Document gjKR8z3azoaqmeZNJM9y1eNL
PLAJiT MANAGERS REPORT 1963
QUALITY REPORT WALLBOARD & PLASTER
PLAINTIFF'S EXHIBIT
Acme Plant
K VJ. Brown Plant Manager
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Ths ait-achsd complaint summary indicates our quality
performance in 19&3 vs ,, 1962. Eeurd shipments were up only slightly
over 1962, halS%) while complaint cost rocs to 0.Clj5> par thousand
aquara feet over last year's SO.Q36
thousand, Piastar shipaanis ware
up by 3,70^ over 1562, and again complaint coat rose to $0,026 per ton
over 19^2'a $0,003 per ton. These figures indicate that our quality
performance for the year is poorer than last year's* Total complaint
cost for 1963 was $8,796*66; in 1962 our total complaint coat was
67,321.29*
We are happy to report that vo have tnado considerable
improvements under all categories in the board plant except under
cracked board and miscellaneous complaints. Other than these two
categories, our greatest complaint cost was under heading #5, split
ply paper. Of the total $1,790.09 paid out, one complaint filed by
the Alert Lumbar Company in Los Angeles cost ua $1,099.00. The board
in question in this complaint wa3 manufactured in October of 1962
anc it*s-causa was thought to be an insufficient amount of Kymeno
treatment in our 75# Ivory paper. Since Pryor has started this treatment,
and splitting problems have been greatly reduced End splitting still
occurs to some extent, but generally only to the extent that it is
easily taken care of in our end grinding operation.
Another area of high cost in 1963 was under heading j?9,
miscellaneous complaints. These complaints are ones over which va
hato no control. For example, several complaints ware paid to cover
the coat of replacement and/of' repair of Eternawall which had
delaminated. `Cn complaint filed by the Ideal Lumber Company of Galveston,
Texas for nail popping cost ua a total of $1*75.00. We are convinced
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that tha causa of this complaint was wot lumber which shrunk during
tha process of application of '-Tailboard . Wo also have claims aeh
year under this category which deal with storm damage to flat cars
during tha hurricane season# Cns complaint of this nature was filed
during 1963 by the Master Lumber Company of Houston. Cost of this
complaint was Sl66085#
We do not knew exactly what can be done to reduce or eliminate
this type of complaint# Our only course of action has been to generally
try to more rigidly inspect our products and improve our quality
standards. Our greatest complaint coat during 1963 la the board plant
was under heading
cracked board# A total of
of all monies
paid out, or $It*220o62, was paid out under this category#
Cracking of board products is almost always reported to be
in the length of the sheet, generally 6" to 2hn in from the edge,
but not extending to the ends of the sheet# Much checking and rechecking
has been done through our entire system from manufacturing to handling
and some changes have been made but so far we have been unable to
reproduce these cracks# Continued efforts are being made in this
direction and we must greatly reduce this type of complaint in 196ii
We feel that if cracking occurs, it oust occur after the board
leaves the kiln and goes through our twin mounter# We feel this is the
case since ve see the face of each and every board that we manufacture
upon exit from the kiln, and with our new lighting system, a crack in
the face is easily discernible#
c=2=3
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One severe case of cracking complaint was in a high riso building where the settlement was extremely high duo to rehandling the board.
W have reduced weights of all board products considerably during the past year, and the recant increase in glass fiber contentj along with the adoption of nuzsy mix as our standard glass has helped us greatly in improving flexibility and strength*
Plaster shipments were up by 3*70% during 1963, but complaint coat rose from 30*008 per ton to .$0*26 per ton. Two complaints under coda #16, miscellaneous pleoter complaints, accounts for $309*37 of the total Clil857 paid out by the piaster department* These complaints arose in 1962 and were finally settled this last year. $75*00 was paid to the Lynwood Brick & Tile Company to cover light sensitive Acoustic Plaster and $23h*37 was paid to Builders Supply Company of Houston to cover some hand finishing plaster that would not dry properly* Only one other complaint was honored during 1963. This was $109*20 complaint filed by Loyd Moreau of New Orleans to cover old and lumpy lime.
Shipping errors have been reduced sharply in 1963 over 1962. We will continue to work on this type of complaint and do all possible to reduce it further in the future.
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DEFT, & TYPE COMPLAINT BOARD PLANT*
1962
i;Oo NO a nr-]---------s
Rac*d Adti 0 ; Total'
Coat
(1) Foor SondjCloan Peeler 3 1
i
0 t *
I'fOo
> Ree!d' ,\ 1
}:
1963 No, j Ad.jJ
1
Total 1
(2) Cora Splits* Blisters 3 5 j17,38 1527206! 2
3 loil?
Cost - * "1 r-
(3) Cradled, Broken
a 9 |17,35 1.270,6.3; 37
15 hlc/:9 h;220^2
(ii) F.dga & Taper Fcrrution > 1 1,69
123ol;0 3
(5) 3piit Ply Paper
11 n0
lj973oIiC| h
1 ,6Q5 20,23 1,790,09
(5) Off Dimension
1? 13 12,28
(7) Surface Imperfections u 3 6,o6
399oli8; 2 1i1i3o68| *>
2 2,30; 203,78 1
2 2,62 232a00
(?) Miscellaneous TOTAL EOARD PLANT
7 1 3 069
270oli8; 19
$6,213,68j
89 Uo fill 087
70
10 lh ,ili ` 1251,73 38 89oC6 7,881,57
COMFIAINT COST PER I.BF
$ o037<
$ 0d*5
PLASTER MILLS
(lO)Setting Tim
60
at
s 2
0
>
=
(ll'/forking Properties
6 2 1,38
2 1,,2.1 109020
(12)Soft, tfeak
.6 Q
cs
<M
f-t . >
-
(13)Cracking
10
era
&- 'ta - 3
(III'Broken Bags (16) f.&scellanaoua
11 52
o!2 o3l
9,1*3 25,CO
X
2
CO
2 3o5a 309,37
TOTAL PLASTER COMPLAINT LOST PER TON
25 5 lo8$
$235*88 $ 0CO8
7
3 Uo73 1*18 o*
QDARRZ't CEMFNT ROCS
CZt
CO a
J
ALL DEPARTMENTS
13
(23 )5hlpplng Errors
27 Hi 13,27
971,83 19 j
5 061 1*96,52
TOTAL FOR ALL DEPARTMENTS llil 59 99,99 7,321,29 96 ! 1*9 99.10 3,796,66
TOTAL WALL80ARD SHIPMENTS, M3F TOTAL PLASTER SHIPHFTSTS, TONS
1 68,332a $.6,051*
I769150BI. 1* 1!?? up by 1,7!
.................15.6?3 up i,,70g
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PLANT MANAGER*S REPORT
1963
QUALITY REPORT JOINT SYSTEM
Acres Plant
K \T, Brown Plant Managar
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CttlFLiUNT SUMMARY
The enclosed summary gives a relative comparison of the year 15*63 va, 'i.962. The aging problem encountered early in 1263 is reflected under the item !!Ecnc Adhesion" whsre settlement was made for $602.00 Policy and $903.00 Dcfcctivoe. Formula corrections were instituted to correct the above problem but over correcting with seme chemicals at this time caused two "lumping5* complaints which ware settled on a Defective basis
We had two serious "Edge Cracking" complaints which were oottled for $1,069.12 and $328.10. Both complaints involved unusual job conditions and there was no indication that our material was at fault. Both settlements were made on the basis of $0% Policy and $0% Defective.
The total number of complaints received was at least eight higher than it should be. Ia two instances complaints were duplicates of previously received complaints. Three complaints were entered where the material turned out to be of competitive manufacture. Tito complaints were entered where the source of the "cracking" problem turned out to be calcined edge competitive board. One additional complaint was caused by face paper failure on board of World War II vintage.
Of the remaining 29 complaints, 13 were entered from Denver, Colorado.
*!<=>
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Quality Ct,jactivea Our objectives for 1961*. are to be a continuation of a program atartsd early in 1963a. This consists of a thorough chemical and physical evaluation of Joint System products, gathering data is graphical form in order to gain basic information cn formula variances* Special consideration is to be given to shelf-life and wet-life in an effort to batter stabilize our products* Efforts were made in 1963 In rsw material studies to improve on the cost of these ingredients* We will continue in l?6l* with this objective.
ca2
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COMPLAINT SE3TART
Lumping Photographing,Burning Beading, Distortion Bond, Adhesion Edge Cracking Working Properties Miscellaneous Shipping Errors
PRODUCT! ON STOMARY
Total Production % Perfect Production
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PLAHT i STAGER*3 REPORT 1963
SAFETY PROGRAM
Aetna Plant
K W, Bream Plant Manager
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In 1>63 -jo worked hh03523 r.:an hours with no lost titsa
accidents and bad a total of i*0 doctor cases. This compares with
iil doctor esses with ['5l}691 vain hours and no lost time in l?c2
20$, or 8, of oar doctor eases last year wore for foreign
body in the ayes. We hod -two coses of dermatitis, one nan burned
his oyoa by a voiding flesh9 $ cases of strains and sprains, 18 cases
of cuts and bruises and 6 cases of sore backs vhora there was no
indication of a slip or fall*
Broken down by departments, this was our picture in 1963
on doetor cases*
Cffico
ran
Quarry P&S
Block & lard Joint System
Maintenance Board Kfg. Board VJhse.
0
o
0 2
3 k
10 10 11
During 1963 wo started a drirs for head protection in our plant
and at tha present time the rock atorsgo operation, all naintenanca man,
all quarry men and all supervisors in the plant are wearing hard hatao
W also continued our regular safety program which includes safety 3hoes
on all employees*
In 19oU wo are following tha Safety Program as outlined by
Mr. Fink* In addition vg are receiving safety filvsa each month through
our insurance carrier to supplement the films in cur regular program.
Also, this year we are planning to take pictures of our plant and employees.
The pictures will be of people doing their Jobs in tha aafa way, not an
unsafe way, that may have resulted in an injury in 1963. Those pictures
will be posted on our bulletin beards and changed periodically*
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