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To: R. T. Ferrell 4 A Interoffice Communication From: Date: Subject: *! Were December 17, 1987 ABERDEEN MONTHLY PROGRESS REPORT NOVEMBER, 1987 There was one first aid injury recorded during the month of November. As of November 30, 1987, the plant had operated 3,070 days or 3,971,292 manhours without a lost time injury. PVC resin production for November was 36.8MM pounds. Major downtime in the reactor areas was due to condenser drilling and hydroblasting of the shell on reactors 700 and 745, replacement of the condenser lid gasket on 745 and installation of Subpart V valves. Resin production year-to-date totaled 77.5MM pounds. The VCM efficiency for November was 1.02151 pounds of VCM per pound of PVC produced versus a 1.00756 standard. Year-to-date efficiency is 1.01393. Compound production for November was 6.9MM pounds. Line I and Line III operated thirty days and Line V operated twenty days during the month. Year-to-date compound production was 14.1MM pounds. Quality performance for flexible compounds was 1.0% off-grade of which 100% was due to mill scrap. "BC" production was 0.05%. Dry blend production was 5.3MM pounds for November and 10.4MM pounds year-to--date. Quality performance for the month was 99.5% customer grade. * 4 The plasticizer unit operated thirty days &n November to produce 1.9MM pounds. Year-to-date plasticizer'^production is 3.9MM pounds. I Attitude survey feedback meetings continued during the month. Each group has now had at least one meeting. Aberdeen's 34862 compound has been approved by AT&T for "skip lot testing". Previously, AT&T "approved" each production run. .Favorable results from "skip lot testing" will allow us to pp^gress to "preferred supplier" status. Total energy consumption for November was 124.579 MMM BTUs. The energy consumption per pound of product was 2443 BTUs, resulting in an adjusted CMA reduction of 51.7%. The adjusted CMA reduction for fiscal 1988 year-to-date is 53.9%. VAB.0001191122 mm mr IfMW iWMpJ*!*'' imqm mmmmrm in IE--i R. T. Ferrell 12/17/87 Aberdeen Monthly Progress Report Pace 2 The total plant variable cost variance for November was $850.8M unfavorable, resulting from an overall unfavorable price variance of $818.9M and a net unfavorable efficiency variance of $31.9M. The total fixed cost variance for November was $72.5M favorable. J. W. Ware rah A I--<! -l-'rAlT' -ill1-:- U! l -"W'+nlByHp.Uj Wf, :! ;u s|i^ *jfj. i* *, n. < |t;-fc-r ifT VAB.0001191123 DISTRIBUTION COVER LET1FR HOUSTON: J. D. BURNS X R. E. LEHEKUHL R. T. FERRELL J. J. LANGFORD X R. E. SWANMJWSKI D. F. HARMAN X H. R. FLAMMER R. R. SMITH K. J. SOGERS D. H. SANDERS PONCA Cm: S. E. MDGUIRE R. L. POE X H. J. HALL OKLAHOMA CTIY: C. M. STARKS HARRY GARRISON LAKE CHARLES VCM PLANT: DICK CONRAD LAKE CHARLES CHEMICAL PLANT: J. A. DEBERNARDI T. H. HUFFMAN X LAKE CHARLES LAB PLANT: L. R. BAUER BALTIMORE: R. W. SEXMXJR X HAMCND: J. B. MAE ENTIRE REPORT COVER LETTER AND QIP X X X X X X X X X X X X Safety Section and X BLANE POLYMERS: EKEMEERE POLYMERS: ABERDEEN: E. L. KTESCHNICK P. L. FOOTE JF, JW, DWH, PJK, TEL, RAF, KLF, RAM, VEM, HOC, CWT, R VLT, J] RBN A I-E,.. ,- , TT.jWH.:^rr^i^^ ,!f?,un *-' IH'VMWHI nmFMFn-'1 '' "'l ' J-< ntnirfi!U^i *m VAB.0001191124 *1 i'iikw *1 SAFETY - K. L. Fogg, J. V. Uptain Occupational Injuries November Fiscal Y.T.D. 1988 First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 1 __0 1 0 0 3 0 3 0 0 Fiscal Y.T.D 1987 A Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 0 0 1 0 0 0 1 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 01 00 00 12 00 00 00 13 Non-Occupational Injuries Lost Workday Cases Days Lost Safety Record Last lost time injury 7/5/79 Days since - 3,070 Manhours since - 3,971,292 On November 30, 1987, the employees of the Aberdeen plant completed 3,070 days with no lost time injury. Topics for the plant safety meetings during the month included: Vinyl Operations Cold Weather Safety, Annual Fire Training, VCM Tank Farm Operations Safety, Home Safety, Contractor Safety, and Maintenance Weekly Safety and Job Reviews. Flow tests were performed on the plant firewater pumps. Fire training for Compound, Vinyl and new employees was completed in November. VAB.0001191125 -y-i-! I'.. i. Er'tlli. + | J' I't*'% s,.. -;i^ *. 'T-f S - ,|-h-- iHjfri | : si |.-r11 ! :rci' ii a -b- -! r <*-w .............................i.s i-i%* it-* | . > *i- Ih.................... .. , SAFETY - Continued Routine dosimetry results for the month are as follows: Chemical Number PEL Percent > Number PEL Percent VCM 72 97.3 Lead 11 91.7 Total Particulates 5 100.0 2 2.7 1 8.3 0 0.0 One of the two VCM overexposures was without benefit of respiratory protection. A 1 : '! -.I 'lie - i - f' i,,-< i i;! 11 'ff-i r i : y- *!. Piu, VAB.0001191126 ^i; th-4i;-.TM.-fc!irt-f:vi: . spa ixittnu?*-- h **'L * irHlTrT' |-JlJ/`,l,n",-- > f 'l- i-i - f . Ji-if A + OSHA RECORDABLE ABERDEEN CHEMICAL PLANT INJURIES TOTAL INJURIES O sj/unrNf jo ysewriN VAB.0001191127 i ?ti j-nj^pn i .. . >: f- , -r mi ittfcfc-.-- - ..wpi=>; . . -t+7,- QUALITY MANAGEMENT PROCESS - D. W. Hollis, R. B. Newton Dave Hollis and Rendell Newton continued acting as facilitators for the Attitude Survey Feedback meetings and began summarizing attitude survey results. Dave Hollis began work on "cost of quality" calculations for the vinyl unit. Rendell Newton prepared a summary for preparing a quality implementation plan. Individual departments will begin work on their implementation plans in January. A VAB.0001191128 VINYL - P. J. Kober, J. M. Edwards Safety The Vinyl and Yard Departments worked without any reported injuries during the month of November. Shift safety meeting topic for the month was Winterization. Quality Improvement Process The CVR employee attitude feedback meetings continued in November for the Yard and Vinyl Departments. The meetings are still in the problem identification stage. The Vinyl and Yard Department Management Natural Team met for the second time in November. The Yard Department's Team met once in November. The two solutions which this Railcar Team developed are presently in Process Engineering. The Team expects to review the Process Engineering work in December. 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 November 36.8 1227 877 29.2 90.9 8731 73.2 30 Y.T.D.(Fiscal 88) 77.5 1271 1839 30.1 92.3 9248 71.7 61 Reactors The reactor stream factor for November was 90.9%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 52.4% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size information before charging, lines plugging, inspecting reactors, and the lack of blend tank room to dump a reactor. 2) Maintenance Service Downtime: Accounted for no downtime because the cleaning of the reactor AMS injection ports and inert vent lines was accomplished while the reactors were normally down for other reasons. A VAB.0001191129 t ii si. r j- f'! U 1 : 1:-: 1 |Hh -= H**1 In**1.- Ub;^H Jn- :irf.ftp rl-.=h. 'in i-pl- . rrt* I ! - - I'-h -.E- -J: i :+;i VINYL - Continued Reactors - continued 3) Maintenance Repair/Revision Downtime: Accounted for 47.6% of the total downtime and a majority of the time was due to drilling the condensers and hydroblasting the walls of 700 and 745 reactors, changing reactor 745 condenser gasket, changing reactor 745 bottom manway gasket. Subpart V valve addition project, and welding leaks on D400 jacket. The dryer stream factor for November was 73.2%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 82.0% of the total down time. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 6.1% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems. 3) Maintenance Repair/Revision Downtime: Accounted for 11.9% of the total downtime and was due to repairs to #4 and #5 star valves, capital improvements to # 4 dryer, #4 and #7 Bird bearings and gearboxes and a feeder valve on the fluid bed dryer. Product Quality Summary Resin Type Prime % of Total "B" "H" Production 5265 5305 5385 5415 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 2,552,332 4,971,660 14,399,832 12,705,955 1,160,650 -- -- -- -- 35,790,429 -- -- -- -- -- 815,620 -- -- -- 816,620 -- -- -- -- -- -- 40,922 172,540 213,462 6.9 13.5 39.1 34.5 3.2 2.2 0.0 0.1 0.5 100.0 Quality performance for November was 99.4% customer grade with 0.6% "H" grade production. A r --i--"-!'. I : z-r- :-J v `MV H & 5-^ -Fs- : I- it#:L 'jS 4- VAB.0001191130 VINYL - Continued Product Quality Summary - continued A total of five railcars were shipped as "B" grade during the month which represented! 3.9% of the 127 total resin hopper cars shipped Load Date Ship Date Car No. Customer Product Reason 10/27/87 11/05/87 ACFX 52783 Customer Vinyl TX Debox Quality 10/30/87 11/06/87 PTLX 41648 Wexford, WI 10/25/87 11/10/87 PLCX 43705 Silverline, NC 11/08/87 11/17/87 VIPX 45713 Wexford, WI 11/11/87 11/17/87 ACFX 53666 Western AG, TX Monthly Variable Cost Performance Debox Quality Debox Quality Debox Quality Debox Quality Variable costs for the month were unfavorable at $649.6M resulting from an overall unfavorable price variance of $527.7M and an unfavorable efficiency variance of $121.8M. Resin variable cost for the month was 23.917 cents/lb. versus the budgeted 22.102 cents/lb. The $527.7M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $564.2M, offset by favorable natural gas pricing of $14.8M. The $121.8M unfavorable efficiency variance can be attributed mainly to an unfavorable variance due to VCM, $97.2M. VCM efficiency for the month was 1.02151 lbs. VCM/lb. PVC versus the budgeted 1.00756 lbs. VCM/lb. PVC. Energy Performance/Progress 1. Plant energy performance for November was 2443 BTU/lb. General 1. Resin raw material in the 0744 account totaled $264.8M. i A( ........ 1 >|r -r iS ` t---- 'f i vi,:r Kp-njT- iK-*:-i_n:n ' VI-.IW' : . -"! !. 1 i- *T ;1 t * .. J VAB.0001191131 rjv r; fH . . n "H.rt COMPOUND - C. W, Turner, J. E. Nickerson A The Compound Department worked without injury in November. One near miss occurred when a Gump dry blend screener was overpressured. An investigation team has developed several recommendations (including regular testing of the relief equipment) which are being implemented. November's safety meeting topic was Fire Protection and Home Safety. Quality Improvement The Compound Department Superintendent's Natural Team is meeting regularly to identify quality improvement priorities and support the work of individuals and teams. Some of the natural team meetings include the shift supervisors. Development of working control charts continues to be a department priority. This month operators continued to work on calculating control limits for the charts they maintain, and on developing control strategies. Line V operators started a new chart in November monitoring the hard particle count for Line V production. The Compound Product Change Team has begun implementing some revisions to product change procedures. Work continues to develop and/or purchase tools specifically designed for product change jobs. Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line III Line V Total 30 2128 71 30 3604 120 23 1195 52 6927 4384 7710 2002 14096 Line I operated thirty days in November at an average rate of 71M pounds per day. Major items affecting production efficiency were: product changes, 56 hours; quality problems, 18 hours; Banbury temperature controller problems, 8 hours; dicing system problems and maintenance, 8 hours; and housekeeping, 4 hours. Line I was down for sixty-one hours due to failure of the Banbury gate activator. Line III operated thirty days in November at an average rate of 120M pounds per day. Major items affecting production were: product changes, 51 hours; mill and hydrotherm system maintenance, 11 hours; and quality problems, 5 hours. Line III was down sixty-nine hours for repair of the main drive and coupling. Line V operated twenty-three days in November at an average rate of 52M pounds per day. Major items affecting production efficiency were: product changes and startup, 25 hours; twin screw maintenance, 24 hours; quality problems and rework, 9 hours; and pelletizer problems and maintenance, 3 hours. Quality performance for flexible compounds was 1.0% off-grade of which 100% was due to mill scrap. "BC" production was 0.05%. VAB.0001191132 I I' |C:. : .. < -**,* '-I**: Pf-HHl VJ'> ih jj|::. j-l-ry-t i;j 4. V k . . I | | i 'i'-T 4.1. COMPOUND - Continued The raw material requirement for flexible compounds was 1.01928 pounds of raw material per pound of compound versus a 1.01198 standard (YTD is 1.01147). The variable cost variance for compound was $112.0M unfavorable with $131.4M unfavorable due to price and $19.4M favorable due to efficiency. The efficiency variance due to product mix was $21.5M favorable. There were no major compound raw material efficiency variances. Total compound inventory rose 1.0MM pounds in November to 5.8MM pounds. Dry Blend Month Average Operating-Day _______ Rate______ Fiscal Y.T.D. Production, M Pounds Operating Days 5346 30 172 - 10369 61 Dry blend operated thirty days in November at an average rate pounds per day. Production included 80172C, 80273G, 90172D, RP-200, RP-421, 180-31, 269-69, 269-151, 269-164, 269-192, A10-001, RP-201T, 317-115, 317-129, and 269-66. of 178M RP-100, 290-61, Dry Blend production was hindered by: product changes, 45 hours; quality and lab problems and normal Q.C., 30 hours; Welex maintenance, 30 hours; transfer system problems and maintenance, 22 hours; problems and maintenance, 18 hours; Orbitran, scale and charge system maintenance, 18 hours; and cooling blender maintenance. 7 hours. Quality performance for the month of November was 99.5% customer grade. The raw material requirement for dry blend was .98736 pounds of raw material per pound of dry blend versus a standard of 1.00489 (YTD is .99482). The variable cost variance for dry blend was $68.8M unfavorable with $134.6M unfavorable due to price and $65.8M favorable due to efficiency. The efficiency variance due to product mix was $36.7M favorable. Major raw material efficiency variances were Liquid Methyl Tin Mercaptan at $13.0M unfavorable and Titanium Dioxide at $23.6M favorable. Plasticizer Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 1904 30 63 - 3922 61 Plasticizer operated thirty days in November at an average rate of 62M pounds per day. Production included 61OP and 108P. VRP production totaled 114M pounds (6.4%). l1---- *. ' - 4-. ! ' -.j. . ;i r.. sfl lj -I .fc1 a.-xSJ-.sFi.T .;! J ! iSfiJS*#.:. . I A^i tT-Hvwdtr 'll.' . ^!- I I I In ' ^J-! h-. Cf : s-'-rrl- n r -r < VAB.0001191133 j : .1 . - COMPOUND - Continued The raw material requirement for plasticizer was 1.11186 pounds of raw materials per pound of plasticizer versus a 1.10057 standard (Y.T.D. is 1.09681). The variable cost variance for plasticizer was $20.5M unfavorable with $25.2M unfavorable due to price and $4.7M favorable due to efficiency. There Were no major plasticizer raw material efficiency variances. The efficiency variance due to product mix was S.2M unfavorable. Energy Compound Dry Blend Usage (BTIJ/Lb.) Actual Standard 1803.5 730.4 1868.8 1758.00 720.0 1550.6 A : r i. s- - --I *r V ft! - I' . : or I? j --il' --,H ?t I'.- I 14. VAB.0001191134 tt-Mrltll-b rn I. <ck ' 11 '-i-T"t:h ..t: * .*u i;.. j;:.i M-- -A- MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - D. A. Miller Safety The Maintenance Department had one first aid injury during the month. Vinyl Both 700 and 745 reactors were hydroblasted and the condensers were drilled. The condenser lid gaskets were changed on 745 and 400 reactors and the bottom gasket on 744 condenser was changed. There were no reactor seal failures during the month. The following major valves were replaced or repaired during the month: - 700 Polyvic Ram valve was pulled and cleaned - 745 charge water valve - 744 sewer valve - 400 recovery valve - 500 evacuation valve - 744 rinse water main supply and cleaning to reactor shell valves - 742 chem wash main supply and cleaning to shell valves - 300 and 400 cooling water control valves were replaced. The slurry screener for the 745 dump system was revised to eliminate a plugging problem. The following pump seals were replaced in the vinyl unit: - South chem wash pump, old unit - New unit south blowdown tank transfer pump - Old unit "B" recovery compressor outboard seal The following major work was completed in the Vinyl dryer area: - Replaced #7 Bird centrifuge gearbox - //I dryer dust collector pulser gearbox - #5 dryer dust collector star valve was overhauled. A r* >1* + . I- *| H-r " lb- -K1 !A1h' VAB.0001191135 tr hiT"r-,:?q . ;j ' = i : l-ri- Tf - . r ' i n* i- MECHANICAL DEPARTMENT - Continued Continued - Replaced the motor on #4 dryer exhauster fan. - Assisted with startup of #4 dryer modifications. The winter preparation work is in progress with all major items near completion. All windbreak shelters, steam tracing system repairs/ revisions and instrumentation/electrical winterization work is complete. The insulation work is continuing with completion scheduled for December 16. Compound, Dry Blend, Plasticizer The Line III FCM motor inboard bearing failed and was repaired. The Line III mill backroll drive inboard coupling failed and was repaired. The Line I Stewart-Boiling mixer drop gate hydraulic actuator failed and was repaired. The DC drive for the Line V compounder had an electronic component failure. A temporary repair was made and parts ordered for permanent repair. The north Gump product screener bowl failed from an overpressure condition. The bowl was repaired and new relief valves were installed on the bowl. The product blower relief valves were pulled, checked and set pressure lowered. The #2 Welex mixer shaft, blades, bearings and seals were replaced. All winterization items for the compound and plasticizer area have been completed. Utilities Problems with the Pall air dryer pressure drop and poor dew point performance were identified and solved. Level alarm modifications were completed on #1 boiler and the air and instrument lines were relocated to improve access to level switches (safety item). The Yard trackmobile was damaged by the railroad switching crew. Repairs are in progress and are scheduled to be complete by 2/15/88. The #5 fire pump engine was overhauled and put back in service November 6. The failure was caused by severe vibration due to mis-alignment caused by the foundation settling. GED is in progress on a design to restore the foundation. A ' * i: i il` ~ir t"" I-;-': -II-I * > > TIM I ill i II V * il-fri I- i ir-lt .1' : i'f .PTfi lr i- i-1" -.c.| . 4 nyi fca -I "U \! ! Mil *! 11 vG|- >: A-? ; r *>r. ikl .-Jl VAB.0001191136 MECHANICAL ENGINEERING - R. .................. I ii II II I I II I I I E. Polk AFE F596/A717 - Reactor Heat-up Loop Piping pre-fabrication is in progress and scheduled for completion in midDecember. Installation is planned for completion by March 1. AFE F786 - Resin Quality Improvement Design at Litwin is 85% complete and scheduled for completion in early January. Site preparation is in progress and scheduled for completion by December 14. Firewater modifications are scheduled for the week of December 28. Drilled pier installation is scheduled to begin the week of January 4. AFE F587 - Laboratory Addition Design is Mechanical December. by May 1. complete and bids are being requested for installation. and electrical construction contracts will be awarded in Construction is expected to begin on January 4 with completion AFE D707 - VCM Unloading Fire Protection Design is in progress and scheduled for completion by February 1. Installation is planned for completion by May 1. AFE D667 - Propane Tank Farm Remote Operated Valves Construction is 20% complete and in progress. Completion is scheduled for February 1. AFE G597 - Subpart V Compliance Installation is 50% complete and in progress the week of December 14. Completion is planned for PCB Elimination Two pad-mounted transformers have been retrofilled and twenty-three pole mounted transformers have been replaced or verified as non-PCB. A total of twenty-two remain to be sampled. This will be completed the week of December 14. A I- .* : i];. -I ...{ IS. 1 I-.1 - .. .h-p -a- .. I............ I. | 7 I'r,:,.J. . .| ................i|Jp.|..j| i- ' iif f ' -f > t VAB.0001191137 : hi! i?t 'I :' > i tn |.j .. . . p :i..h . T- : . PROCESS ENGINEERING - V. E. Messick Resin Quality Improvement Project Review of the "For Approval" drawings for structural steel, piping and concrete was completed during the month. Review of instrumentation and electrical "For Review" packages are in progress. Site preparation work is in progress. Piping changes to separate the suspending agents (GH-20, F-50, Alcotex) in the new module were defined and material is on order. Resin Debottlenecking Assistance was given to PED personnel to outline ways to expand Aberdeen's resin production. Review of this scope of work and costs was delayed due to increased priority on 5415 production in D600. 5415 Production in the Old Module Assistance was given to PED personnel to develop the scope of work to make 5415 resin in reactor D600 and process the resin downstream of the reactor. 745 Temperature Control Improvement The trial temperature control system was used throughout the November 5305 run with good IV performance. The class "A" design for installing new temperature control systems on 745 and 700 is being prepared. Dual Catalyst Test Run The twelve runs for the dual catalyst experimental design were completed. A report is being prepared. Lines I and III Preblend Magnets A class "A" design was issued and a review meeting held for installing magnets to remove possible metal contamination from the preblend out of the blenders for Lines I and III. Reactor Condenser Revisions Recommendations were 500 and 600 to the shell diam approval. made on design of the heat The AFE request the replacement condensers for D400, surface area without increasing for this project was submitted for Plant Water Study The hydrologist obtained existing information on the Gordo and Coker aquifers in the area around Aberdeen. A bid pack for a pilot well was prepared. Second Fiscal Quarter Capital Budget The Second Fiscal Quarter 1988 Capital Budget was prepared and submitted. A J- -Mi I L- A.3. .L. _ 4PI-. i --r-ftt*. . .. *|! iPjH'if!* I W. < i T'll VAB.0001191138 . P- f : 1 I ifl-J . 4' . l. 'fJ n>' * l-j _ --I hK1 '""V . tor -iv r ii Mi-r. i f TP - A PERSONNEL - R. A. Miller EMPLOYMENT None PROMOTIONS/TRANSFERS Jimmy Autrey, Mechanical Engineer, LCCP, to Mechanical Engineer, Aberdeen Plant Bobby Chaffin, promoted from Maintenance Helper to General Mechanic "B" RETIREMENTS Jimmy L. Walker TERMINATIONS None TO/FROM LEAVE OF ABSENCE None IV I- iri: :ir. ..-4M ^ I , >!A .| - 4 l|-!lh|-;;*< ftif-'.- I.h^r4 r'Han^ti : . I-Hill.*---n ! :i ^ I IffijiiIf. VAB.0001191139 J l'|l l. | I *> m i I| . - I'-rtH v ............ |"(| | ith i n niTWIifiini~ipiiini~[iiiriT>irip i' Tt-mawim mi mi ** *-w=.. I!hr.,., .. - n ........................................... u i M i V -mi i-#^H H*f-n.igfrj Aberdeen, Mississippi A Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations U 166 239 0 0 DEPARTMENTS Warehouse Gen. Plant Maintenance laboratory Compound Vinyl Plasticizer PAR 16 40 24 JUL 32 5 EMPLOYEES 16 40 32 5 NOVE MONTHLY PERSONNEL REPORT Minority Employees # Salaried Hourly Total 1 66 73 10% &QZ 30% Hourly Min. Hired % Min. Hired Hourly Min Term. % Min. Term. g 0 0 EHP % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD 7 44 O 0 7 g 90 g0 9 23 0 0 5 21 00 g 28 g 0 a 26 g g 00 2 40 0 0 g 00 Number of Applicants: Month 21 Year to Date APPLICANT BREAKDOWN: # Minority 8 % Minority * Female % Female 4 Hires (Hourly) : Month g Year to Date Terminations (Hourly) : 9 Month 0 Year to Date 2 Overall Turnover 0 Projected Annual Turnover 1.3% * Includes 1 temporary employee and one Co-op Engineer. ...................... ...................... VAB.0001191140 eK H4 OS rH -3* o 00 Csl cn Csl X X w n 1--1 4 *4 4 Csl X X 6C 6U H u $! M*9 rH Cs| m n X X m m o o ** * 4 ltd X Csl CN X o H M_ 6 Awl X Csl o 4 ^ cn O * rH 00 * o o 4 o o 4 to m jo tH oo on *4 o 00 oo *6 rH o 00 oo 4 1--1 o rH cn as Cs| 4 cn os X * in c o U) H c XJ c (0 u & <0 a. uo 0 ac o H c >> 4 ooei o cwacn x u LO OS CN m os X cono mco * in n "O X X 4 Csl Ifi * 01 tt A) e o O ou too C rJ to XI w J! to C os n CO Cs| CN <r CO 00 tn Cu 9 * O Uo 3 ON cr^. 9 to 60 01 > U n *o 60 C H o u o 3 to 4J 60 in Cs| cn o CS| Csl cn CO 00 I 4#4 4 4 4 VIMj o CN m Csl CO cn Csl O Cs| CN rH h (A r^- Csl a\ rH 44 ON CN r^ O 4 o CN o C c >s 9a i *o OVERTIME AND ABSENTEEISM o> ^o 1* o tv X 9 00 01 e uo CM 0> 6c0 to u 9 X* O u o o^5 Ul n Csl ** 3M in to Csl rH 4* 9 CN CN Csl oo 00 60 CO uo 00 Csl CO 01 01 CN 9 Ui Ii 9 60 M9O C Ui UO 8 0>1 3 u 0) m o n O O n n n in r- in Csl m n Csj r- CN *44 4 4 * 4 (0 00 ^-| CN O o CN 00 o ON n 1--1 Csl 44 n r- cn o> CN o r-> rH n u4UeooJt rH cn 0 cOf) 0) 9 9 UB X H 01 i-J U* 01 > O 1 tf 5 w o O in n n n o o O CN Xx 444 CN r^. 44 60 as m 00 rH Csl *H <0 X O cn <r 00 o m u CN cn i"-* in cn U9 CN cn X tn AJ o Xx On n O Csl eg 4 * * X as X X <r r^ in X rH <3* eg u 01 tv > o AJ rH 1 rt cy i CD Ui s 0> > ao u ft 41 '* o > j-jJ vj U3 ut/3 g UJ H u2 0 w 2 6U4J .J DU3tf O 3 M ffl &u 4H U r g =3 O H a* BX 3 S* HpX L 'I f -i, 8 a. 'V a VAB.0001191141 t VF qb- ii .'...1 I I I\\F$| ]!.; -p.; -jSfJfgiqlf- JJ.U..,. H... > -! * |- 4Y ^1 "r nli; jf/".l-rmi": :4kl>lpMHJXa j;.. I -,t%AJ.4l . |i|-B-jrifcl- ' I- "- "*inf.IF-. -,i|.t+'.:fr'1d-|i t"1:1 'U3H 1#lt 'v-'-K.:^. ..T>'iKii-('iv in:. ..vi. pl, "-f I- - -: i- - - IP ., "i-v: .............. . r ., tf - i <:: ENERGY CONSERVATION - F. G. Jeanson I. Plant Operations Total energy consumption for November was 124.579 MMM BTUs. Energy consumption increased to 2443 BTU/lb. from 2278 BTU/lb. in October. An adjusted CMA reduction of 51.7% was obtained for the month. The adjusted CMA reduction for fiscal 1987 is 53.9%. II. Plant Energy Conservation Program Maintenance There were one hundred twenty-four energy related items completed in November. Ninety-eight of these items were steam leak repairs. The remaining twenty-six were steam trap repairs. III. Boiler Operation Boilers Combustion Efficiency % Nov., 1987 Nov., 1986 No. 1 No. 2 No. 3 83.6 (1) 83.2 Note: (1) Boiler number two was not used during the month. (2) Boiler number one was operated two days during the month. (3) Boiler number two was operated twenty-eight days during the month. * VAB.0001191142 Month ENERGY CONSERVATION DATA 1987 November Production, MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL 36.8 5.4 6.9 1.9 51.0 Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 64233 1020 65.518 1285 Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 5.9061 10000 59.061 1158 Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 0 92000 0 0 Total Energy Consumption, BTU/lb. 2443 Energy Consumption, MMM BTU Actual Unadjusted Actual Adjusted 1972 Base Period 124.579 103.530 214.446 CMA Reduction (%) Adjusted Unadjusted Fiscal 1988 Year-to-Date Performance 53.9% Adjusted 44.2% Unadjusted 51.7 41.9 1986 November 36.5 4.0 7.4 1.8 49.7 55391 1020 56.499 1137 5.6667 10000 56.667 1140 0 92000 0 0 2277 113.166 92.919 212.600 56.3 46.8 h -1 i t i'- :v.-i.'iii."'M4q 1S.L III >r: .| '"P ' '1 - rinittHijjfr- :N t: -; JJ- t Ift .? . I. . j|. VAB.0001191143 ' 1'11!' >-. K ' :cn .1 h- - j -.i-- ' :| !- ENVIRONMENTAL - R. A. Frohreich Water All wastewater discharge parameters were within NPDES limits in November. Two seven-day chronic bioassay tests were conducted on the process outfall in November. Test organisms were the fat head minnow and the water flea. No toxicity was detected in either test. Air A vinyl chloride leak resulting from a condenser lid gasket failure was reported to the National Response Center. NESHAPS The Consent Decree, which resulted from the settlement of alleged NESHAP violations, terminated November 8, 1987. General Two truckloads of waste oil were shipped to Stauffer Chemical Company. A r1 J 1 -- -t' " A il--n- i> r J-J*;- Hif**ip ,* lr * Citi. VAB.0001191144 i.. :n , 11,4,1,... ft,. .Lr0 -I r 1 '-i 4 TABLE I WATER COMPLIANCE WITH NFDES PERMIT PARAMETERS Oct. -- Ave. Max. Nov. -- Ave. Max. Dec. - Ave. Max. Jan. - Ave. Max. Feb. - Ave. Max. Mar. - Ave. Max. Apr. - Ave. Max. May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Flow GEM 1229 1264 1222 1430 BOD PM LB./DY. 5 77 7 100 15 212 22 378 GOD PM LB./DY. 28 433 39 553 43 607 65 1117 Sue. Solids PM LB./DY. 10 147 15 215 22 310 25 370 Digs. 0 8.4 8.6 7.4 7.9 NEL LB./DY. 1.8 2.9 1.4 1.7 pH 7.5 7.9 7.5 7.8 NPDES Permit Limits - Decenber 1 through April 30 Ave 32 431 Max 43 800 NPDES Permit Limits - - 1462 - 2713 Novenber 30 Ave. Max. 26 357 40 744 - 1212 - 2523 674 1396 > 6.0 13 6.0 - 9.0 28 674 13% y 6.0 13 6.0 - 9.0 28 VAB.0001191145 I't ; ' i; ''1 -I- ............... : - -! I| . : S- t.H :! . i Hf!11 4 -V LABORATORY - H. G. Coleman Safety A. Safety There were no safety incidents in the Lab this month. Harold Coleman and Brian Harrison received fire training. Attendance of other Laboratory personnel was not required. B. Customer Relations Customer Contacts Vinyl Therm - Brian Harrison accompanied Jerry Janes and J. Telford on November 15 to this customer to discuss color problems/targets and to observe trial runs. AT&T - Bob Stebbins of AT&T visited Aberdeen on November 4 to qualify us for their "skip lot inspection program". Blane Polymers - Joe Ford visited Aberdeen on November 17 to discuss quality control among other things. Harold Coleman gave the standard Laboratory presentation. Requests for Corrective Action Date Customer Product Reason 11/23 General Plastics Marion, IN 196-172 WOT 112 Chunks in dry blend. Customer Problem Reports Date Customer Product Reason 11/14 Dayton Extruded Plastics 269-151 WHT 145 High fusion torque. Stow, OH 11/04 AT&T Omaha, NE 34862 Gray Lumps on jacket wire; foreign contamination. 11/05 UTC Plainwell, MI 5415 Static/bulk density issues. 11/13 General Cable Kingman, AZ 5415 Oil contamination. 11/16 Condutel Mexico 34501 Gray Color. 11/17 Klockner Pentaplast Gordonsville, VA 5305 Contamination; railcar rejected. A VAB.0001191146 LABORATORY - Continued B. Customer Relations - continued Customer Problem Reports - continued Date Customer Product 11/18 HiTech Cable Corp. Starkville, MS 35851 NAT Reason Cross-contamination; black pellets. 11/20 United Thermal Plastics 269-192 \m 141 Poor die flow, gloss, color Philadelphia, PA 11/30 United Thermal Plastics 317-115 BLD 170 Color of purge compound. Product Return Notifications Date Customer 11/06 Precision Trim Boaz, AL Product 14941 BLK Amount 22,500 Reason Line V not approved by this customer. 11/06 Flexible Tech. Abbeville, SC 17121 WTR CLR 1,377 Contamination. 11/30 Columbia Plastics 5385-3P Columbia, TN 4,720 Contamination. Waivers Issued Customer Product Reason No. 2M Company Nibco 5465 5265 Viscosity Static Flew 1 R/C 1 H/T Nibco 5305 Static Flow 1 H/T Sample Shipments Resin Ship Date 11/03/87 11/05/87 11/13/87 11/18/87 Product 5415 5265 5305 5305 Amount 50 lbs. 50 lbs. 1 lb. 2,250 lbs. Reason Royal Electric Arrow Adhesives Finish Kare Products Vista (Ponca City) A VAB.0001191147 LABORATORY B. Customer Relations - Continued Sanple Shipments - continued Conpound Ship Date Product Amount Reason 11/02/87 34642 BLK 200 lbs. Procables Ltda. (Export) 11/04/87 39031 NAT 1,500 lbs. Electric-Flex 11/04/87 18162 NAT 100 lbs. National Extrusion 11/06/87 18162 NAT 100 lbs. Alenco 11/10/87 34551 NAT 50 lbs. Teledyne Thermatics 11/10/87 11/12/87 36451 NAT 15041 CB 50 100 lbs. 100 lbs. Atlas Wire Corp. Medical Plastics Lab 11/12/87 2153 NAT 50 lbs. Teledyne Thermatics 11/12/87 17462 GEY 545 14331 CB 50 200 lbs. Trim Plastics 11/12/87 86-136 BLK 1,600 lbs. Calvex 11/16/87 38901 GRY 559 3 lbs. Blane Polymers Dry Blend 11/12/87 RP201T NAT 100 1,500 lbs. 180-31 WHT 138 1,500 lbs. Astro Plastics Plasticizer 11/03/87 DH3P 5 gal. Vista (CKC) 11/04/87 61GP C. Development Lab Stannary 1 pint Blane Polymers RVCM of In-Process Sanples The following is a summary of residual VCM results on in-process samples. None of the reactor daily averages exceeded 400 ppm during the month of November, 1987. Number of Sanples Average ppm, VCM Reactor ________ Dryer Slurries52655305 882 36 187 0.4 66 0.3 A VAB.0001191148 \i>\ | i- : 4 Li " -:. ,i ' . ' :)'!.+ - fl- I. | ...> -i LABORATORY - Continued C. Development Lab Sumary - continued KVCM of Shipment Samples The following is a summary of the residual TCM analysis of shipment samples for the month of November, 1987. Product 5265 5305 5385 5415 5465 Debox Dry Blend Pond No. of Sanples 49 109 38 57 7 16 Average KVCM, ppm 0.20 0.10 0.30 0.20 0.10 0.3 Resin Process Capabilities 41 0.10 4 4.2 5265 5305 5385 5415 5465 Bulk Density Inherent Viscosity "L" Color Value 0.88 0.56 5.42 0.60 0.95 3.80 1.40 0.64 2.92 0.28 0.67 4.11 0.93 0.50 3.08 "A" Color Value 6.67 8.33 "B" Color Value 1.33 1.17 3.00 2.17 5.00 % on Pan (vs. 2% max.) % thru 140M Drytime 1.86 1.42 4.89 1.36 2.47 2.11 4.67 (0.44) (1.33) 2.56 2.35 3.64 0.83 0.44 1.22 Mets I.R. (vs. 95% of Control) 0.51 (0.27) Hard Particles a > io) 3.00 12.1 ConpCTmd Quality Sunmaiy Hardness Color/Clarity Heat Stability Cross-contamination Hard Particles Streamers Dicing Metal Total Adjustments M lbs,. (%) 39.0 (0.56) -- -- 7.0 (0.10) -- -- -- -- -- -- -- -- ---- 46.0 (0.66) Rejections M Lbs. oo 26.2 18.3 7.8 2.3 10.9 1.5 11.6 1.4 80.0 (0.38) (0.26) (0.11) (0.03) (0.16) (0.02) (0.17) (0.02) (1.15) VAB.0001191149 | | J I- l| j. hf.. - - t r|i i. r ................... . J .j : .|.i` c '-i- ! ;> !. J-|hril- -mI- : - .^i . I - S' i ---41 --iHttUBEnrsM > r^t;! - . : > =a ^ m * > n ei-n . t -n\ Siv4 4H0"l--Li 1-bM ii|r.r- l'PI-ShUwHK | , i-LI' -21 irif .: . . -fj' i-k I L IABORATOR* - Continued F. Pry Blend Quality Summary Stability High Torque Color Torque and Color Total Rejections M Lbs. (%) 5.2 13.5 11.9 19.4 50.0 (0.10) ( . )(0.25) 0 22 (0.36) (0.93) G. Quality Development 1. AT&T approved our 34862 ccupound for their "skip lot inspection" program. Basically, this neans we mist call their inspector in quarterly rather than every production run. The next step is "preferred supplier status", requiring annual inspections only. 2. Continuing a procedure we began in October, a Mets IR. value is obtained on sample lot 04234 (5415) each day we run the Mets test. We are plotting this result (raw value and % of control) on an individuals chart and the controls (5425 resin) on an X and R chart. When sufficient data has been generated, a report will be written on test variability. 3. 5415 Control Resin (Lot 04169) Test n X 3 <r Moisture Drytime Particle Size - 60 Mesh - 100 Mesh - 140 Mesh Pan Bulk Density Color - L A B How Time Hard Particles, 7 Min. Inherent Viscosity 60 0.134 0.025 56 4.96 0.285 30 0.84 0.62 28 33.95 1.22 30 6.67 1.40 28 1.12 0.63 60 0.5034 0.0058 60 100.450 0.245 60 -0.071 0.132 60 2.143 0.325 60 7.81 1.08 59 7.63 3.43 28 1.0024 0.0104 H. Mi grf>11 aneous 1. Brian Harrison investigated problems with coarse dry blends. The culprit was Blendex 338, a Borg-Wamer substitute for Rohm and Haas1 KM-653 impact modifier which is being phased out. 2. Brian Harrison responded to five dry blend customer cocoplaints mentioned in the Customer Problem Reports. 3. Brian Harrison conpleted and/or adjusted color matches for Vinyl Therm, Thermal Industries, Condutel and Viceroy. A * : i. i | - !!! I .......................i. <..-Mi i jttWhfH-' II r r.rt.i ilr , >.fj- ll'-i'-sj, -*i i: JiM-in- li i- -jr I ' i. h- *! J- . . 7 (|.*+ir:i. :i; VAB.0001191150 ' 1 I '< P ' l :! Tfl ! LABORATORY - Continued * H. Miscellaneous - continued 4. Brian Harrison attended the SPI VSI/VWDI technical conference in Chicago. 5. Dave Cox drafted a raw material and vendor approval proposal to clarify how to handle new vendors and raw materials at Aberdeen. This will be issued pending approval. 6. Dave Cox switched to a phenylisocyanate column on the HS-100 in order to separate an interference peak from the KVCM peak on shipment samples. * " < . | I -III-- -l-l-H 'r . - . Vi .. I r f 1 *h .fTT- M-' =:: "fl| W ta-t i- = *' -hit* Ml VAB.0001191151 1 -T K'-A If-I '.ri--I-': 4 SHIPMENTS BY PRODUCT - M LBS. NOVEMBER, 1987 FISCAL YEAR-TO-DATE RESIN PLASTICIZER DRYBLEND COMPOUND NUMBER OF SHIPMENTS BY MODE: TOTAL 30,840 533 4,869 5,950 42,192 61,134 1,312 10,106 12,569 85,121 RESIN-Bulk Package 1 VISTA TRUCK RAILCAR BULK [ VAN 137 1 60 1 TRAILER ON A FLAT CAR COMMON CUSTOME R CARRIER PICK-UP CONTAINER 2 91 TOTAL 290 1 16 1 11 8 26 Export PLAST.-Bulk 2 5 1 6 Package DRYBLEND-Bulk Package Export COMPOUND-Bulk Package Export TOTAL NOV. OCTOBER 23 11 1 173 182 | 3| 8 I 6I 1 1 36 | 72 50 62 56 i 1 2 8 51 41 1 1| 34 61 142 51 145 1 34 14 17 111 1 499 499 MJ ' ' * liSn. ffrii:------ ry iK'nn ' k- i ; -- r* ;~~i rmyiUrwyt\++44H-fu-awjj rwfrigrMijuifr n^ar i0iW^MiHKpigjtj^wjeii^|jiii! i:v. :.i "*"* 1 *"***:> VAB.OO0fl91152 mp--fc--i w^atMHi^WUMjNun mi^WL iir |! sfilbt- ------| .rrmi I'siktiti -I'1 -i 'p T `flffirT' }: |r :*K'rj-*-:' !.: r,,ih II H'T.i.+ii, r .. f K- ENERGY USAGE A cr> CM ro BTU/LB !*-r I.- CO Zo in > Q o o X -? cn PP Z '' g ir> u> Lu ton: , < j<jJ Ll. ^ UJ ro rl H JL nf 1503 ~h- >t 'T ; ; 85 \ Lj C.J 2^ 86 ! ^ 87 Monthly 12-Month Moving Avg hMh^^^iMiwyitPP|ii-- m mwmuu * m mi msmm n n j *mm\* *mn n !*i**--****** 11-^ VAB.0001191153 * ' r*<**ff-fffflipT<nFTW '! l - >: !* . ia1Hi = . -::*< I' MONTHLY HOURLY TURNOVER A 1 T i > 'I li I c* w> 4iB*Hiw4-^ipiiil*|'4^^M4vn^: Jf-..r, ;-i-dM^ T|<" ^ : W1 WffnptfnE&Hlit* JW*11 i-wrrt*rtj.+tfFf*tPtfr1^ WIWWW11W.WWWIIII -twi '1"'H 1^1 -- mw VAB.0001191154 .t.mmln--*MH.MH- inl-ii`' U- U, HM POUNDS *9 V ' MONTHLY 40 35 30 25 20 15 8 6 4 "Vr-.. V 2 6 BLtNuf\\a jpvi pim ukt 5 4 - i i -- i. - 3 .- 4- - 2 lrrr - +- ---------- 1 ,, _ v js. =i-. Oct. Nov. - I p,- , i .i .1.; . V'**' 1 *** n pswnnu-. ! rf - h s|^ j. r.... ABERDEEN PLANT PRODUCTION 10/01/87 - 09/30/88 f ------ -------- l n i 4 T rl4 4 A MM POUNDS CUMULATIVE 450 400 350 300 250 200 150 100 50 80 70 GO 50 40 30 20 10 70 r 60 p*0 40 30 20 10-- . r t 25 20 1 10 5 Jan. Mar. ie> 8if88 June Budget Actual Cumulative VAB.0001191155 w L. ^ Tr_+>-i ABERDEEN PLANT EFFICIENCY 10/01/87 - 09/30/88 A 1.020 1.010 1.000 .990 1.200 1.150 1.190 1.050 I * Oct. Nov. iDec. iJan. I Feb. Mar. Apr. flay j June July i9_12/03 F Aug. i < t * I 1 I i Septi > t 1 H 1 4 .......... -|- .ip-iq-. `-i . i-1 N-IWM-l-rJ-i ^p. > . N-- !< |Kfl thwjwh ipn\rn *m I HflWI 'WlMPWWHIIHrtW VAB.0001191156 ut Vi Till ABERDEEN PLANT QUALITY PERFORMANCE 10/01/87 - 09/30/88 A PH i. . ... .. P WfS! w-nnw PUP P ift * r. hintt**Mteiin.mi'KP. VAB.0001191157 MM POUNDS PRIME 10.0 8.0 6.0 0