Document gbKvxv9gmjoMaqEJK5DknbgNV

ABD00282815 VINYL - D. W. Hollis/M. L. Nathan Safety The Vinyl and Yard Departments operated with one first aid type injury in March. The injury involved a puncture wound from a frayed wire on a section of flexible conduit. Shift safety meeting topic for the month was "Job Safety Analysis". Operators on each shift presented a step-by-step description of one part of their job including safety aspects. Production .1 Production, MM Lbs. 2. Daily Production Rate, 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 March 36.1 1163.3 907.0 29.3 93.1 8906.5 68.0 31.0 Y.T.D. (Fiscal 1985) 208.8 1147.5 5077.0 27.9 90.8 10315.1 59.1 182.0 Vinyl Department production for March was 36.0MM pounds which was 101% of the Business Area's targeted production level of 35.8MM pounds. Reactors The reactor stream factor was 93.1%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 54.4% of the total downtime and was due to reactor scheduling conflicts and processing caustic con taminated VCM. 2) Maintenance Service Downtime: Accounted for 1.9% of the total down time and was due to cleaning reactor AMS injection ports. 3) Maintenance Repair/Revision Downtime: Accounted for 43.7% of the total downtime and was due to two reactor valve changeouts, agitator seal replacements on 500, 700, 741, and 743 reactors, 745 condenser lid gasket replacement, 700 agitator motor rewiring and drilling/ brushing of 743 condenser. Dryers The dryer stream factor was 68.0%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 84% of the total down time. Dryers were shut down when possible for energy conservation purposes. 2) Operational Downtime: Accounted for 11.8% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer clean ing, and transfer activator problems. ABD00282816 VINYL - Continued Dryers - continued 3) Maintenance Repair/Revision Downtime: Accounted for 4.2% of the total downtime and was due to activator, centrifuge and screener repairs. Product Quality Summary Resin Type Prime "BC" % of Total "H" Production 5265 5305 5385 5425 5465 Sifter Overflow Pond Resin 2,519,128 5,314,227 18,225,940 7,859,819 1,867,310 - - 84,350 6,750 - - - - - 28,284 428,460 6.9 14.9 50.2 21.6 5.1 0.1 1.2 Total 35,786,424 91,100 456,744 100.0 Quality performance for March was 98.5% customer grade with 0.2% "BC" production and 1.3% "H" grade. A total of five railcars were shipped as " Bn grade during the month which represented 3. 5% of the 144 total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 1/28/85 3/18/85 PTLX 41606 Vulcan Resifted Sifter Overflow Quality 2/8/85 3/18/85 PLCX 42374 Vulcan Resifted Sifter Overflow Quality 2/13/85 3/28/85 PLCX 43706 Extrusion Techn. Resifted Sifter Overflow Quality 2/12/85 3/29/85 PLCX 42666 Vulcan Resifted Sifter Overflow Quality 3/01/85 3/31/85 PTLX 41646 Silverline 5385 Particle Size The Vinyl area received eight short lead time emergency type orders comprising 3.4% of the 237 Aberdeen resin shipments in March. Monthly Variable Cost Performance Variable costs for the month were favorable $266.3M with $154.4M due to price and $111.9M due to efficiency. Resin variable cost for the month was 20.139 <?/lb. versus the budgeted 20.887 c/lb. The $154.4M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $80.1M; VCM freight, $29.4M; Lupersol 223 initiator, $19.2M; and utilities, $19.9M. ABD00282817 VINYL - Continued Monthly Variable Cost Performance - continued The $111.9M favorable efficiency variance can be attributed to lower than budgeted VCM efficiency, $141.2M and lower than budgeted usage in the utilities area, $29.9M. VCM efficiency for the month was 0.98268 lbs. VCM/lb. PVC versus the budgeted 1.00500 lbs. VCM/lb. PVC. Year-to-date VCM efficiency is 0.99985. Year-to-date variable cost efficiency variances in the Vinyl Department totaled $417.3M favorable. Energy Performance/Progress 1. Plant energy consumption for the month totaled 2517 BTU/lb. 2. A total of thirty-nine steam leaks and twenty-two steam traps were repaired during the month. General 1. Packaging for the month totaled 336,024 pounds. Resin raw material in the 0744 account totaled $163.4M at month end.