Document ke9M54nGQdXg2pvzJrD3emaD

T. H. Huffman Interoffice Communication From: Date: Subject: D. C. Skokna April 19, 1989 ABERDEEN MONTHLY PROGRESS REPORT - MARCH, 1989 No injuries were reported during the month. As of 3/31, the plant's employees had worked 3,557 days or 4,673,313 manhours since the last lost time injury. Kev Statistical Information PVC Production, MM 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 Variance, $M Variable Cost Price Variance, $M Variable Cost Efficiency Variance, $M Costs March 40.2 92.0 97.4 0.9926 7.7 96.3 4.2 99.1 1.7 89.6 < 2.3> <265.3> 1317.8 1138.9 178.9 Y.T.D. 229.7 91.6 96.4 1.0107 40.4 95.2 31.2 99.7 9.7 92.2 < 5.3> <186.6> 3683.7 3273.5 410.0 Fixed costs were unfavorable due to 5 pay weeks during the month, high benefit clearances, and a $175M unfavorable "ad valorem" tax charge from 1988. Variable costs were favorable as recovery of pond resin resumed with favorable weather conditions. |....| ,-r....... t-n-n- i --i mm -1 it..................... i wimm .................................................................................................................................................................................................................... VAB.0001190531 HP XIIMP T. H. Huffman 4/19/89 Aberdeen Monthly Progress Report Pace 2 - March, 1989 A Ford Motor Company representative visited the Compound Department to discuss Ford's Q-l Rating. Twenty-seven percent of the plant's natural teams met during the month. The Store Team made a presentation to the Manager's Natural Team on their progress to date and future plans. A presentation of the engineering project process flow diagram was given to plant management and PED. Environmental The daily maximum for BOD was exceeded three times; however, the monthly average was below permitted levels. The cause of these excursions was traced to the Plasticizer unit, and procedures have been put in place to prevent a recurrence. We hosted Aberdeen's 20th Century Club for a tour and presentation. D. C. Skokna Plant Superintendent tjs A .UC* I , j-*- VAB.0001190532 -i i-. 4 ' I i.. ii 1 'Wit ' v^.D4|, u ffif-p M J* *** -*- DISTRIBUTION COVER LETTER ENTIRE REPORT Houston J. D. Burns X R. T. Ferrell X T. H. Huffman X C. J. Matson X D. F. Harman X H. R. Flammer X R. R Smith X K. J. Eggers X R. H. Gerlach X R. D. Gamblin X Ponca Citv 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 LCLAB Plant J. W. Ware X Baltimore L. R. Bauer X Hammond J. B. Maher X Blane Premiere Aberdeen C. R. Miller P. L. Foote RWS/DCS (File Copy), PJK, JEN, DWH, TFL, JEB, HGC, JEL, REP, BLT, RBN, SCH X X A .fr *1-4: . .. Hftl PHWPtVIW'trilr Jfr: 17 H*-| i -AM *^-|li!p7>ri,-v >|l Lq !.F .r !' I k. v-i ri*l VAB.0001190533 :--li-- Jm 1 r. n is *L-ni n f c nl- flTjp.t i^-j . i-j?i. j.. >1 : !; JT'i n.15- -r : ' + .- "S'?< 'Ift.NM*''' : SAFETY - B. L. Trego, J. V. Uptain March Fiscal Y.T.D. 1989 Fiscal Y.T.D. 1988 First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 0 0 0 0 0 6 2 8 1 0 6 1 7 0 0 Injuries bv DeDartment Vinyl Operations Compound Operations Maintenance Laboratory Re c eiving/Warehouse Office Totals Iniuries bv Tvpe 00 02 06 00 00 00 08 1 1 4 1 0 0 7 Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Non-Occupational Iniuries 01 00 02 02 02 00 01 08 2 0 2 2 0 0 1 7 Lost Workday Cases Days Lost Safety Record 02 7 42 7 99 Last lost time injury - 7/5/79 Days since - 3557 Manhours since - 4,673,313 On March 31, 1989, the employees of the Aberdeen Plant completed 3557 days with no lost time injury. Topics for the plant safety meetings during the month included Plant Health Physicals and Maintenance Weekly Job Safety and Planning. A 'f . ?*<;*(-1it*:-i-.< . rr \ hn-" 'JH - r i -* i & v Jit nil VAB.0001190534 SAFETY - continued The safety portion of the New Employee Orientation program was expanded to 20+ hours. Seven new employees received Safety Orientation and nine employees hired in the last year received Safety Refresher Training in March. Routine dosimetry results for the H onth were 9 * Chemical < PEL Number Percent > PEL Number Percent VCM Lead Total Particulates 74 100.0 13 100.0 3 100.0 0 0 0 0.0 0.0 0.0 Monthly Iniurv Summary No injuries reported for the month. *kl q |1-fc`---<T^liiT |j-.nfTifl it in '!-T"T...........i.............hi H----------------------------------~--Tn--- mm in ...................... initinmiiiiii'i I HI-Wjil -i -.r. :nlTllh^UN.i tfwNMfWM 3HhrmMWRncivntti VAB.0001190535 QUALITY DEVELOPMENT Vinvl Department The Vinyl Superintendent's Natural Team met once during the month. The meeting agenda included a review of each of the active employee team activities during the month as well as continued work on key performance area identification and calculation of appropriate CPK's. Construction of the Railcar Cleaning Team's project was nearly complete in March with start up planned for April. Two activity teams met during the month; Plasticizer Unloading continued their process design work and V-ll Dustbusters obtained a full set of the modified boots for installation on one fo the rotary dryer Sweco screeners. Compound Department A Ford Motor Company representative, Jerry French, visited the Compound Department in March. Quality Teams meeting in March: Mill Scrap Improvement Team, Dryblend Improvement Team, and Plasticizer Waste Minimization Team. A review of all charting taking place in the Compound Department was conducted. The results are being analyzed at this time. Laboratory Department H. G. Coleman held a Resin Analytical Capability Team (REACT) meeting in Aberdeen on March 1. In attendance were Diana Fenton (R&D) and Bob Battles (OKCity) . Resin test methods were discussed and priorities were established for the team. H. G. Coleman participated in an all-day discussion on 3/30 with Jerry French of Ford concerning our ability to pass their Q-l supplier survey. Administrative Services Department There were several project team meetings in March. The Spare Parts Teams - 0739, met three times, one of whch included a presentation to RWS' Natural Team. The Millscrap Team met March 1 and 15. The CQIP Team met in Houston on March 29 and 30. A if. L- ::rw*CTlHaT13rtPWI 11 \[ * - I- - VAB.0001190536 - i * V* I * t;. rd !' 1 : z: r v. . j'm-i:- . *>* I1- Plant Manager The Store Team gave a presentation to the Manager's Natural Team on their progress, plans, and needs for warehouse stock improvements. This was an employee survey item and was an item addressed in the Manager's Quality Meetings by plant supervisors. Process Engineering R. B. Newton's Natural Team met during the month. Topics included future engineering, manpower requirements, developing long term project plans, and plant environmental training needs. Both Senior Process Engineering Natural Teams met in March to define and work on projects. A presentation on the Engineering Project Process Flow Diagram was given to plant management in Aberdeen and PED in Houston. Shoo Utilization Team The Shop Team met as a whole once and two sub-teams met twice each during the month. The sub-teams are evaluating two different proposals for the shop floor plan. The team plans to meet as a whole in April and reach concensus on the plans. "l Jill K rfrl4#.lfL: liTMl.-LiOn. fL. un* -- -H !" ri::41 |!s-:ifH.U***! rVM-, Ji.-S.-.fl: -1-I& L-Jii4Wl('4T ! /* VAB.0001190537 ! . : ti^.- i<- --Ji-i:wiUI-l-iit?_Vh . . lb -rl" I : ill a .Ibbi I -H I- J '- COST VARIANCES - D. C. Skokna Variable Costs Product March 1989 Variance. SM Efficiency Price Total PVC Flexible Compound Rigid Compound Plasticizer $ 228.9 <15.2> < 6.4> <28.4> $ 178.9 $ 785.3 183.8 81.7 88.1 $1138.9 $1014.2 168.6 75.3 59.7 $1317.8 PVC - Efficiencies were good as recovery of pond resin resumed as the weather became warmer. Flexible Compound - Efficiencies were close to budget. Rigid Compound - Efficiencies were essentially at budget. Plasticizer - Efficiencies were above budget due to an adjustment in plasticizer production. Price Variances $M VCM Resin to Compound AlfolR 610 610P to Compound DIDP Alfol* 810 AI Pthallic Anhydride TiOa Other Price Variances Fixed Cost Variances Total $798.3 187.5 83.7 55.8 17.4 10.3 <12.1> <12.4> 10.4 $1138.9 - Payroll and Benefits - MM&C - Miscellaneous - TI&D - Clearances Total SM $<61.5> 1.5 <38.8> <168.1> ____ 1.6 $<265.3> A . . .-j. , . .-j . ........ | t - .}: I -v\-:-i .'3`-- i i u .1; ... i. -f.-1 VAB.0001190538 V-|r; #7^11 HTTri-lNr^ V-^-= `( ,'j^^tj-ni j. ITM.UlL'il.'-ii f.J- t. jT-jfp-i-L ^pjaiy-| , j.. .k 1 , ,;. .: I "| . s- ife .. M. /j* !1 \ . .1*. .. l-twni. I 1 . |l "r\I COST VARIANCES - Continued Payroll and Benefits - March had 5 weeks causing the hourly payroll to be high. Clearances for benefits were above the budgeted ratio. Miscellaneous - Unclassified was $25.4M unfavorable as the annual van physical charges cleared in March. T.I.&D. - A $175M unfavorable variance in "ad valorem" taxes from a prior period adjustment caused the unfavorable variance. A VAB.0001190539 i ,;n M t i,| h . I* lit ...................-| #|V. i * :' : | ' - : ML' I t.i H a| i. '. j VINYL - P. J. Kober, C. J. McDonald General The small blend tank piping was modified to improve resin removal when transferring 5305. This is part of the 5305 Contamination Reduction Program. 2. A recovered VCM receiver condenser was hydroblasted to improve inerts removal. 3. The resin raw materials in the 744 account were valued at $367.5M. March 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), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime % 40.2 1297 952 30.7 92.0 58.6 93.5 97.4 Reactor Downtime Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks, new module rinse/charge water conflicts, low steam pressure and inclement weather) 229.7 1262 5434 29.9 91.6 78.0 95.8 96.4 Hours 230.0 Maintenance downtime (hydroblast D741, D744, and D745 reactor shells and condensers, repair D700 and D742 agitator seals, D745 condenser gasket, D744 agitator motor, replace #7C transformer, no place to dump while making fluid bed repairs, and miscellaneous instruments and valves) 363.2 Total Downtime 593.2 A . ............................................... . . .............-V' i.................tJwrir-ir"Til TT-ri-rti nr I ........................................ hw VAB.0001190540 ....................vV**in* mum, j,.. r VINYL - continued. Reactor Downtime - continued Drver Downtime % of Total Downtime Reactor limited production 66.6 Operational downtime (centrifuge plugging, dryer cleaning, activator transfer problems, checking dust collector socks for leaks, pulsing socks, natural gas outage, and flameouts) 10.4 Maintenance downtime (#7C transformer, repair broken baffle in #6, fluid bed hot water line, fluid bed #7 and #8 screeners, fluid bed screw feeder motor, fluid bed feeder valve, #5, #7, #8 transfer line leaks, and various activator and centrifuge repairs) 23.0 Kev Maintenance Work - D. A. Miller, J. B. Hegwood Reactor Area Reactor 700 was shutdown for a seal change during the month. The seal was changed due to an excessive oil leak that was caused by the failure of an "0" ring. The Dura seal unit was cleaned during this time due to the presence of metal flake found in the seal. Reactor 745 was shutdown and the bottom condenser gasket was changed. A new flexitallic spiral wound gasket was used in place of the monel jacketed type which had failed. The cause of the failure is due to the smoothness of the gasket surface on the reactor and condenser flanges. The monel jacketed gasket also has a very smooth finish which allowed it to slide around under the condenser. However the spiral wound gasket has a serrated surface which will help it to adhere to the smooth condenser and reactor flanges. Reactor 744 and 741 were shutdown during the month for hydroblasting. The shell and condenser was hydrobiasted on reactor 744 but only the shell was hydroblasted on reactor 741. The condenser on reactor 741 had to be drilled due to the excessive hardness of the plugs in the condenser. The lid was also changed on reactor 741 due to a gasket surface problem. This completes the changing of all condenser lids that were identified with problems. Reactor 742 was shutdown for a seal change during the month. The seal was changed due to an excessive oil leak. The seal was in service for 21 months. Number 6 dryer was shutdown for repairs to its baffles. One baffle was pulled, repaired and reinstalled on a new frame. A L i. .. ' -i i'i : h- t |,l11 L *r I n nui 11 m mw nnnwiwn--i iiwnor.r-nitriMWiimtfi'Jrwj "u VAB.0001190541 VINYL - Continued Key Maintenance Work - continued The New Unit preheater was hydroblasted due to a build up of Calcium Carbonate on the tube side. This build up had greatly reduced the efficiency of this heat exchanger. There were four major valves changed out in the Reactor area during the month. A :I ...................... < III S- .fHv4err: H*tWkJ>WWI NJfcjjpUlJi '-.Urfllft VAB.0001190542 >Ja\-. -isi et i iml.cTi. v. ' :j : :u.. e: i-' iI -d. 1 hi COMPOUND - J. E. Nickerson, J. B. Autrey General The first truckload of re-processed mill scrap pellets was shipped in March. We are awaiting feedback from the customer before any more pellets are re-processed. A performance test of the Line I Sweco screener was conducted in March due to complaints from a customer earlier this year involving a rarely made, small cross section stringer (undiced pellets). The test revealed that the screener removed the normal type stringer very efficiently, but had difficulty in consistently eliminating the stringers in question. It was determined that increased operator observation of dicer performance is the best way to insure that stringers of this type never get into the final product. A plan to implement this is underway. The Compound Department worked without injury in March. The topic of the monthly safety meetings was health awareness. Two accident investigation teams concerning the Compound Department met in March. These investigations pertained to an operator injuring himself while operating a valve in the P-1 area, and to a near miss incident where a phthalic anhydride (PA) pipe ruptured. A representative from the Stepan Company, a PA supplier, visited to discuss a near miss incident involving one of their cars. During our preparation to off-load the car, some hot PA spewed out of the dome-lid flange. The lid seal failed because a sampling device had been left in the car during loading. He assured us that steps were being taken to prevent this from recurring. Operating Compound Production Davs _________Production (M Lbs . 1 Month Ave./Dav Fiscal Y.T.D. Line I Line III Line V Downtime Total 31 31 31 2388 3922 1393 7703 77 127 45 Hours 12478 21501 6402 40281 Line I - Product Changes - Transfer Problems & Limitations - Dicer Problems & Maintenance - Miscellaneous Maintenance 88 20 9 9 A iplfr-nrv-fj'i = 44-1+:H"; -"i i VAB.0001190543 `i-1*.** r .1 r-:i COMPOUND - continued Line III - Product Changes - Transfer Problems & Limitations - Quality Problems & Control - Miscellaneous Maintenance - Mill Joint Maintenance - Dicer Problems & Maintenance - Sweco Maintenance Line V - Welex Problems & Maintenance - Product Changes - Miscellaneous Maintenance - W-P Maintenance - Quality Problems & Control 50 20 19 10 9 6 5 117 57 15 13 5 Operating Days Month Rigid Compound 22.3 4200 Downtime - Product Changes - Quality Problems & Control - Miscellaneous Maintenance Operating Days Month Plasticizer 30 1747 Production (M Lbs.) Ave./Dav Fiscal Y.T.D. 188 31182 Hours 42 17 13 Production (M Lbs.) Avg./Dav Fiscal Y.T.D. 58 10459 A mittbvQMm******v JumqciM VAB.0001190544 Kev Maintenance Work - D. A. Miller, J. B. Hegwood A new Phthalic Anhydride line for the plasticizer R1 and R2 was installed due to a leak that developed during heat up after the reactors had been shutdown. The pipe failed along a weld seam. A section of the pipe was sent to Cindy Gross for insepction. The Line V welex bowl was changed out due to a leak that had developed because of thinning around the dump nozzle. The old bowl is being sent out for repairs and will be ceramic coated to help prolong the life of the bowl. Line I was shutdown for repairs to its blender gearbox. This was done due to a suspected bad bearing and a leaking seal on the input shaft. The motor protection circuit was reevaluated for the Line III blenders and the fuses were changed from 90 amps to 150 amps to solve a premature fuse failure problem. All of the VCM tank cars unloading flex lines were pressure checked as part of an annual inspection. On two different occasions R2 plasticizer reactor was shutdown for repair to its cold water coil. Utilities - D. A. Miller, J. B. Hegwood The boilers were run on propane for two days during which time the eight inch Natural gas feed line for the boilers was repaired. This line had developed a leak previously and was temporarily patched. The line was replaced to complete the repairs. The boilers were run on propane for two days in order to empty the middle and east propane storage tanks. These tanks are scheduled for inspection early next month. Number 2 water well was shutdown and the plant was run on number 3 water well during which time the number 2 water well pump was repaired. The pump casing had cracked. -. iii &rtSt4fa -l WW'i'MN'.W* VAB.0001190545 i; : i-i #i*-i ai= w-^p4J-l3-.U" I ri-94*f vrHBrtrtT tirn--iwmi r ec-nt umibhimhpiii "iBi^nninmnci m-h . ENGINEERING - R. E. Polk, S. C. Hillman, V. L. Thornhill PROJECTS IN DEVELOPMENT - GENERAL Vinvl Control System Modernization Quad-S Control Consultants made a presentation of their findings to the plant. Project economics justification is being evaluated. Drver Baghouses Process Engineering and Mechanical Engineering personnel visited a bauxite plant in Little Rock, Arkansas to see a similar size dust collector in operation. Resin Contamination Reduction Recommendations for a raw materials filtration test were issued to the plant. The installation of the small blend tank contamination improvements was completed. Vinvl Product Silo Extension The design to extend the 600 series resin silos was issued to the plant and a copy was sent to GED for structural and windloading evaluations. Plasticizer Process Improvements R & D lab scale testing verified effectiveness of NaC03 as alternate neutralizing agent for plasticizer neutralization. Arrangements are being made for full scale plant testing in reactor R-3. 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NEWTO ,N S.C. HILLMAN ENVIRONMENTAL - F. G. Jeanson Water The BOD of outfall 001 was above the daily maximum 3 of March. These excursions were reported to the monthly average for March was below the permit limi However, the The excursions occurred when material from the plasticizer area that was not properly treated entered the process sewer system,. Once this material worked its way through our wastewater treatment syste i. the BOD and other wastewater discharge parameters returned to normal lev Procedures have been implemented to prevent this type of discharge in the future. All other wastewater discharge parameters were within NPDES limits for the month of March. We also passed our Bioassay testing that was completed in March. Air The NESHAP's quarterly report was issued this month covering activity in December, January, and February. Included in this report was the results from the annual 200 Valves in VCM Service Survey which was completed in December. A construction permit application for new dryer baghouses was completed. A meeting was held with the state to review this application. Permit board approval for construction is expected in mid-April. Waste/Offgrade Management March waste shipments included: One bulk load of separator oil to Stauffer Chemical One bulk load of floor sweep to Chem Waste Management One bulk load of lead bags to Chem Waste Management March offgrade shipments included: One bulk load and one super sac load of reactor culls to Sun Polymers One load of resin from pit #2 to Sun Polymers Sunerfund Results from samples taken by EPA in February are expected by mid-April. These samples were taken to determine the environmental impact of the 4 superfund sites located on the plant site. Duplicate samples were analyzed at Mississippi State Chemical Lab on five groundwater samples. A VAB.0001190548 j , r j |- Irl! ; i- : - r -p... | r;: i j ii , 4*--. L-- :f : it--:: 1 Environmental Pace 2 Continued Groundwater Permits for our current water wells in the Eutaw aquifer were received this month. These permits for our four water wells expire in 1999. However, the permits can be revoked when the state believes damage to the Eutaw aquifer could occur. A meeting was held with the state to discuss the above mentioned permits into the Eutaw aquifer and obtaining new permits for the Coker aquifer. SARA - Right To Know Vista hosted 20th Century Club - presentation and plant tour were given to 15 ladies in this club. Miscellaneous I attended a course on the transporation of Hazardous Wastes. A - ----------------------------- ------------------------ . r.........i tt nun hi rim riffnpn mu mi .! VAB.0001190549 11? ' -rV??. :i k1W I 'VHai: r|fchr.r:vr:h-4ii.i i^.vn.i- ENERGY CONSERVATION - D. A. Moore March. 1989 I. Energy Conservation Data A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU -1.43% -2.34% 2509.45 135.17 This corresponds to anadjusted CMA of and an unadjusted CMA of 52.27% 41.42% Fiscal Y.T.D. -4.40% -5.26% 2546.17 793.11 51.18% 39.67% II. Plant Energy Conservation Program A. Maintenance There were 19 energy related items completed in March 1989. All 19 of these items were leak III. Boiler Operation Boiler Combustion Efficiency % Mar..89 Fiscal Y.T.D. No. 1 No. 2 No. 3 ,u 83.37% 83.05% 83.71% 83.49% 83.16% (1) Boiler #1 was not operated during the month. A I* nilrlH'n * *T '7W I i-* -inn n-piril ~ f j||' mt m m 11 ill I VAB.0001190550 HUMAN RESOURCE REPORT PERSONNEL - J. E. Beall EMPLOYMENT Henry Rogers, Jr. - New Hire Dale Wilbanks - New Hire Jimmy Winders - New Hire Victor Elliott - New Hire Mark Williams - New Hire Mark Whitehead - New Hire Denton Cunningham - New Hire PROMOTIONS/TRANSFERS Robert Stone promoted from Maintenance Helper to General Mechanic "B". Freddie Franks promoted from Maintenance Helper to General Mechanic "B". Jeffrey Sykes promoted from General Helper to Lab Trainee. Dave Hollis, Director of Plant Quality Development - Aberdeen, transferred to Lake Charles Chemical Plant as Quality Management Coordinator. RETIREMENTS None TERMINATIONS/RESIGNATIONS None TO/FROM T.F.AVE OF ABSENCE None A -'t _1v I *i: i.r?: . i . : <.iirTifilit-: r r< ; -i VAB.0001190551 "-=1' *' " k: I- 1- -^1i-..................................... I i'U-'.-'- it. -r, : Aberdeen, Mississippi Salaried Employees Hourly Employees 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* 176 255 MARCH, 1989_________________ MONTHLY PERSONNEL REPORT Minority Employees 7 Hourly 67 Total 74___ % 9% 38% 29% Hourly Min. Hired ____1 % Min. Hired 14 Hourly Min. Term. 0 % Min. Term. 0 ./ EMPLOYEES MIN. EMP. 16 7 % MIN. 44% NEW HIRES 0 YTD + 0 TERM. 0 YTD TURNOVER YTD 0 00 19 7 37% 7 70 0 0 0 40 10 25% 0 00 0 0 0 23 5 22% 0 00 0 0 0 40 26 65% 0 00 0 0 0 * 33 10 30% 0 00 0 0 0 5 2 40% 0 0 0 . -Q_ 0 Number of Applicants: Month _______5______ Year to Date 21 APPLICANT BREAKDOWN: // Minority // Female i 1 % Minority % Female 20% 20% *Includes 1 Co-Op Engineer. v- Hires (Hourly): Month ? Year to Date 7 Terminations (Hourly): Month 0______ Year to Date 0 Overall Turnover 0 Projected Annual Turnover 0 -1 - : : h- : . ^|.,r ..--r.v =. ...... i. ............................................................................................................... . . VAB.0001190552  OJ EH Q* Ht 4~> >-< J0Z0 cd 4J i--l 4cJd w *4H HO 0 K cd *opQUC> co 0 cd 0) dO0A^' -r <CCuOO ol tr*! 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E. Little Safety There were no safety instances this month. Cost Savings Savings due to competitive bidding were $4,162 for the month, and $37,654 for FY1989. Savings due to prompt discounts were $2,939 for the month, and $11,770 for FY1989. Meetings Mike Swierc, Pat Wells, Dean Honeycutt, and Jack Little met with John Farrier, S & T - Traffic, on March 13 to discuss fleet requirements and Pat Wells and Jack Little met with Phil Foote, Plant Manager at Premiere Polymers, on March 29 to review warehouse procedures. Jack Little attended the VMS meeting in Lake Charles on March 15. Implementation is approximately three months behind schedule. Jack Little met with Fred Williams, Polymers Business Area, on March 30 to discuss new cost reports for compound. Mike Swierc was in Houston March 29 - 30 to attend the latest CQIP Team Meeting. The Stores Team made a presentation to RWS' Natural Team on March 10. It has been determined that educating the storeroom users is the most critical first step to improving storeroom operations. 'l-'jp.: . i ,!i j:1}.. -i ` . ' -IT--<1,1^! n-fl- I |J nl: 1 wi In - - fi V'-MM ***: mmV.* .. . r.! r. . -b'n J tI v I11- !* '-tt VAB.0001190554 Ji-i-- h , , -.in.-, if. / ^11 -?! ;1| -1 'v ' s H.l'-: -.-hi-: I-' 'i- LABORATORY - H. G. Coleman A. Safety - There were no injuries in the Lab this month. The safety meeting this month featured a presentation by Ginny Belk, Plant Nurse, on blood testing - what each test represents and how to interpret the results. B. Customer Relations Customer Contacts 3/6 - B. J. Harrison attended an extrusion trial at Vinylume with C. 0. Yoder. 3/7 - B. J. Harrison visited Thermal Industries to discuss processing problems with RP-34 wht 142 on their new K-M extruders. 3/23 - Brian called on Silverline with M. Eramo to discuss variability with OKCity-produced 5385. Requests for Corrective Action There were no RCA's received this month. Customer Problem Reports Date 3/3 Customer Flexible Technolog Abbeville, SC Product 46801 Blk Reason Low hardness values. 3/9 Intek Hastings, MN 180-31 Wht 138 Short stability. 3/21 Nibco Greensboro, NC 3/31 Vycom Scranton, PA 5265 RP-421 "Silver streaking", blistering on surface of fittings. Bolts in dryblend. Waivers Issued There were no product waivers for the month. h ........................................................................................................................................ . ilHIIIHHtf ....... ...... VAB.0001190555 ^ LABORATORY - Continued C. RVCM Summarv RVCM of In-Process Samples The following is a summary of residual VCM results. None of the reactor daily averages exceeded 400 ppm RVCM during the month of March, 1989. Reactor Slurries Drier 5265 5305 Number of Samples Average RVCM, ppm 946 158 0 0 99 0.448 RVCM of Shipment Samples The following is a summary of the residual VCM analysis of shipment samples for the month of March, 1989. Product Number of Samples Averaee RVCM. ppm 5265 5305 5385 5395 5415 5465 Dry Blend Debox Pond 3 138 58 3 55 0 27 16 5 0.230 0.284 0.312 0.064 0.050 -- 0.111 0.279 2.004 D. Resin Process Capabilities 5305 5385 5395 5415 Bulk Density Inherent Viscosity (vs. 0.715 - 0.754) 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) 0.95 1.58 (0.75) 3.42 3.83 1.44 7.00 -- 1.78 -- -- -- -- 1.31 0.63 -- 4.11 -- 2.00 3.78 -- 2.41 1.00 -- -- 8.5 0.52 1.22 -- 4.56 -- 2.67 1.00 -- 0.65 1.33 4.30 -- 0.0 Average particle size, microns 146.2 166.0 149.9 NOTE: There was no 5265 production this month. 0.26 0.52 -- 6.67 ------2.67 2.83 0.33 2.20 1.17 2.39 1.61 1.8 173.1 K I- - L p . . _ . p- r : "t -.1 -I^' : JJOM1 iv :i- A..................i , j.- -41 M rl !ifc '! < if.......... ................................................................................. . :vjb :q-r+|(r?3f :h-: : : I; . f rifHiiTiurr.i^J'f I-: : >f+H;! r|,i VAB.0001190556 > .......... i . ' -I IPU"_- hll*S:tl: LABORATORY - Continued E. Compound Quality Summary Hardness Color/Clarity Hard Particles Contamination Dicing Adjustments M Lbs. m 89.0 -- ------------- Total 89.0 (1. 16) ---- - *-- -- - --* <1. 16) Rejections M Lbs. 111 _ -- ^ 23.4 105.6 9.9 7.4 146.3 ^ ^ V B (0.30) (1.37) (0.13) (0.10} (1.90) F. Drv Blend Oualitv Summary Contamination (Color) Fusion Torque High G. Compound SPC Test Results 38401 - Hardness - Specific Gravity - Hard Particles 35031 - Hardness - Specific Gravity - Hard Particles Mill Temperature, F Oven Temperature, C Rejections M Lbs ___L%1_____ 2.4 18.8 Total 21.2 (0.06) (0.45} (0.50) n X 3r 59 84.14 0.54 59 1.383 .006 58 21.66 3.62 59 50.53 0.90 59 1.384 .007 60 5.02 2.13 59 324.6 1.8 All Readings 204. * .... * ........... i null,i VAB.0001190557 JCrJttjl-^p^^ifyrrrK i i- pto-l-h". .v-i-ih ' LABORATORY - Continued H. 5415 Control Resin Test Results n Moisture Drytime Particle Size - 60 mesh - 80 mesh - 100 mesh - 120 mesh - 140 mesh - 200 mesh Pan Bulk Density Color - L A B Flow Time, sec. Hard Particles, 7 min. ^Inherent Viscosity 62 58 62 61 62 61 62 60 62 32 53 47 46 34 62 60 * 5305 control resin X 0.169 4.90 1.62 35.42 32.68 17.03 7.33 4.69 1.26 0.4999 100.46 -0.04 1.95 7.29 6.45 0.7487 3J3T 0.024 0.33 0.53 4.58 1.05 1.83 1.20 1.51 0.42 0.0045 0.34 0.22 0.45 0.66 1.76 0.0062 I. Miscellaneous 1. Dave Cox and Morey Osborne visited two vendors of slurry particle size analyzers (Malvern and Coulter) this month. They are close to recommending one unit for purchase. 2. Brian Harrison investigated technical issues for Thermal Industries (water in extruder vent tanks), Polytex (varying gloss), Intek (poor Brabender stability), and Silverline (variability of OkCity 5385 heat stability). 3. Brian replaced Sunolite 160 with Theolub 165-010 in all appropriate dry blend formulations. 4. Brian performed color matches for one rigid and two flexible formulations this month. * M ------------------ -----------------i-t- n -r n- l i ifinniT mrirrr " .............................. hi munim i in'"in iMoniiMinniiMiin--iii 11 nn i nm jiiti t i tdi in i i i mm > mi 11 VAB.0001190558 Berate tit+*nriT*-i w :nr..,.- n*.. vi- ABERDEEN CHEMICAL PLANT INJURIES sjiynrNt jo yjsnnN lit: . .imtti ni.,>:*! r : ,iJ' ?! : r k- , r.- ........ i. i-tTH- * :iir. -hi->. VAB.OOOl190559 iLrt'i- .< ' Jj|. : > A i --------- 12 MONTH AVERAGE ABERDEEN ENERGY CONSUMPTION MONTH ai/rua i 2\. " ! Id. :.i.: v 'ill" -,,*f 'rp "r-ifr P! 4.;^!. 1-r.' `esri^A.sili-.y 'JJi 'I : - .-b Ht-L-rfi ^ri: I'M ^ r^r VAB.0001190560 :n .i :Tnjlj. i j.i.-.. . 44~-i......... . .| .. RESIN Ship Date 3/08/89 3/09/89 3/14/89 3/15/89 3/21/89 3/22/89 3/28/89 COMPOUND Ship Date 3/02/89 3/03/89 3/08/89 3/09/89 3/09/89 3/13/89 3/14/89 3/15/89 3/17/89 3/17/89 3/20/89 3/21/89 3/27/89 3/27/89 SAMPLE SHIPMENTS MARCH 1989 Product Pond 5415 5305 5385 5385 5415 5385 Amount 4 X 1 lb. 100 lbs. 50 lbs. 50 lbs. 50 lbs. 100 lbs. 50 lbs. Product 416-5E NAT 416-21D NAT 48562 BLK 34431 NAT 419-19-B BLK 419-23 BLK 34311 NAT 419-12C NAT 38601 BLK 34501 NAT 16851 CB 50 14941 BLK 48451 BLK 48562 BLK 18961 NAT 416-5E NAT Amount 300 lbs. 300 lbs. 100 lbs. 250 lbs. 1600 lbs. 1600 lbs. 250 lbs. 1500 lbs. 100 lbs. 50 lbs. 100 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 150 lbs. Customer Wexford International J. C. Neiman (Export) Dupont Calzado Sandak (Export) Calzado Sandak (Export) Jampoo Trading Corp. (Export) Calzado Sandak (Export) Customer Storm Products J. C. Levardsen Fabryka Kabli Zatom (Export) Times Fiber Comm/Scope Superior Optics Northwire Inc. Feeda Training Co. Prestolite Wire Central Plastics Aeroquip Corporation VCFE Universal Plastics Inc. Storm Products A PLASTICIZER Ship Date 3/10/89 Product 108P -I I i I -! . i.ir-.r^i.rJT- '-`1 i 'nFf j~i*i p? f.-* Amount 5 gal Customer Blane Polymers L . . J ----- ... '.m i.tfi ^ .............................. **.*" 1 ! "I r I ...j;.I i. . ..I-. - .1 VAB.0001190561 * i*&?*'.:r. .. i.-o-.i.... SHIPMENTS BY PRODUCT - M LBS RESIN PLASTICIZER DRYBLEND COMPOUND NUMBER OF SHIPMENTS BY MODE: TOTAL MARCH 1989 29,502 258 5 ,628 8,001 43,389 FISCAL YEAR-TO-DATE 172,381 3,643 30,316 42,613 248,953 A d 1: Hii-r'1' h III I M- -I - - t 'i 1 .1 1 v p; !" r S-S'ill h'r ! ' -1. :i:ifc: i* 1.^4^ ' .m::: in - , ^5fc*: VAB.0001190562 .. r ... . . :tnp--ir; :t>i- ' ;-i . in* r 1 ^-*7