testing Preliminary results of the revised stripping procedure show approximately 50% decrease m res idual VCM (from 130 ppm to 65 ppm) . No signs of additional reactor fouling have occurred. Dryer Dust Collectors The dust collector for dryer #8 is operational. Installation of #7 is underway. Stack testing will be completed in September. TC Wastewater Treatment We participated in a test run at the 0KC plant to determine operating parameters and size of a chemical oxidation system. The system uses ozone and ultraviolet light to decompose VCM. The test showed the system will work and will allow the vendor to size and quote the equipment. The quote will be compared to steam stripping to determine the best method to reduce VCM concentration in wastewater streams. THE SA NODULE IS OPERATIONAL KITH PUNCHLIST ITEMS IN PROGRESS. CONSTRUCTION IS COMPLETE. PROJECT IS CLOSED TO FIELD CHARGES. EN IGNEERING IS IN PR06RESS IWTH COMPLETION PLANNED IN OCTOBE .R -L tn tn cn cn cn A to tn tn cn Lu cn cn cn tn cd ctnn ccnn cn cn cn c"n *c--n tzn cn cn o E Ui cn OS CO CO uj cn uj cn o El u cn cn cn cn cn uj lu uj oc cn uj a: LU cn tn cn u cn cn os tn cn tn a IT* UJ to * to lu cn cn cn m cn o lu cn cn tn cn to cn cn cn k oe cn tn cn u u u e cn tn lu UJ cn cn ccnn cn ccnn cn o u u cn n cn cn ctnn tcnn oc cn as ctnn ir> cn cn cn m cn cn cn cn ccnn ccnn ccnn LU uj * cn cn M cn cn cd cn m a) cn tn as tn cn cn cn cs cn cn cn cn tn cn cn cn cn cn cncDcnotncntncncoocD 3 tn z cn cn tn to tn z tn lu cn cn cn to cn >- cn cn tn uj tn h* co cn tn cn cn cn cn uj e cn <r cn e c=a cn Ui <E Cp tn uj z cn cn cn u ccnn cn cn cn LU cn tn e lCtnu-J as u u* zx |mn c<nt aass aa ao in o in in RESIN QUALITY IHPRQVEHENT PROJECTS PLANT AIR SYSTEM MODIFICATIONS ALTERNATE NATURAL 6AS PIPELINE F786/F557 A718 A858 -.-pm; >ti- 'if1 p*1 f.' ? ill- l|i| .1 "r 'l'Til' ' A ' " ' ' fc'-!-k+r:l 'Ml??*** i" ''s+r r. "<i- --'vl M-i . ** h- HIl* * p^l` ^ rt-y KWP't,: . J- jf- J- : = -ps-*ir -mi*-": -.|- c - ..............ik. ' i.--- r hf-j+n ,i.., y^--- ir!f - -i| ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were met for the month of August. A bioassay test was completed during the month. this test. No toxicity was found in A permit for a new well into the Eutaw aquifer was received this month. Waste Management Waste shipments included: Twelve bulk loads of acid contaminated dirt were sent to Chemical Waste Management. A total of 420M pounds was sent at a cost of $32M. Two bulk loads of separator oil were sent to Systech in Demopolis, Alabama. One bulk load of lead bags was sent to Chemical Waste Management. One load of floor sweep was sent to Chemical Waste Management. Ten drums of phthalic anhydride spill were sent to Chemical Waste Management. Alabama banned all disposal of hazardous waste from Mississippi in their state. This ruling will have a significant impact on our operation. We will now have to ship our hazardous waste to the Lake Charles Chemical Waste Management facility. Other options are being investigated. The ban takes effect on September 14, 1989. The plant started recycling aluminum cars from breakrooms. The proceeds from the recycle of these cans are going to the off-the-job safety bingo game. Fifty-five dollars worth of cans was collected in August. Wastes from the Prairie Transportation facility closing were recycled or disposed of this month. A meeting was held with Sun Polymers to discuss pond #2 resin reclaim. A meeting was held with the Department of Environmental Quality (DEQ) on disposal of sludge generated from the proposed Coker water treatment plant. The API separator was cleaned out during the month. VAB.0001190387 ENVIRONMENTAL - Continued SARA Two meetings were held during the month to revitalize this team. Current work will concentrate on community relations and employee meetings to update changes since last year. Air Notification was received from EPA that the low molecular project did not need NESHAP authorization. SUPERFUND Results were received from the second groundwater monitoring. significant contaminants were found. No Miscellaneous I attended an Environmental Committee Meeting on air toxic regulations. A 'I-) I'jiTt-p-j-: irj-HrMmdmu).ii.j.v:-.j*:- ........... -ihtra : If4pyfr-f|*|l)^Hr VAB.0001190388 . >i:.;" ! II i V.. |1 4 F-i 4:- - -I i -1d : . -- ^ irvtf-lprii w H. i. F.WKRflY CONSERVATION - D. A. Moore August. 1989 I. Energy Conservation Data A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU 3.70% 2.60% 2445.40 122.14 This corresponds to anadjusted CMA of and an unadjusted CMA of 55.03% 43.61% Fiscal Y.T.D. -3.11% -4.09% 2527.34 1403.04 51.75% 40.22% II. Plant Energy Conservation Program A. Maintenance There were twenty-six energy related items completed in August, 1989. Twenty-four of these items were steam leak repairs. The remaining two were steam trap B. Steam Trap Survey The survey for vinyl and plasticizer areas identified no steam trap items for repair. Ill. Boiler Operation Boiler Combustion Efficiency % Aug.. 89 Fiscal Y.T.D. No. 1 No. 2 No. 3 (1) 83.44% 83.86% 83.71% 83.48% 83.13% Boiler number one was not operated during the month. VAB.0001190389 -ilpr i-Lcr-L xf;-- A- HUMAN RESOURCE REPORT AUGUST. 1989 Personnel - J. E. Beall Employment: Deborah Tollison, Rehire Promotions/Transfers Dwain Lucas promoted from Lab Technician "A" to Lead Technician. T. Reed Mackay transferred from Process Engineering - Houston, TX to Process Engineer - Aberdeen. Retirements None Terminations/Resignations Brian Aftergut Matthew Smith To/From Leave of Absence None A ......... ihl >1.' 'nrH :r- VAB.0001190390 ;4^-J:J-. - r T't *f .... .1 <-, lh. '< -ni.M-HT'i -IJ. ! .11.n- Aberdeen, Mississippi Salaried imDiovees Hourly Employees + ml Total Employees -- * Employees (Hourly) New Employees Terminations DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound Vinyl Plasticizer PAR 16 13 41 24 40 33 5 79* 173 AUGUST. 1989___________ MONTHLY PERSONNEL REPORT Minority Employees if, Salaried 7 Hourly 66 Total __73 0 Hourly Min. Hired 0 % Min. Hired _____0 0 Hourly Min. Term. _____0 % Min. Term. 0 * EMPLOYEES MIN. EMP,. Z MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD 16 8 50 . 0 _Q_ 0 0 QQ_ 16. 5 31 7 41 10 24 0 JL 23 5 22 0 Q_ 39 26 67 00 33 10 30 0 0 0000 5 2 40 0 0 0____. 0 0 0 Number of Applicants: Month ______0_______ Year to Date 21 APPLICANT BREAKDOWN: if Minority Q % Minority ______q if Female Q % Female ______Q Hires (Hourly): Month 0 Year to Date 7 Terminations (Hourly): Month Q Year to Date 7 Overall Turnover Q Projected Annual Turnover * Includes 2 Co-ops Engineers and 1 Summer Engineer. VAB.0001190391 ** :. . !.,^:.r,_'^;j #=l . Jih-.-i.-ni ,-iv. . v --I 1 -- i -i *! siHi O9 *-* k H* >* J-t 1 * in <r CN LO i-H M0 o CN 00 CN CO VO O Ht CO r^- m H -- OO rH Osl \u* 00 1-4 f0 i--4 u C0 i to o [ ^ cr\ * m oO O M2* o LO r--4 COt ON LiO * CO CO4 o o* <r o4 <cT* 1 to- r^. M2 CO CN CM U a> to C 73 X CN CN o ^H 00 CO o <r ^H O f-H 00 uo CO CO CO o o u0 CN aj CO u CO --V CN 1--t 00 o o o o o CO '-0 -1 o\ r^ o o CN o o o CN .O 4 "C . lO CO CM i w; muOD li yV <cLaJ I i<f---Hf> cCMo \<oN ulCToNN cr--mt Ocm <r^3-0 *i 1 "N? Ej X f- | X -W aotr jc a. th *ew m <U> -LJ uQt to o> o i--i i-H -<r O OO <T CN i-H m ao vO MD ** * -O' CO4 CN 004 1--I 4 O ON m CN i--4 i-H CM 4 X t0 X c u y u 5" yp--s c >, *v >, 'M V * -* - ^ 73 rm*X4 V . ft A OVERTIME AND ABSENTEEISM V u o> o JH uoa O uo M0 r-^ o o o UO UO CN UO oO UO o U0 o o o r-H CN 00 00 o\ <i-Hr O *3- UO CO o \D rH u0 00 l-H MO CN i-H CO 1--1 CN CN 0) e -a] -rt 4# H u O -c ob 00 H OH CO KU3 iJ o C^l X \oU0 i--4 rH m * o ON \> UO 4 <3CM CM vO O UO i-H CM M2 OoGO 0CM0 oo CO* o oo oo\ oo oChMk4 uCN0 * OaOOs ao COrCHMON f bJ H 1% 1 2i i-4 Z % tftj N3 O00 -4 a, l-H -4 o --1 H CO >^ H r<-4 nJ < Q UJ < H C H 3 H z U3 cu =D O >o CO I V B u 1y-1 uQJ o> o> a> u0 <cu 1^ c uc1 *4 CM VAB.0001190392 fc_ ryirTifttg^Trfl4*,;jH^lW1rKflrltt^.T-^ :v?:- -v <t-> ........ ^T'- 'J.l .1^-- l+fftfUjt-3 |-41 B-J H-l* .!( : F I!-fcVJ i! ** . F ^ Ji-l>v. . m4 r j.'iff :-!. * . Ji,.itK<rj *:. +*(i*^>Kv`r+r ,p-' . .! !J rv t"r~ =l'i 'PCUrtC.lj' 7J Hsr-Clfl W,.|:*|iHI.-*'> v.h- **-- ADMINISTRATIVE SERVICES - J. E. Little Safety There were no safety instances August was Industrial Hygiene. conducted basic CPR training. this month. Also, Amy The safety topic for Vernon and Ginny Belle Cost Savings Savings due to competitive bidding were $1445 for the month, and $122,999 for FY1989. Savings due to prompt payment discounts were $3686 for the month, and $23,435 for FY1989. Warehouse - Finished Goods Inventory Total packaged inventories decreased an additional 279M pounds from 5376 pounds to 5097 pounds. Off-grade inventories remain a problem; there was a slight increase in August - from 708M pounds to 713M pounds. Training The Stores Team held their second training session August 14, 1989, for the Vinyl Department. Meetings The month of August was dedicated to completing the budget and making revisions. 8/29/89 Tim Arbeiter, Pat Wells, Amy Bagwell, Dean Honeycutt, and Jack Little finalized the Aberdeen Motor Carrier Performance Program. We had a meeting later that day with Ergon to review carriers' operations for the first month, and to explain the carrier performance program. 8/30/89 Tim Arbeiter, Pat Wells, Amy Bagwell and Jack Little met with M.S. Carriers to review August operations and reiterate performance criteria. Carrier dispatching, previously handled by Transports, was absorbed by the plant: Amy - bulk shipments; Pat - van shipments; and Teresa - inbound raw materials. -ii VAB.0001190393 ABBBDIIB CUBICAL Ptlll S3IPPI8G U1LISIS AUGUST ISIS -saipams BY PBODOCTS- PUBLIC BES1S-B0LI B8SIH-PACEAGED 21,184,593 472,556 BOITI IPT/ITC BIC1AIG! 8,878,000 123,750 0 0 A TTD PUBLIC IPT/ITC EICSASGE 203,462,310 113,791,579 5,014,700 537,350 0 0 FLEI1BL1 COBPOOIB-BOLI 1,224,870 1,068,450 FLIIIBU COBPOUID-PACIAGID 4,359,041 86,400 0 0 14,544,550 12,934,640 41,798,267 1,154,046 O O IIGID C0BP0U8D-B0LI BIGIB COBPOUID-PACIAGID PUSTICIZIt TOTAL 3,152,480 174,419 0 0 90,340 350,550 37,950,301 10,513,150 0 0 549,100 549,100 42,521,940 3,867,950 5,343,039 1,551,971 0 0 2,056,690 1,916,050 3,290,550 315,542,304 135,753,500 3,298,550 -SIIPUITS BT MODI- BOLE: tTAaDvfuiOuSvTi** BESIS FLIIIBU COIPOBID IIGID COHPODID PUStICIZH TOTAL A8G0ST BAILCAB 181 11 16 5 213 TISTA CBSTOBII comoR PICIUP CASSIES 0 42 72 0 08 0 64 0 02 0 48 86 TOTAL 295 19 26 7 347 fiSSII TTD* hiiibu cohpoobo IIGID COIFOOID PLASTICIZES 1,459 447 003 99 146 27 0 13 242 66 38 9 29 15 0 34 2,808 100 355 78 TOTAL TTD 1,070 555 841 155 3.42T PACIAGED: *A8G0ST* BESII FLIIIBU COHPODID BIGID COKPODKD PLASTICIZES TISTA 0 0 0 0 COSTOHES COKHOI PICKUP CASSIES 7 14 36 83 09 00 Tore COSTAIEES 00 00 00 00 AIB/DPS 9 6 4 0 TOTAL 30 125 13 0 - TOTH AUGUST tmt SESII FLII1ILI COHPODID IIGID COHPODID PLASTICIZES TOTAL TTD 0 43 106 0 40 55 111 0 367 322 493 1 84 8 126 0 0 0 30 l i i t* iCnO 491 733 1 0 19 168 0 49 255 3 20 1,206 2 4 224 0 03 vAR nooi 190394 1,688 l1 l1 1 i 1 1 il -- li l iI lI 11 i iiII ltII II M IIIIIIIHIIIIIIIIIIIII I*vj- * ' 7'pl T T.! V* H 1' PI| ilf.' : . !l ' + ' Jf-.-fi. Itb-Lnw---1*111^ H I" L-^_. -g . .. |r- |f. i. I .-L , . . *flS'V| rr. '-.-n- . f. | r-n- :M' - ::i R=-= -S ^ . v,i- -I-It*. -`ib. -,> - y l*. MY .1 U -t - ir I .. LABORATORY - H. G. Coleman A. Safety - The Laboratory operated injury-free during August. The safety meeting topic for the month was the annual industrial hygiene training presented by J. V. Uptain. B. Customer Relations Customer Contacts 8/08/89 H. G. Coleman visited AT&T in Omaha, Nebraska, to discuss their Vendor Certification Program. 8/15/89 The Lab participated in an audit by Nibco, an important low M.W. resin customer. The results of the audit were very positive. Customer Problem Reports Date Customer Product Amount Reason 8/10/89 Twitchell Dothan, AL 5415 1 R/C Hard particles STATUS: Customer's concern over high hard particle count on this shipment appears due to confusion over test method. Hard particle test method sent; customer trying to correlate processing problems with hard particle results. 8/10/89 Blane Polymers Mansfield, MA 5415 2 R/C's Metal contamination STATUS: Customer rejected railcars due to metal found in two com partments. A problem in a production dryer has since been corrected. C. Product Waivers Customer Product Reason No Chelsea Building Products RP-166 WHT 144 % Retained on 40 Mesh 1 RC Dayton Extruded Plastics RP-151 WHT 145 % Retained on 40 Mesh 1 RC Eagle Plastics 80273G WHT 110 % Retained on 40 Mesh 1 RC Essex 5415 Particle Size, % on Pan 1 HT U-Brand 90172D WHT 110 % Retained on 40 Mesh 1 RC VAB.0001190395 LABORATORY - Continued D. RVCM Summary The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of August, 1989. Reactor Slurries _________Drier 5265 5305 Number of Samples Average RVCM, ppm 942 147 30 0.540 65 0.585 RVCM of Shipment Samples The following is a summary of the residual VCM analysis of shipment samples for the month of August, 1989. Product Number of SamDles Averaee RVCM. vvm 5265 5305 5385 5395 5415 5465 Dry Blend Debox Pond 28 75 87 0 62 0 40 25 7 0.066 0.195 0.215 0.111 0 0.103 0.115 0.916 E. Resin Process Capabilities (based on dryer "regulars") Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Drytime Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) 1.73 1.56 -- 8.00 6.33 5.67 0.97 -- 0.77 -- ----- -- 5 1.06 0.85 0.48 3.00 7.00 2.33 1.52 -- 1.05 -- ------- -- -- 5385 2.83 0.78 -- 4.22 -- 2.67 1.21 -- 1.97 2.67 -- -- 3.0 5415 1.00 0.80 -- 4.56 -- 6.67 2.67 0.17 2.60 2.67 1.03 0.60 2.1 Average particle size. microns 139 145 168 171 * VAB.0001190396 LABORATORY - Continued Flexible Compound Quality Summar Ad justments M Lbs . (11 Hardness Color/Clarity Hard Particles Contamination Dicing Heat Stability Cross Contamination Streamers Totals 75.0 15.0 ----------- ----- -* --- --- --------------- (1.44) (0.29) -- --- --------------- ----------------- -- 90.0 (1.73) Rejections M Lbs. (%) 5.3 63.2 55.6 6.0 9.9 4.8 1.4 16.0 162.2 (0.10) (1.21) (1.07) (0.12) (0.19) (0.09) (0.03) (0.31) (3.12) Rigid Compound Quality Summary Rejections M Lbs. (%) Contamination Total 4.2 (0.13) 4.2 (0.13) Flexible Compound SPC Test Results n X 3cr 38401 - Hardness - A Scale - Specific Gravity - Hard Particles - 20 sec. 26 26 26 83.92 1.376 20.50 0.41 0.012 3.38 35031 - Hardness - D Scale - Specific Gravity - Hard Particles - 2 min. 26 36 26 49.96 1.379 5.31 0.20 0.005 2.76 Mill Temperature, F Oven Temperature, C 26 324.8 All Readings 3.44 204C. 5415 Control Resin (Lot 04169) Test Results n X 3a Moisture Drytime Particle Size Bulk Density Color - L - 60 mesh - 80 mesh - 100 mesh - 120 mesh - 140 mesh - 200 mesh Pan 62 62 62 62 62 62 41* 47* 41* 31 42** 0.146 4.68 2.54 39.63 26.04 17.83 8.76 4.15 1.16 0.5011 100.578 0.034 0.19 0.88 4.18 0.71 2.06 1.30 1.44 0.42 0.0029 0.224 iH fiV VAB.0001190397 r LABORATORY - Continued I. 5415 Control Resin (Lot 041691 Test Results - continued nX 3a Color A B Flow Time, sec. Hard Particles, 7 min. Inherent Viscosity 39** 40** 21 60 28 0.017 1.734 6.94 6.3 1.0116 1.21 0.302 0.27 1.9 0.0086 * Changed during the month. ** Color shifted mid-month. J. Miscellaneous 1. We began testing some Visalia compound samples this month for plasticizer identity. Several instances of plasticizer cross-contamination were identified. 2. D. S. Cox performed a precision study on slurry RVCM. A 40 ppm sample had a 3a spread of +/-30 ppm. No further work is planned at this time. J|!M .* irt*i : rsns^: VAB.0001190398 !: i*.. ' -kgii- n RESIN Ship Date 8/01/89 8/02/89 8/07/89 8/08/89 8/08/89 8/15/89 3/18/89 3/31/89 8/31/89 SAMPLE SHIPMENTS AUGUST 1989 Product Pond Resin 5415 5385 5265 5305 5465 5 385 Pond Resin 5305 5415 Pond Resin Amount 10 lbs . 500 lbs. 50 lbs. 5 lbs. 5 lbs . 100 lbs. 100 lbs. 100 lbs. 250 lbs. 200 lbs. 200 lbs. Customer Conex of Georgia Triboro Electric Synthetic Products Collins & Aikman CHISSO PETRO RES. CNTR. Zoecon Industries Wexford International PUSH PA NIGERIA LTD TRANSWORLD IND CORP. COMPOUND Ship Date 8/02/89 8/03/89 8/03/89 8/07/89 8/07/89 8/08/89 Product 87-006A BLK 870-37B NAT 48451 48451 48451 BLK BLK WHT 35 36 374 38101 BGE 11 416-2ID NAT 240-180 BLK 8/08/89 240-180 BLK 8/16/89 8/16/89 8/16/89 17121 WAT CL 16851 CB 50 87-006A BLK Amount 200 lbs. 150 lbs. 200 200 200 lbs. lbs. lbs. 1 lb. 500 lbs. 1500 lbs. 1500 lbs. 10 lbs. 100 lbs. 500 lbs. Customer Tandy Cable Products Tandy Wire John C. Levardsen Comm/Scope Inc. Prestolite Wire Corp. Communicaton Cable Inc. (Hayesville, NC) Communication Cable Inc (Siler City, NC) Conex of Georgia Master Halco Tandy Cable Products VAB.0001190399 k Ln COMPOUND (cont *) Ship Date Product 8/17/89 34862 BGE 10 (Type 536C-1) 8/18/89 MSP-90 Pellets 8/21/89 16851 CB 50 8/24/89 34862 BGE 10 (Type 536C-1) 8/31/89 419-44B NAT 419-44D NAT DRYBLEND Ship Date 8/16/89 8/22/89 8/31/89 Product RP-2Q0 WHT 111 RP-151 WHT 145 Control 80273G WHT 110 Amount 2X5 lbs 50 lbs 50 lbs. 2X5 lbs 50 lbs. 50 lbs. Amount 100 lbs 12 lbs. 400 lbs Sample Shipments/Aug. 1989 Page 2 Customer REKO GRUPO IMPORTADOR JALISCO ABC Plastics Ron Walker Prestolite Wire Customer IFER DOMINICANA, C. por A. Dayton Extruded Plastics PUSH PA NIGERIA LTD * VAB.0001190400 1 ip. j.. xi(.uHh<{i1.'tnfrfjH;'Jii|.|:nAiM hi. \\ & Trt-" i i ' i Mi|rk i-| - .j- !: : i r!- k ' .k-jf 'vi/,j,, ... j?. - j, h.-f: 1 HI m : S- ibim Sil'i t+| nL-N--!-Hf ' : ; -e ABEROEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) r i--i--i--;--r 1----1 '87 F M A M J J A S O N D J'88 F MAMJJASON OJ'89F M A M J J A TOTAL INJURIES OSHA RECORDABLE VAB.0001190401 % * -*lt !| r: mi*l r . !-- . r. . . ABERDEEN ENERGY CONSUMPTION I iBtreMl; iin:;i: "t,i-4i|Tiir^i: .1 .. :-,::x.4ii: ai/nxa 1ffl'WIll|S|l'U-iMj*IhrWB^WUlH^irtWur.lyitrMtf j;Hjjj+ .j=ii>. j :.# VAB.0001190402 T-! L- I-:W-ihh !!-i;-!-aau,i ( !:1 -b--. V-J'L' ................ '|> I ;ti i -L^ji l-it! JiN" I :t ' ` *- . v,jh... Wf,rt "J5T fc' |iP-,M .T' '** * <r+ flt-' MONTH --------- 12 MONTH AVERAGE