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I T. H. Huffman From: Dahl: Subject: D. C. Skokna July 29, 1991 ABERDEEN MONTHLY PROGRESS REPORT JURE, 1991 There was one first aid case reported in June. At month's end, the plant's employees have worked 4378 days (5,856,295 manhours) e injury. Jane 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 Efficiency Variance, $M 39.4 98.6 93.8 1.0091 6.0 96.8 3.9 97.5 1.5 82.9 < 3.6> < 274.7> 24.2 Y.T.P. 357.7 98.2 88.8 1.0225 42.4 97.7 42.4 99.3 14.0 83.9 < 7.6> < 52.4> < 214.9> The resin unit ran well during the month. Switchover to the VCSM control system in the new reactor module is scheduled to begin July 5. Flexible compound production rates were high as orders remain tight. Variable efficiency costs were near budget overall. This month's 1PA was based on the first OASIS closing, and there may be some corrections to this close that will impact July variable costs. VAB.0001189637 T. H. Huffman 7/29/91 Aberdeen Monthly Progress Report Page 2 - June, 1991 Costs - Continued Fixed costs were over budget due primarily to unfavorable variances in benefits, $42.8M; taxes, $96.1M; and warehouse gain/loss, $204.0M. The tax variance is due to an unexpected $96M charge that was a result of a State audit of sales/use taxes. The warehouse charge corrects errors that were caused by the VMS. The Vinyl NBn Shift Natural Team recommended changes that will make changing resin reclaim filters safer and more efficient. The Safety Supervisor's Natural Team recommended improvements to the maintenance call-in process. These recommendations reduce the time needed to make call-ins, and call-in errors will also be reduced. Since the new process was implemented, the time needed for call-in has been reduced 46% and no callin errors have occurred. John Pace, Vice President of Manufacturing for NAPCO, visited the plant. NAPCO Is a potential rigid compound customer. The Southwire Supplier Excellence Team visited the plant to discuss the new supplier excellence ment and to learn more about how our natural and project teams work. We did not pass the June bioassay test of our wastewater. We passed a retest. The outfall pH fell below the permit limit of six for four hours; the minimum pH was 5.8. The 1990 SARA 313 inventory was completed. Results showed a sixteen percent reduction of VCM emissions; total reportable releases were thirty-three percent less than 1989. +A VAB.0001189638 T. H. Hoffaui 7/tt/fl Abaxdatn Monthly Progress Report - June, 1991 Pago 3 Continued Joe Ledvina, Lynn Zimmerman, and Frank Jeanson held an environmental seminar In Aberdeen; twenty-five people attended. D. C. Skokna Plant Superintendent rah VAB.0001189639 i DISTRIBUTION Houston J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblln Austin R. L. Poe X H. J. Hall QfrltfrPfn* Cltv LCVCM Plant H. D. Garrison P. D. Carrico LCCP Plant kciAP Plant J. Friend J. V. Ware X paltlffiPIt Hammond L. R. Bauer J. Pavao X X Blane r-AHUUr P. L. Foote &VS/DCS (File Copy)t TJA, JBA, JEB, JME DAB. DAM. JEN. JDO. BLT I X X X X X X X X X X X X X X jf' VAB.0001189640 SATOTT - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 1 & 1 0 0 0 0 1 0 0 G 1 Fiscal 11 o 17 4 0 Fiscal Y.T.D. 1990 3 0 2 5 8 0 0 17 Cuts and Abrasions Eye Injuries Bums Bruises S trains/Sprains Stings Other Totals 146 011 033 032 031 002 0 _2 JL 1 17 17 Lost Workday Cases Days Lost 06 0 127 First Aid Cases Medical Treatment Cases Lost Workday Cases Safety Record 04 01 01 Last lost time injury - 7/5/79 Days since - 4,378 Employee hours since - 5,856,295 On June 30, 1991, the employees of the Aberdeen plant completed 4378 days with no lost time injury. VAB.0001189641 guriTT - Continued The naln topic for plant safety meetings during the month was "Rescue". An emergency drill involving a chlorine leak was held during this month. Routine dosimetry results for the month were: <_________________________ Number > PEL Number Percent VCM Lead Total Particulates 72 97.3 2 11 100.0 0 3 100.0 0 2.7 0 0 One of the VCM overexposures was with benefit of respiratory protection; the other without. Monthly Injury Summary Department Description Maintenance Bruises and abrasions left "ring" finger and left "little" finger. * '""'N VAB.0001189642 - T. J. Arbeiter All of the plant's natural teams met during June. Some of the team highlights for the month were: Vinyl B-shift made a presentation to Management on June 19. The team recommended changes to the resin reclaim filter housing that will facilitate the safe and expedient replacement of the filter. The present design of the access door creates a safety hazard in that it is not hinged and can easily fall on an operator's foot while being removed. The length of the filter housing will be increased by ten inches and the filter mounting rod will be welded in place to speed filter replacement. m The Safety Supervisor's Natural Team made a presen tation to Management on June 20. The goal of the team's project was to reduce the time spent making maintenance call-ins and reduce the likelihood of error by streamlining the recordkeeping system. The team accomplished their goal by combining the call-in list and the call-in report into one document - the weekly schedule. The average time required for a maintenance call-in has been reduced by 46% and one report was eliminated completely. There have not been any reported call-in errors to date, although It is too early to pass judgement on this aspect of the new system. John Pace, Vice plant on June 5. President of Manufacturing for NAPCO visited the NAPGO is in the process of building a vinyl siding ility and is a potential dry blend customer. The Southwire Supplier Excellence Team was in the plant on June 7 to discuss details of the new supplier excellence agreement and to learn more about the work our natural and pro ect teams are doing. The first two meetings of the Snyergy Team were conducted during the month of June. The Synergy Team is comprised of the following individuals: Ken Campbell, A-Operator, Vinyl; Curley Payne, Lead Warehouse Worker; Charlie Holcomb, General Mechanic "A"; Melvin Tallie, Lead Technician; Don Whatley, Compound Operator; Jim Edwards, Chief Plant Chemist. The team is facilitated by Tim Arbeiter. The Snyergy Team's mission statement is: "To enhance natural team participation and effectiveness by revealing barriers that inhibit participation, while exploring and creating alternative QMP methods". VAB.0001189643 4 Product Efficiency Price Total PVC Flexible Compound Rigid Compound Plasticizer Total $102.4 < 60.9> < 45.2> < 27.9> $ 24.2 $1214.5 53.0 57.5 < 39.9> $1285.1 $1316.9 < 7,9> 12.3 < 12,Q> $1309.3 NOTE: June's variances were calculated by the OASIS system. There are still some details to be worked out in the closing process. Some error may have been introduced in the switchover to the new system. Malor Price Variances: Variance - $M VCM Resin to Rigid Compound Resin to Flexible Compound Fhthalic Anhydride Alfol* Alcohols Natural Gas Other Price Variances Total $1296.6 61.2 58.3 15.6 < 56.4> < 72.2> < 18.0> $1285.1 Fixed Cost Variances Variance - SM m Payroll and Benefits MM&C Miscellaneous - TI&D m Clearances Total <$ 11.3> 55.2 < 230.7> < 87.9> _______Q <$274.7> - A favorable maintenance payroll of $38M that was a correction of VMS errors was offset by an unfavorable benefits clearance of $42.8M. MM&C - Continued cost control efforts minimized activity in this $204 than The main cause of this month's unfavorable variance was i warehouse loss charge that was taken to correct for VMS cause* Materials taken out of the warehouse have been charged at lowei VMS These VAB.0001189644 T.I.& D. Continued A $96.1M charge was taken as a result of a State audit of our sales and use taxes. This total represents what the State has found for 1989 and an estimate of possible liability for 1990 and 1991. interest charges. Also Included are * VAB.0001189645 vxhil. - J. D. Olson, D. B. Knittig SifatT The Vinyl Department had no first aid case or OSHA recordable injuries during June. The monthly safety meeting topic was "Safe Rescue and Removal." General 1. Phase 2 of VCSM reactor training was completed. This training emphasized specific reactor programs. All panel operators were tested and qualified. 2. OASIS started up. Closing was completed with the new system. 3. The shutdown date for New Module VCSM conversion was set for July 5. 4. New reactor rinse nozzles were installed in D745 and D700. These nozzles have hardened gears to improve nozzle life. June YTD Production, MM Lbs. Daily Rate, M Lbs./C.D. Capacity Utilization Factor, % Total Reactor Charges Charges/C.D. Reactor Stream Factor, % Rotary Dryer Stream Factor (#4>#8), Fluid Bed Dryer Stream Factor, % Resin Quality, % Prime % 39.4 1312.2 102.9 922.0 30.7 93.8 93.3 99.8 98.6 357.7 1310.2 102.7 8366.0 30.8 88.8 92.5 95.5 98.2 Hours Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts and inventory control). 320.0 Maintenance downtime (repair D500 seal oil unit, New Module water meter, D400 jacket, welding, D300 agitator motor, PM D600, D400, D300, and D745 gearboxes, and torque D742 condenser. Repair D745 piping to pressure transmitter. Replace D700 and d745 rinse nozzles, unplugged D700 lip seal, D700 seal, Old Module substation fuse, D745 catalyst valve.) 129.5 MMlillRVPViPiBIIMmM mump VAB.0001189646 Continued Drver Downtime % of Total Operational downtime (centrifuge plugs, dryer cleaning, flameouts). Maintenance downtime (centrifuge maintenance, dryer PM, #5 Trunion bearing). Reactor limited production. 40.7 34.9 24.5 - J. B. Autrey, S. A. Truitt 1 The reactor coupling on D400 was replaced. 2 The #7 dryer feed screw broke on the motor coupling end. The screw was switched out with the spare, repaired and put back into service. 3 Reactor 700 seal failed when the water flush line plugged. The has been rebuilt for spare. 4. The motor on reactor 300 was pulled due to excessive vibration. The rotor was found to be out of balance, and the motor has been repaired for spare. 5. One major valve was changed out this month in the Vinyl unit. * *****l ****** *** H*t W VAB.0001189647 COMPOUHD - J.E. Ilektrscn, V. R. Kane g&ffiSl The Compound Department had no OSHA recordable injuries in June. GgBSCTl Control of costs and inventories continued to be a high priority during June. Orders remain tight on all production lines. Close monitoring of dry blend product quality has caused higher than normal downtime and slower than normal rates. Operating Line I 30 Line III 30 Line V 12 Total % Prime Capacity Utilization Factor Month Are.Ttttv Fiscal Y.T.D. 1901 3589 -512 6049 96.8 76.8 63 120 Jk1 202 14526 25163 2683 42372 97.7 60.6 Downtime Line I - Product Changes - Quality Problems & Control - One Dicer Offline - Miscellaneous Maintenance - Waiting on Raw Materials XjJLihig XXX - Product Changes - Waiting on Raw Materials - One Dicer Offline - Quality Problems & Control - Miscellaneous Maintenance Line V - Product Changes - Miscellaneous Maintenance Hours 102 28 22 20 12 68 20 20 9 7 6 39 h -i VAB.0001189648 COMPOOBD - Continued Operating Para Rigid Compound 29 % Prime Capacity Utilization Factor 3939 97.5 62.1 136 42377 99.3 77.6 Downtime - Product Changes - Quality Problems & Control - Miscellaneous Maintenance Operating Plasticizer 30 % Prime Capacity Utilization Factor Hours 130 74 35 1474 82.9 64.8 Avg./Dav 14026 83.9 79.5 J. B. Autrey, S. A. Truitt The inert gas heat exchanger was replaced because of recurring leaks in the tubes. The Line V Werner-Pfleider barrels were disassembled to check for wear. A Werner-Pfleider representative came, inspected the barrels, and recommended reconditioning the barrels and screws because of severe pitting and wear. The machine was re-assembled to continue production. Ft VAB.0001189649 w i;m > L .4 I C. Hillman, M. L. Carter SSSS Reactor program testing was completed on the simulation panel by the VCSM Team and Operations in late June. Final software verification will be done during the New Module shutdown. Operator training is complete with the exception of some verifies tion on the panel with a few trainees. Community Advisory Panel The first Community Advisory Panel meeting was held on July 18. Ten community members met with plant representatives to discuss the organization and purpose of the panel. The next meeting is scheduled for late August at which time panel members will be given a plant tour. Performance testing of the vinyl cooling towers will be conducted in late July. This testing will help us determine modifications necessary to address current cooling limitations and provide cooling for debottlenecking purposes. y^V VAB.0001189650 nmoi csniui pur ipnoro capital pmjicis nomniic - h.i. cum, s.c. siuaii hi mm 1519 1(49 1909 D5U 0550 0570 05)0 0600 0T49 0(49 0659 H99 1951 1(50 mo 9779 05(0 05(1 0(10 0(30 G6$9 0939 (500 1501 (510 1531 1541 1571 mi 1(20 PtoJicr Disoimoi HUT MCniCU, IPOUH ran cum srsm urnmuia hub umi wnnonm too uuunc womcinois unra sous pumas ou Buuncwm sum icoss (Bonn non php mssni m. nisncim mono. t nuiuiic. wo. uu hw in mosm uwcnn uu 3 sn-Mi uu unuK oomuo sno wm name uncu cuuiKua KUO SCUUU UFUCODT 53(5 nsmu ra uucnu KUCimO MTU umtw.415 caiumna imcnu tc soul animat usmm imim nuuuhu tc comma mum man am sinmu omuanu huturn ncicu hut urn sum nsaumois cipitii pbjicts < mi mt nemuna mucum wmnauumntwmmucunuuiimicmn 0-745 n wn sun nn, snbman uiumwiu ustiocihuni mucum sum mnuimcruusouounuusuiumnoutmo nnsonuu.ui wt/i.is n wo up snnci n sn ui. nonet is mariom, mam mu cusm mi it si. mnioououu. mmt u maun raw, mum couuiiu nu n n. usia is comm, nsmunn huuo m ou mu oona. non is num m m t/i. nm usi ms mums, memo mu cusm on on.mi. neou uciuune is mnnuc wuncinou. i mi m ou oaacm a m m is cumu uuc mmuo. canna, mam m cum io mu cram n mr n . pub usr nuc nun, mam m nco oosm in on n 9i. saums un uu moo a aum, asm mu non ii ju. nona mi a cum it mu anas n on on. n 9i. no nuns an an mm a am mam cowunw na on m. man nu u cum ma emus n nu n si. mum nu u cum to mu cunts n 4n on. mi. emmena a cornu n hubs. mmaims ntoaumcaunmatoumomu oeinoams is,nmona.nmo ti.o cua u m on m hhud sans aa sum, mnci is iuk mnom. nonet nu a cam mu aum in on.im. no. n mom, am m sm oanoaia u noasss. aomuno is n mam a a nonets. 10 nonets emurn. mncsiuisuHmaumummom. noanmet manau.ria mom on 9/91. man m nu mmoioun cumni aum m nam a nime. emmu MBios nn nms n mcno. nenmm osunm. num enpuna puusd ra mi. VAB.OOOl189651 - K. 6. Akins Bioassay testing began in June using the Ceriodaphnia dubia (water fleas) Survival and Reproduction Test. We did not pass this test. Sampling for confirmatory tests began in late June and was completed in early July. Results from the retest should be available in mid* July. 1 There was also a pH excursion at the outfall of Pond 6 (NPDES outfall 001) on June 25. The pH fell below 6 for approximately four hours with a minimum reading of 5.8. The MDEQ was notified. Continued sampling of water discharged to James Creek confirms we are well below Mississippi's Water Quality Criteria limits on lead. Superfund Royal Plastics and Conoco wish to have the resin removed from Pond 2 dried on site using our existing Pond Resin recovery system, They indicated a desire to begin reclai lation in the near future. General Letters were sent the State permitting agencies notifying them of the merger between RWE-DEA and Vista. A conversation on June 26 with Jay Barkley of the MDEQ provided some information on our pending air permit. Mr. Barkley said the MDEQ has not contacted the EPA regarding the unit risk factor for VCM that was proposed by Vista. Based on our presentation, Mr. Barkley feels comfortable with the proposed number and believes the issuance of an air permit will take place as priorities warrant. SARA Leal Release Inventory for 1990 was completed during June. VCM issions for 1990 totalled 64,004 pounds This represented a 16% reduction from 1989 reported Total releases of all listed substances were reduced by 33% as compared to 1989. An environmental seminar was held in Aberdeen on June 13. The seminar was conducted by Frank Jeanson, Joe Ledvina, and Lynn Zimmerman. Approximately twenty*five people from the plant attended the seminar. The Aberdeen Plant's Equipment Opening Procedures were revised to incorporate TCLP regulations for use in the upcoming shutdowns. VAB.0001189652 h Mississippi can now resume shipping hazardous wastes to Alabama based on recent court rulings. However, the relatively high hazardous waste tax may still make it more economical to ship to other locations. Waste shipments during the month included: Bulk shipment of API sludge to Chemical Waste Management in Emelle, AL. m Bulk shipment of empty lead/antimony bags to Chemical Waste Management in Emelle, AL. VAB.0001189653 * PPM - J. &. Ganc June. 1991 I A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU < 4.4%> < 3.6%> 2616.8 134.6 II Boiler Operation YT.D. < 8.30%> < 7.60%> 2729.9 1239.4 Boiler No. 1 No. 2 No. 3 83.1% 83.3% 82.6% Fiscal Y.T.D. 83.1% 83.4% 82.8% All three boilers operated continuously throughout the month. VAB.0001189654 Beall 'h None Michael L. Carter - Lead Mechanical Engineer at QKC, transferred and promoted to Senior Mechanical Engineer at Aberdeen. Mitchell Bishop -- Lab Department - Promoted from Trainee to Lab "AM Technician. Kenneth Killian - General Helper - Normal Retirement. None. None. VAB.0001189655 90 50 80 52 23 1 10 1 20 62 4 7 18 60% 45% 20.5% 20.8% 59% 30% 40% 37.3% 9.3% 0 0 0 8.3% 2.6% 3.0% 0 2.4% 24% 0 1 0 0 0 0 0 0 1 0 0 2 0 0 DEPARTMENTAL SUMMARY HOURS REPORT ............... YEAR TO DATE ................. is Vo CN 8 8 Kl i' Sn aw m in N 89 89 O 9 . ie# s K9l 9 Non Paid Hours Jury Duty 1= ii -oJ o1c ^ hi *s9-- ;2? l3 3 2 sS o 3M "8 ii ii i 18 oA 8 O 8i * 8 o&9 8 a 8O9 j 8O ii rp 8 * s 8 8O'9 , 8 O 8 O 8 V 8 $ A f 8 Oa 8 P 8 8 O9 8 S 8 8 8 * 8 8O 8O* 8O 8t T 8 8Oft ff oft :l1 8O# 8O9 O 8o* 8 O9 8Oft A8 8 OA 8 9 t 8di CP O 8 A 8 T8 a9 8O 8O 8 O9 i< i * 1 . i 1I i , *i ' 8* 8* s>ft ** 9 &* fta &* fg r 8*' 3 i 00aS 9 8 8 e e 8 8 IQ ft 8 ifc O 5t < 9 5? nN 8R 5 K<5 i-' ft f1 T- 120.00 056.00 J "5" ftl i I IS |8 8 : 8 8 # 8 8 : - 8 , 1 9 i 3 i 2 8ss MH K P rin te d 7/10/91 i3 s 5 I2 u nn R9PM999W99 9P99PPPP9W9W 9 s S s . .. s U Si 8 1 -8 9 *i p' VAB.0001189657 iUI 5 o X 8 8 * N 8 1 8 * O 8 i V * 8 8 r 8 8 h* ft i tc s 8 ff 0 .: & 8 ft :O i j. K O ft' 8 ft ' O 8 $ * 4 fc ' 8 ft 8 ft 'O 8 8 1C s 8 ft 8 i H o u rs 8 A ANII 3 S1 4 38 0. & 2 * S 1! O tm* 0ft l 2 . _ L_________ I'T- Vt I........... .... VAB.0001189658 n- h D. A. Barclay There were no reportable safety Instances this nonth. Ovality All natural teams met In June. Natural Team score is 10.8. To date, Administrative Services June was the first month to use Prism software. Many manhours were used to correct inputted information and to close the system. Aggregate reporting was not used for June closing. During June there were many treasury holds placed on customers which were not resolved quickly and caused delays in shipments and demurrage charges. Overall, June's closing of OASIS was not satisfactory. Hopefully, July's closing will be better. Processed Invoices Working Fund Checks Written Cost Savings Through Bid Process Raw Material Purchase Orders Issue MRO/AFE Purchase Orders Issued Spare Parts Purchase Orders Issued Month 939 12 $1668 113 190 207 Y.T.D. 8173 111 $22064 759 1628 1566 (Decrease) % Compound nAn Grade PLENEX Compound Off-Grade (BC) Compound Off-Grade (H) Millscrap(*) Dry Blend "A" Grade Dry Blend Offgrade Resin Type I Resin Type "BC" Vacuum Dust Total Packaged Warehouse 3,919,042 97,949 317,645 49,787 76,730 517,995 167,586 636,250 100 - 227.095 6,010,179 3,905,357 127,883 317,385 111,174 43,765 587,556 254,608 620,950 100 6,202,361 < 13,685> 29,934 < 260> 61,387 < 33,265> 69,561 87,022 < 15,300> 0 6-788 192,182 < 3%> 31% 0% 123% < 43 %> 13% 52% < 2%> 0% ___3* 3% * Includes PLENEX millscrap and cleanout. VAB.0001189659 Continued Compound "A" Grade Compound Offgrade Dry Blend nAn Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade Total (Decrea.se) Mav 1M1 June. 1991 /Increase 752,156 177,500 2,592,530 816,160 8,509,718 14,808,014 799,263 177,500 3,222,540 1,157,610 13,321,959 1,982,95Q 20,660,922 47,107 0 630,010 341,450 4,812,241 22.100 5,852,908 % 6% 0% 24% 42% 57% 1% 40% VAB.0001189660 ABERDEEN CHEMICAL PLANT SNIPPING ANALYSIS JUNE 1991 'SHIPMENTS BY PRODUCTS- PUBLIC RESIN-BULK RESIN-PACKAGED 14,560,200 367,712 FLEXIBLE COMPOUND-BULK 435,435 FLEXIBLE COMPOUND-PACKAGED 3,533,181 NEW BUSINESS 18,788 RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED 2,424,190 376,841 TOLLING - BULK TOLLING - PACKAGED 0 0 PLASTICIZER TOTAL 0 4 21,716,347 -SHIPMENTS BY MODEBULK: JUNE* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER RAILCAR 129 12 13 1 TOTAL JUNE 155 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 1,434 90 197 21 TOTAL YTD 1,742 PACKAGED: JUNE* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER CUSTOMER PICKUP 4 29 1 0 TOTAL JUNE 34 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 29 222 8 0 TOTAL YTD 259 MONTH IPT/ITC EXCB/TOLL 12,841,190 222,300 0 0 1,969,990 80,968 0 0 00 353,700 0 0 0 00 00 0 185,850 15,468,148 185,850 CUSTOMER PICKUP 24 0 0 0 24 CGNNON CARRIER 53 6 13 0 72 365 358 0 38 26 99 29 27 420 522 CARRIER 15 72 14 0 101 TOFC AIR/UPS 00 00 00 00 00 113 0 0 665 0 0 126 0 0 30 0 907 0 0 YTD PUBLIC IPT/ITC 175,432,496 114,20,490 2,297,316 1,800,950 6,258,465 10,968,340 27,183,545 898,470 112,076 0 30,009,240 3,209,649 5,119,800 699,756 00 00 779,150 1,480,530 245,361,935 135,164,536 AIR/UPS 1 5 0 0 6 50 76 4 0 130 EXCN/TOLL 1,777,400 0 0 0 0 0 0 1,401,960 33,600 3,838,010 7,050,970 TOTAL 206 18 26 1 251 2,157 128 322 77 2.684 TOTAL 20 106 15 0 141 192 963 138 3 1,296 CC: DAB,TLC,AEV,JRF VAB.0001189661 I aoAc cu s s J LU v> 5 (II O) W to tf) iiiei O CM o m o en M^WW MM s M Kt *> M N M W N N W MCMCMCMCMCMCMCMCM T??????. CM CM mN mM<Mh Cc6Mkl rsCM ^MS FCMt ^ vi CM fO C9B^S f<* f<> in CM CM CM 1*0 CM CM in m CM CM N M M m tfl S o pw' * CM CM CM CM 04 m i ss 2 i s-> CM I CM O CM < > o I- MS --4 *" ss i w K tiUrtUHOcnaufttn CQ CO Ul UJ 31 U) 828SS --4 CMCM r-. o cm p o t l S u! S I CM CM HIII*It III * 4** un CM O -H CO m n mts hts in m its noma) cn --^ as eg tiii tillm m in *) n*> <3 ics in *0 MI MS Ml MS C^ MS MS o oo oCM CM r4 CM CM m CM CM O K* o O ss II # a s& - mmfmm UlUIUJUJUIUlUiUI sCal^^aisials'' O* m mmm o ai s* cn cn VAB.0001189662 MCPrif* p-* TAWABATfiPY - J. M. Edvards A. Safety There were no safety incidents in the Laboratory during June. The monthly safety meeting was "Emergency Rescue Training" taught by Ginny Belk. A group from Southwire visited the Plant on 6/7/91 to discuss our next Quality Agreement. Vista was also evaluated against last year's Quality Agreement by the Southwire Tea 6/06 The customer complained that 5305 railcar 46456 was too yellow. Stripping conditions in the Old Module reactor were modified to get the "b" value back in line with historical shipment values. Klockner would like 5035 with a 2.0 maximum "b" value. Customer complained that a lot number on a shipment did not match the lot number on the COA. A corrected COA was faxed before the complaint was heard. 6/07 Also, the customer needs fifteensecond aged hardness reading for each lot of material shipped. There is a logistics problem with this request. The Aberdeen lab will provide test data correlating instantaneous unaged durometer readings to aged fifteensecond delay readings for products shipped to Donnelly. Egpwmfr Customer complained that 1 RP-91 WHT 110 was high in The Aberdeen lab confirmed results. With only seventeen in dividual points plotted, this lot could be an out-of-control point. - Continued Continued The customer complained that Ille gible stenciling of bagged 46234A caused two lots to be confused which comprised their lot Integrity. The customer complained of "very large" particles and 0.16% on the 40 mesh in one compartment of the RP-151 shipment in PLCX 43123. New procedures are in place and new screeners are on order to help correct the problem. 6/12 Donnelly Lots 31F13 and 31F18 of 46234A Black exhibited poor thermal stability in Honda Accord rear windshield encap sulation. Chemical analysis of the two lots showed 31F13 to be low in E50 and 31F18 to be low In D1DP. The customer complained that a ship ment of RP-27 was delayed because of CPE shortage. They have asked R&D to suggest Alternative modifiers. The customer complained of black specs on wire insulation made with 34643 Natural compound. The specs appear to be undispersed color con centrate . Customer complained of "streamers" from 5265 clogging unloading equip ment screens. T-A1MffiliTOIiY ~ Continued SttrtVRg Available Plastics Producl 80273G WHT 110 Reason Oversize Material 86. 1 H/T Dayton Extruded Plastics RP-151 WHT 145 40 Mesh 1 R/C Dayton Extruded Plastics RP-151 WHT 145 Color 1 R/C Dayton Extruded E. RVCM Sunmarv RP-151 WHT 145 Color 1 H/T RVCH of In- The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages ex ceeded 400 ppm RVCM during the month of June, 1991. Number of Samples Average RVCM, ppm Reactor Drier 5265. 18 0.538 5505 83 0.279 The following is a summary of the residual VCM analysis of shipment samples for the month of June, 1991. 5265 5305 5325 5385 5395 5415 Debox Pond Dry Blend 39 128 0 38 6 65 12 0 3 Average RVCM. ppm 0.102 0.077 0.155 0.087 0.033 0.203 0.017 h VAB.0001189665 oo tJumpATOP - Continued (based on dryer "regulars") 5265 1115 5415 Bulk Density Inherent Viscosity (vs. 0.64 - 0.67) (vs. 0.715 - 0.744) "L" Color "a" Color "b" Color % on Pan (vs. 2% max.) % thru 140 Mets I.R. (vs. 95% of Control) Hard Particles, (% > 10) Average Particle Size, Microns 1.28 1.44 0.22 -- 5.33 3.83 1.78 15.67 5.05 -- -- 171 0.53 0.81 ---- 0.63 2.07 4.50 2.22 3.58 -- 1.60 -- -- -- 1.45 0.62 -- -- 2.50 ---- 2.17 4.33 -- 3.42 -- -- 0.9 1.16 0.57 -- -- 6.00 -- 2.00 5.11 -- 2.58 3.11 -- 0 1 .27 0 .41 --- --- 4 --- 2 .83 7 .83 2 .83 8 .05 2 .62 1 .30 0 152 174 160 184 Hardness Color Hard Particles Heat Stability Dicing Cross Contamination Streamers Mischarge Moisture Totals M Lbs 31.0 20.0 <0.50> <0.33> 51.0 <0.83> M Lbs. HI 8.0 39.2 3.5 11.2 26.0 15.0 1.6 27.0 17.6 149.1 <0.13> <0.64> <0.06> <0.18> <0.42> <0.24> <0.03> <0.44> <0.29> <2.43> Torque Rheometry and Color 40 Mesh Moisture Total M Lbs. HI 9.1 16.7 2kJL 49.8 <0.24> <0.44> <0.63> <1.30> VAB.0001189666 TAfwq^TXHLY ' Continued 1. All natural teams met once during the month. 2. The new brittleness tester low temperature bath arrived. Startup was not completed. 3. Assistance was given to Administrative Services to develop the plant budget shell software. VAB.0001189667 V SAMPLE SHIPMENTS JUNE 1991 RESIN Ship Date 6/07/91 6/12/91 6/12/91 6/13/91 6/14/91 6/14/91 6/14/91 6/19/91 6/21/91 6/26/91 Product 5395 5305 5305 5386 5415 5385 5415 5416 5415 5385 5395 Amount 5 lbs 100 lbs* 50 lbs. 2X5 lbs. 150 lbs. 50 lbs 200 lbs. 50 lbs. 50 lbs. 5 lbs 50 lbs. Customer Gary Chemical AMERICAN CONTAINER U-FREIOHT LTD. (Hong Kong) Armor Bond Building Products Inc. CONDUCTORES LATINCASA ABERDARE CABLES (South Africa) RJF International PDMTR Achilles Dayton Extruded Plastics COMPOUND Ship Date 6/10/91 6/12/91 6/24/91 6/24/91 6/26/91 Product 46234A BLK 46234A BLK 48562 BLK 419-50-A NAT 02 419-50-A NAT 02 38931 NAT Amount 2 Plaques 50 lbs. 50 lbs. 200 lbs. 100 lbs. 200 lbs. Customer LOF Technical Center Lord Chemical Alcatel NA Inc. Belden Corporation Tandy Wire A Cable Co. MISC. Ship Date 6/07/91 Product Vent Dust Amount 1 gal. Customer RFC Plastics VAB.0001189668 'N* R OF MM J S N J*89 M M J S N J*90 M M J S NJ*91M M MONTH TOTAL NJURES OSHA RECORDABLE VAB.0001189669 ei/rue ABERDEEN ENERGY CONSUMPTION AVERAGE VAB.0001189670 ERDEEN ENERGY CONSUMPTION VAB.0001189671