Document ppxqQoRwreBkkK0odj39pnaqk

\ji1l To: T. H. Huffman From: Dote: D. C. Skokna July 27, 1990 Subject: ABERDEEN MONTHLY PROGRESS REPORT JUNE, 1990 Safety There were no reported injuries in June. At month's end Aberdeen plant employees had worked 4013 days (5,340,396 manhours) since the last lost time injury. June X,T,p. 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 37.4 92.0 98.9 C.97642 5.8 98.5 4.6 99.8 1.4 85.6 < 3.2> < 12.0> 40.7 336.5 88.4 97.3 1.0013 54.4 98.3 44.3 99.6 13.6 87.1 < 7.7> 215.3 594.0 Operations Six railcars of low calcium 5305 were produced for Klockner. Installation of the permanent clean wall system began and will complete in August. Some 56 hours of Line I time were used for Plenex Polymers development. Rates in the ridgid compound unit were adversely affected by screener problems (136 hours of downtime). VAB.0001190036 T. H. Huffman 7/27/90 Aberdeen Monthly Progress Report - June, 1990 Page 2 Variable costs were favorable In the resin and compound units. Good efficiencies and low offgrade rates in these units and favorable product mixes caused the good results. Offsetting these variances was an unfavorable (high use of raw materials) variance in the plasticizer unit. A process change made earlier may be the cause of the inefficiency. 1. 100% of the plant's natural teams met during June. 2. Overall, natural team scores for the 3rd quarter are up 46% from the previous quarter; an average score of 7.3 points. 3. The plant's estimated Q-Scorecard results as of June 1 are 10.3. 4. The Vinyl "B" Shift Natural Team made its management presentation. They recommended improved blend tank sparger design that benefits the environment, improves safety and quality, and reduces energy consumption. 5. AT&T (a compound customer) presented us their 5 Star Rating (the highest) as a result of our semi-annual vendor rating. ------------------------ D. C. Skokna Plant Superintendent rah Hous ton J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson D. F. Harman H. R. FI amine r R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin W. L. McClain J. P. Stokes Aus tin R. L. Poe X H. J. Hall Oklahoma City H. D. Garrison LCVCM Plant R. A. Conrad LCCP Plant J. Friend LCLAB Plant J. W. Ware X Baltimore L. R. Bauer X Hammond J. Pavao X Blane C. R. Miller Premiere P. L. Foote Aberdeen RWS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, MRK, JEL, DAM, RBN, JEN, JDO, REP, BLT X X X X X X X X X X X X X X X X 'H*' 1 VAB.0001190038 f SAFETY - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases June 0 0 Fiscal 3 0 Fiscal 2 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Lost Workday Cases Days Lost Last lost time injury - 7/5/79 Days since - 4013 Employee hours since - 5,340,396 On June 30, 1990, the employees of the Aberdeen plant completed 4013 days with no lost time injury. The major topics for June safety meetings were CPR and Respirator Training. S j' / VAB.0001190039 SAFETY - Continued David C. Sheffield of International Loss Control Institute, conducted a plant-wide safety audit during the week of June 25, 1990. A report of the findings is expected from ILCI during July. Routine dosimetry results for the month were: Chemical <_________________________ Number VCM Lead Total Particulates 77 98.72 18 94.74 7 100.0 1 1 0 Both overexposures were benefit of respiratory protection. Percent 1.28 5.26 0.0 latery Class Department No injuries reported during June. Description m MR MM T VAB.0001190040 f ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) 40 35 30 Z8 20 15 10 5 0 J'ffJF MAMJJASONQJ' MAMJ JASON QJ* MAMJJASON QJ'9QF MAMJ TOTAL INJURIES o OSHA RECORDABLE * VAB.0001190041 T. J. Arbeiter Q3FY90 Natural Team scores are in! The Aberdeen Plant team activity resulted in an average score of 7.3 points, up 46% from the previous quarter. Our Natural Teams and facilitators deserve great credit for the accomplishment. These "points" represent a lot of good work done by our teams. The Vinyl "B" Shift Natural Team made a presentation to management on June 20th. The team recommended changes to sparger design aimed at benefiting the environment, improving safety and the quality of our products, and reducing energy consumption. The Aberdeen Q-Scorecard score as of June 1st is 10.3. Our progress by line item is as follows: Item 1990 Card Submission 1991 Card Submission Average Natural Team Score Safety Cost Control Quality Waste Minimization Linkage Score i- 10 10* 10 12 12 10* 13 4 * Assumed VAB.0001190042 P pwmwmmm D. C. Skokna PVC Flexible Compound Rigid Compound Plasticizer $74.0 38.9 11.3 ( 83.5) $ 40.7 ($65.5) ( 21.4) ( 1.6) .... MJfc ($ 44.1) $ 8.5 17.5 9.7 -C39.il $( 3.4) PVC - $74.0M favorable. VCM consumption was below budget, and product mix was favorable. Offgrade production was 70% below budgeted levels. $38.9M favorable. Raw material use was slightly above budget ($20.1M) , product mix was $49.3M favorable, and variance due to offgrade was $10.6M favorable. Millscrap production was 62% below budget. $11.3M favorable. Operation was essentially at budget. $83.5M unfavorable. Raw material use was significantly above budget. Investigation indicates that a switch to soda ash neutralization (done to reduce the amount of BOD going to the wastewater system) may be the cause of this month's and recent month's inefficiencies. To evaluate further, use of caustic has been resumed. $44.1M unfavorable - Alfol 610*Alcohols - 610P to Flexible Compound - VCM - AllOther PricesVariances Total M $ 31.9 . 28.9 ( 68.9) ( 36.0') ($ 44.1) Fixed Cost Variances - $12.0M unfavorable - Payroll and Benefits - MM&C - Miscellaneous - TI&D - Clearances Total $ 24.2 42.5 62.5 ( 137.2) ( 4.0) ($ 12.0) VAB.0001190043 * mmm u COST VARIANCES - Continued Payroll and Benefits - Payroll was essentially at budget while benefits clearances were $179M favorable. M. M. & C. - Activity was below budgeted levels. Miscellaneous - Most items in this group were favorable; the most favorable item was ''packaging supplies'' - $26.2M favorable. T.I. & D. - An unexpected city tax clearance caused this category to be significantly unfavorable. We are trying to determine why this happened. jr VAB.0001190044 VINYL - J. D. Olson, J. M. Vlnoskl The Vinyl Department had no first aid or OSHA recordable injuries during the month of June. The monthly safety meeting topic was "Plant Emergency Action Guidelines". 1. Six railcars of decalcified 5305 resin were produced and shipped to Klockner in June. Resin calcium levels were reduced to about 10% of normal. Additional June production of decalcified resin will be held for Klockner's July order of six railcars. 2. Work began in June of the permanent BUS-80 system. Installation will be completed by mid-August. 3. The resin raw materials in the 744 account were valued at $334.6M. - Production, Mrt -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 % June 37.4 1246.7 102.3 870.0 24.0 92.0 89.2 97.6 98.9 336.5 1232.6 101.1 7898.0 28.9 88.4 80.5 92.3 97.3 Hours Operational downtime (recovery scheduling conflicts, New Module rinse/charge water conflicts, waiting for Q.C. data before charging, 0-ring leaks, no place to dump, rinsing chem wash tanks power outage). 405.5 Maintenance downtime (sewer valve replacement on 741, condenser drilling on 500, condenser jacket acid cleaning on 300 and 400, hydro blasting and condenser drilling on 745). 170.5 VAB.0001190045 VINYL - Continued Drver Downtime Reactor limited production. Operational downtime (centrifuge plugs dryer cleaning, and flameouts). Maintenance downtime (#4 resin hopper repairs, activator, baghouse, centrifuge, and exhauster maintenance, screw conveyor repairs). % of Total 41.2 22.9 35.9 Number "6A" cooling tower east cell was shutdown during the month for repairs to its drive shaft and three of its blades. The fan shaft broke causing damage to three of the fan blades. The north recovery condenser and both sub coolers in the Old Reactor Unit were shutdown during the month for >leaning. The tube sides were drilled and the shells were acid cleaned on each. Reactor 600 was shutdown for relief valve changes during the month. The new relief valves were installed as part of the Low Molecular Weight Resin project. The "A" recovery compressor was shutdown during the month for repairs. The bearings and seals were replaced. Reactor 745 was shutdown during the month for condenser drilling and hydroblasting as part of the contamination control program. The Number 7 dust collector was shutdown during the month to replace the screw feeder on the dryer discharge. The screw shaft had broken on the screw feeder. Reactor 500 was shutdown during the month for condenser drilling because of cooling control problems. The motor on the #4 dryer exhauster was replaced during the month because of bad bearings and windings. There was one major valve changed out in the Reactor area during the month. * mm VAB.0001190046 T COMPOUND - J. E. Nickerson, K. G. Akins The compound department worked without injury in June. The topic of the monthly safety meetings was respirator training. General Continued formulation testing for PLENEX polymers consumed 56 hours on Line I. UL testing on different jacket/insulation combinations and constructions continues. Line V operated 12 days in June. Line V was down for 34 hours for a pelletizer clutch repair. Rigid compound rates were adversely affected by problems with the Gump screeners in June. Maintenance required on the screeners as well as rescreening several railcars of material caused 136 hours of downtime in June. Plasticizer rates were also reduced by reprocessing "cloudy" plasticizer. It is suspected that the "cloudiness" is caused by monoester and/or filtering agent. Several tests including additional filtration, water washing, and return to caustic neutralization are underway to solve the problem. Operating Davs Line I 30 Line III 30 Line V 12 Total % Prime Capacity Utilization Factor Downtime Production (M Lbs.) !&nh AVg,/Pay Fiscal Y.T.D. 1932 64 3489 116 -Aift 5839 216 98.5 .735 17869 31137 5437 54443 98 .774 Hours - Product Changes * PLENEX Polymer Testing - Miscellaneous Maintenance - Quality Problems & Control 92 56 30 4 - Product Changes Miscellaneous Maintenance - Quality Problems & Control - Dicer Problems & Maintenance Line V - Werner & Pfleiderer Maintenance - Quality Problems & Control - Product Changes - Miscellaneous Maintenance 73 19 15 9 34 33 n 11 VAB.0001190047 COMPOUND - Continued Operating , Month Rigid Compound 30.5 % Prime Capacity Utilization Factor 5412 99.8 .909 177 Dp.wptjffiq Hours - Screener Maintenance & Product Rescreening - Product Changes - Miscellaneous Maintenance - Quality Problems & Control - Welex Maintenance 136 64 73 42 22 Operating __Pavs Month Plasticizer 29.5 % Prime Capacity Utilization Factor 1434 85.6 .652 X,.L.P. 39493 99.6 .827 Fiscal Y.T.D. 13600 87.1 r- i . 708 Key Maintenance Work - J. B. Autrey, J. B. Hegwood The vacuum jets on Plasticizer Reactor R-l w< for cleaning during the month due to an calcium carbonate build ud. removed The #7 air compressor was shutdown during the month for repairs. The valves and wipes were replaced due to wear. The #1 welex was shutdown during the month for repairs because the motor was kicking out on high amps. An IRD analysis was run on the motor and the welex bearings and it was determined that the jack shaft had a bad bearing that was causing the motor to pull high amps. The jack shaft and motor were replaced and the welex was put back in service. The Line I "A" blender was shutdown during the month for repairs because of a failing bearing in its gearbox. The gearbox was replaced with a spare and the blender put back in service. - Several repairs were made to the VCM unloading compressors during the month. Numbers 1, 2, 3, 4, and 5 compressors were shutdown for repairs. Numbers 1, 2, 4, and 5 were shutdown and rebuilt because of blown gaskets. Number 3 compressor has a broken crank case and shaft. It was sent back to the factory for repairs. VAB.0001190048 W MMMMnHPVPWHWlWPVWiMVffWVMHVMMMNMMMMMpMPi ENGINEERING - R. E. Polk, S. C. Hillman, M. R. Kane * GENERAL 5305 Decalcified Resin Production of decalcified 5305 resin continued using the temporary system in the New Module. Enough resin was produced in June to satisfy Klockner's requirements for the month of July. Evaluation of the technology options for removal of calcium was completed. Ion exchange has been chosen over membrane separation because of the relative economics. A Class "A" design will be issued by the beginning of August. Batch Water Improvement of the batch water stripper performance has occurred during the last two months. Most of the improvement is due to monitoring the system. Recommendations to further improve the stripper reliability include standardizing the operating procedure and some minor maintenance and capital modifications. The AFE request for the TC Compliance Project was submitted for approval. This project provides the implementation of EVC containment from the Batch Watch Strippers. A Hazard and Operability Study (HAZOPS) has been completed on this project. A consultant from Stone and Webster Engineering led a team of operations, maintenance, and engineering personnel through the review of P&I diagrams for the project. Representatives from PED and the Oklahoma City Plant also participated to learn HAZOPS techniques. PED is preparing the HAZOPS report from the study. Production Model Building Production Model Building began last month. The production models will be used as a part of OASIS to provide more accurate product cost accounting. The production models will include not only the current IPA items (utilities and raw materials) but also the activities which were recommended by Price-Waterhouse in their activity-based cost accounting evaluation. VAB.0001190049 ENGINEERING - Continued h Economics were identified for the justification of a method to produce compound samples at Aberdeen. The cost of having samples produced at Premiere and filane and the cost of the excess material when samples are produced at Aberdeen justifies further work. A design basis is being identified with a Class "A" design expected by September. Boiler Feedwater Tank Replacement The boiler feedwater tank has been condemned. This project will use an existing tank to replace the condemned tank. The tank will be lined with placite and located next to the existing boiler feedwater tank. VAB.0001190050 F. G. Jeanson Water All wastewater discharge parameters were met for the month of June. Results were received from the State on our NPDES inspection. We were in full compliance. Waste Waste shipments for the month included: One bulk load of lead bags was shipped to CWM in Emelle, Alabama. Two bulk loads of stormwater solids were shipped to CWM in Emelle, Alabama. Thirteen drums of stabilizer spill were shipped to TES in LaPorte, Texas. The Louisiana House and Senate have both passed a bill that would increase for hazardous wadst'es disposed of in their state and would ban Mississippi from disposing of hazardous waste in Louisiana starting January 1, 1991. This bill is very similar to the one Alabama passed. Superfund A draft order was received from the State this month to do a remedial investigation of the superfund sites. Comments were gathered from legal, Joe Ledvina and Conoco. These comments were communicated to the State in a meeting held in Jackson. Our comments were incorporated into the order and the State reissued the draft order for our review. We gave our final comments to the State. The final order is expected the first part of July. DuPont Environmental Remediation Services (DERS) was in the plant this month to do a geophysical survey of the superfund sites. Two other contractors contacted the plant about pond 2 resin removal this month. We are considering these options. The modeling study was reviewed by the State. The risk calculated from the fenceline concentrations determined in the modeling study was greater than the State's internal guidelines. A meeting was held with the State to discuss the results of the modeling study and determine what action needed to be done in order for us to get a construction permit for the VCSM Project. VAB.0001190051 ENVIRONMENTAL - Continued Air - Continued We presented an option to reduce total emissions even though we will increase production by combining two projects. The VCSM Project and the Steam Stripping Optimization Project will be done in parallel; thus producing a net reduction in emissions. The State agreed with this option and wrote a draft construction permit. This permit was reviewed and sent back to the State. The State Permit Board will review this permit in the first part of July. A construction permit should be granted the first part of July for the VCSM Project. However, our current operating air permit expires in March, 1991. The State plans to address the high risk associated with our fenceline concentrations at this time. The NESHAP's quarterly report was completed and issued to the State. SARA The 1989 313 emissions were completed and issued to the EPA and the State. Ten chemicals were reported this year. A summary of the emissions is attached. ffl3C$UftfiePUg I attended waste minimization conference held by the Mississippi Technical Assurance Program. The dust collectors sold to Louisiana Chemical Equipment Company were tested for asbestos. Twenty samples were taken and no asbestos was found. I attended the DOT training held in Houston by the Corporate Environmental Department. I participated in an environmental audit of the Oklahoma City Plant this month. * pi wm wmm mm rnmmmmmmmmmmmmmmmmmmmmmmm VAB.0001190052 AIR WATER FUG. STACK LAND OFFSITE S ECOND TOTAL OFFSITE OFFSITE ANTIMONY 00 0 0 1386(1) 2(2) 1(7) BARIUM 00 00 24(1) 335(4) 2(2) BISPHENOL AO 0 Di-N-Octyl Phthalate 0 0 335 0 5232(3) 732(7) HYDROCLHORIC 0 ACID 296 00 0 LEAD 07 0 0 5233(1) 26(2) 8(7) METHANOL 1-499 1-499 00 0 PHTHALIC 00 ANHYDRIDE 0 0 6072(5) SULFURIC ACID 0 0 0 0 20970(8) VCM(6) 3016 73196* 6 0 0 0 0 0 0 0 0 0 0 1389 * 361 * 5964 * 5267 * 0 6072 20970 0 (1) Empty Bags (Sent to Chem. Waste Management, Emelle, AL) (2) Floor Sweep (Sent to Chem. Waste Management, Emelle, AL) (3) Filter Cake (Sent to Chem. Waste Management, Emelle, AL) (4) Stabilizer Spill (Sent to Chem. Waste Management, Emelle, AL) (5) PA Spill (Sent to Chem. Waste Management, Emelle, AL) (6) Fugitive emissions were calculated using correlation factors developed from a bagging study done at this plant) (7) API Sludge (Sent to Chem Waste Management, Emelle, AL) (8) Sulfuric acid contaminated dirt from Acid Dike Replacement Project (Sent to Chem. Waste Management, Emelle, AL) A Represents a reduction from 1988 emissions reported. Upww mm m VAB.0001190053 * WASTE production vs GOAL 89 it 90 ALL WASTES EXCEPT WASTEWATER LBS WASTE/M LB PRODUCTION Dc--88 Mor--89 Jon--89 S#p-89 D#c-89 1988 ACTUAL o 3 MO. ROLLING AVG. + 1990 GOAL Mar-90 Jun-90 WASTEWATER DISCHARGE VS. GOAL 1989FY -- 1990FY MM LBS WASTEWATER/MO. Dpc-88 Mor-69 Jun-89 a lOM ACTUAL - 3 MO. ROLLING AM6. Spp-89 D#<-89 + lOOO COAL Mor-90 Jun-90 VAB.0001190054 wmnmi mmmmmmmmmmmmmmmmmmmrnm immm w D. A. Moore June. 1990 A. Unadjusted EUI <3.1%> B. Adjusted EUI <3.2%> C. BTU/Lb. Product 2545.0 D. Total Energy Consumption MMM BTU 125.50 < 7.5%> < 7.7%> 2640.0 1181.93 III. There were seven energy related Items completed in June, 1990. Six of these items were steam leak repairs. The remaining one was steam trap repairs. No. 1 No. 2 No. 3 Combustion Efficiency % June. 90 Fiscal Y.T.D. 83.3% 83.2% 83.0% 83.4% 83.3% 83.0% * VAB.0001190055 BTU/LB VAB.0001190056 ABERDEEN ENERGY CONSUMPTION BTU/LB MONTHLY MONTH -------- 12 MONTH AVERAGE Carina Cook, New Hire Robert Wil liens from Lab Trainee to Head Building Attendant. Jerry JenJcins from Head Building Attendant to Compound Operator i Mitchell Bishop bid from General Helper to Lab Trainee. Brskin Morgan promoted from Yard "B" Operator to Yard "A" operator None None None VAB.0001190057 Aberdeen* Mississippi Salaried Employees Hourly Emolovees * ** Total Employees Employees (Hourly) New Employees Terminations DEPARTMENTS Warehouse ' Gen. Plant Maintenance Laboratory Compound Vinyl ^ Plasticizer PAR 16 13 41 24 40 33 _________ ____ 5 80* 172 252 JUNE* 1990______________ MONTHLY PERSONNEL REPORT Minority Employees Z Hourly Total 0 Hourly Min. Hired 0 0 Z Min. Hired Q Hourly Min. Term. Q Z Min. Term. q ft EMPLOYEES MIN. EMP. % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD 15 16 41 24 24 38 33 10 5 40 fe Number of Applicants: Month ________Q Year to Date APPLICANT BREAKDOWN: 0 Minority q % Minority 0 :t Female o % Female n 0 * This total includes 2 Co-op Students and 2 Summer Process Engineers. Hires (Hourly): Month 0 Year to Date Q Terminations (Hourly): Month 0 Year to Date Q Overall Turnover 0 Projected Annual Turnover 0 VAB.0001190058 114-If* ' "n.^ I M. b.r-- -J. *7* c.r F-SG onncn o mcn m CO 04 * roi >1 091 -sil *ft41| 0 I l 1 t 1 -si <2> 04 a i i i on '-sj oon. i * a i i on t4o) i i a i i "O to 1 1 1 1 1 00 Ig i i a ! * 04 i t a ii ro o * ro on on i i on i i co cr> %Ol 3Ol * * ^si on i i o i i to on a i o0 1 1 on 1 I 0 i t o ro on to on CD I U Ii II II II II oI I I II I fI f ro -o CO Ul o 0 o a 1 a i a 00 on <0 i ai a* --4 CCOO on i ti ti oon ^Osjl ai i ii 04 04 O 1 a a a a o 0 ! a i a i oO 1I t 1 1 04 0* O ! ! 11 1 a ro -4 on i a a 1i 04 on O *4 on a a i i i 41 'O CO o 11 f a a co o. nj on i i ii i a ro on ft to on i NM ft | o 1 04 1 0 t i I 0onti oJ 1 OO 1 t g o 1 1 4) 1 1 on oo a a NO 1 1 roi i i 1 04 wn 1fr t 1 oni o *ii 1 04 a oo 1 *o 1 I r 0 1 NO a JN f ft I ft * * \ 1 oN 14 t\ o ta fw 1 1 -41 oni o 1 1 to on i a 0 0 1 1 on 1 1 * Wi 1 1 Ol i ) <E* 0 1 l NO 0 a 0 1 04 I 0 04 0 i 0 a oo a 0 0 a 04 a NJ a 0 O' J o 1 1 NO o 1 o 1 J* a on a on o 1 o 1 NO a a co oi fr oro> on NO I oo J on o i on on CO 1 J1 04 04 1 1 1 0 0 a t a o 0 0 ) 1 1 0 on o a ii 0 CO 1 i i i 0ft NO 43 1 1 1 1 fOt 0OD 1-4 I * a on 0044 II 4) a i i t on 04 I 45 II tO ro I I I (4 on on on co ! 1 1 04 -"4** I 1 1 0 1 1i 04 on 1 i 1 -ft on 0 1 a a i * 04 Ia aa 0ft 4 aa on i a -H I m-4 o a NO ro o 00 00 $! o 04 o* on NO U i QO I II I I ro i ii ii 0O f a a aa --* -4 ro 0 a a a a CN* 0 0 a a a a t sj to 0 1 1 a 1 1 --* to 0 0 aa i a i t rcn o cr --4 cn o X i aa a a ai a a a 'Sr CO o m *TJ T) ?5 5? 5 cn VAB.0001190059 ppm pm Ir A II I I I I I I t 1 I I I I I I I I rot rot N) 04 ro ro co ooV o <3> <D O mi t i \ i 041 so* 041 "Ol rol Mil i i I I o- I Os ii mto i t i ii 3 ii m i 04 I -- 04 iI sim * m o I ot I I o tOI 04 I M3 sO I to * I * -Sj I <S> ro t ^i * t mm tI II mi o i rhr i mFi ?s roi rot l *-oii rooitl <t> i i rOo i t -si m i i t m ro t t Os ro i i Os ro t t Os t i o* 04 t 1 CO i i Ml i co t ro i o i Ml i ro i 1 Ml i Ml m i i m t i Ml o i i m o i i m o i t m<S> 1 1 to Ml 1 1 m i i Os |i I04 U1 CO I I o ti m i ro t -o i mt *\ i i co Iii -- -Of rot S i 04 to i i t i to i i 04 m ii oo i * s ro co ro Ml 04 ii ii ii I 04 I I* t m I --t i #o t m ii i 1 1 I 1 --COICO 1 1 1 30 m* 04 sO t 1 t 1 1 ro ro 0s4j 11 1 11 M l o Ml 1 1 1 1 1 --f m3: o i msiij cot ir*moti Oi tl t ti mr ott orooti i i i i I to 00 I -- so I CK 00 04 04 m m m i Im ro i mi mi m ro m ti i it ti Os 0044 m ii* i tt i t sO Os <x> J1 *** 1 111 ro Mr ol 1 1 i 1i 11 1tf t ro Mr 3 o 111 11t 1 1 OCXs 3D cr*n<2mni on cnn oo 00 i t i i t 04 * r 04 i mi m 04 04 0ro4 04 * i t f i l I 04 1 i o i ro i ro i oo SO CO o ** 04 I CO CK I CO i 3 i i 3 i -041i 04 | m rI m II i <Z> I o ro o ii mo o iii m04 f 04 I I CO --4 I I ^0 1011I M3 I Os I cc. --j j oc i m i 1 I i m\ CO I I I 041I ro *I -b>( U1 I N3 Oil i mi i mi ii i i 04 i o i ro i ro i *i m -si t m i co i 04 I i mi o \ i 1 i m 041I 04 *I I m i ro I i 04 I O ro ro i Os m I 04 t CO mt ck i mi 0* 4 ii OO I mm-oiii rol m i N> I ro 1m 1 oo i Os 00 oo I ro i i ro i oo i i ro ro ii i m ro i 1 1 CK I oo i cn l sll t t i o o i tti o i t i o ii coo i 30 O mPMPPIIVMfWMMMMli VAB.0001190060 - D. A. Barclay Safety There were no safety Instances this month. Cost Savings Savings due to competitive bidding were $8,620 for June, and $100,039 for FY1990. Savings due to prompt payment discounts were $1,645 for June, and $17,977 for FY1990. Savings due to using excess materials (AFE and work order stores) was $17,090 for FY1990. Warehouse - Finished Goods Inventory Slow moving and off'grade inventories are still a major concern approximately 35% of total packaged inventories. tir.aT;figj.c Joe Lutz, U.E.&C., r>.inducted VMS training during June. Jack Little met with Price'Waterhouse to discuss activity based cost accounting. Mickey McGee (EDS) and Gerald Burzynski visited the plant to oversee VMS implementation. Employee Development VMS training held during the entire month of June. Meetings Various meetings and training sessions for VMS. VAB.0001190061 m In Immmmm tun MUM HlciOn n fMMCTS MHtU pnuc 11,211,1$! 139,511 MTI ipi/hc UOU8K 1,090,111 141,750 0 0 umu mmmm imtWMHM * v`i OUlMItU HUM - Hcum 1.SII.IH MM.ttl 1M2I 1,115,510 111,119 9 0 1,207,951 119,499 0 0 00 l.m.isi 0 0 0 0 9 i.in.u0i usneun * mu lunnn vr 1T0.I2I Ml,l 0 IN 11,019,009 1,021,120 unit 1i1nSiu. u comm uwrnncmisonm uiua 141 2100 2 C0STOIII COIVOI rim C1II1II 42 47 94 1 12 04 rciu jin 195 49 $7 TTI PIUIC irr/ifc mum lM.Ml.Ul 1.UI.IH iii.,nhii..hiiii 1.NMN 0 11,HUM MSI,111 U,III,IN 1,111,111 9 0 51,010 0 0 20,141,720 1,IN,111 i.iss,in nun 0 0 9 0 1 Mii.iii 0 129.205 1,304,200 2,275,010 MiMii hi,in,in 111.111,141 s.iii.ns TOTAL 230 20 39 I 295 usu ruuntcNnm inn mom puifiatn mU TTI PICU6II: Mlllt Kill nmuimom nmcNmn mmm mu jut r tiro mu rUtlNi CWMU nmcNmn umeiut mum 1,321 113 217 21 1,N1 243 11 10 9 270 C0STOBKK piuip 9 29 4 9 C0HOI C1IIIII 11 07 3 9 32 91 529 39 141 33 742 TOFC COITMin I/ PS11 0 09 01 90 99 4 12 9 0 10 10 ' 39 291 14 9 245 112 040 73 3 934 09 50 01 09 51 04 49 1 1 199 V 2,993 193 304 54 2.074 TOTU 15 199 7 4 139 200 995 99 4 1.194 * r * VAB. OOO1190062 J. M. Edwards, Jr. A. Safety - There were no safety incidents in the Laboratory during June. The monthly safety meeting topic was respirator and breathing apparatus training taught by Bruce Trego. B. Customer Contacts - There was one customer contact during June. Jim Edwards, accompanied by Mark Washington, visited AT&T Network Systems in Omaha, Nebraska. Two recent contamination complaints were discussed and the packaging of the boxed material was discussed. Cheryl Cincetti presented us with a full Five-Star Rating for our semi annual vendor rating grade for the end of 1989. / 6/14 Vvcom, Scranton. PA Vycom reported "white streaks" while making gray sheeting. It is suspected that the problem could be from undispersed Ti02 or line scale in the dryblend. Jerry Janes is investigating. The product is RP-421 WHT 110 6/28 Formtech. Stow. OH Formtech reported finding metal contamination in RP-91 WHT 110 bulk trailers. The contaminate was ground ferrous magnetic metal the size of color concentrate particles. No metal contamination was found in the retains from the suspected shipment lots. 06/29 Madison Cable Corn.. Worcester. MA Gordon Snyder at Blane reported that Madison Cable's screens were clogging up on 1 1/2 to 2 hours with white fines using 384 FR NAT. Austin R&D analyzed the white contamination and found it to be very high in aluminum concentration. The aluminum trihydrate used in the compound was Aluchem AC 712K (lots V0289-00286, 0131 and 766870). D. Requests for Corrective Action There were no requests for corrective action during the month of June. Dayton Extruded Product RP-151 WHT 145 Reason Color mrnrnmmmm PP 2 R/C VAB.0001190063 LABORATORY - Continued F RVCM Summary The following is a summary of residual VCM results on in- process samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of June, 1990. Reactor Slurries ________Drier 5265 5305 Number of Samples Average RVCM, ppm 865 124 22 0.214 80 0.243 The following is a summary of the residual VCM analysis of shipment samples for the month of June, 1990. Product 5265 5305 5385 5395 5415 Dry Blend Debox Pond Average RVCM. ppm 33 0.063 93 0.103 54 0.311 9 0.043 60 0.034 54 0.065 8 0.199 4 0 603 (based on dryer "regulars") mi Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) 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) Average particle size, microns 1.60 4.33 11.67 6.67 5.33 0.52 -- 0.39 -- *----- *---""- 139 5305 1.07 1.67 0.83 3.17 7.33 2.33 1.28 0.69 -- -- -- --*- 136 5?85 1.67 0.50 4.00 2.17 0.83 -- 0.91 1.67 -- -----37.5 161 5395 0.11 0.26 13.00 2.50 0.88 *--* 0.63 0.89 2.99 ---- 0 145 5415 1.23 0.89 6.67 6.33 2.67 0.17 3.33 2.00 3.46 1.85 2.3 172 VAB.0001190064 Continued Hardness Color Hard Particles Heat Stability Contamination Dicing Cross Contamination Totals unwary 47.0 <0.77> 12.0 <0.20> 59.0 <0.97> Rejections M Lbs. (%) 39.5 9.8 88.0 <0.65> <0.16> <1.45> 10.2 16.8 U.4 178.7 <0.17> <0.17> <Qt ZU> <2.95> Summary Torque Rheometry Color Total 3.3 11.1 <0.07> <9.IZ> <0.24> 1. The program to extract data from the resin shipment database for importing into letters of analysis is complete. A list is being prepared on the letters that will need to be converted using PFS Write to accept the data. 2. After a floppy disk failure of an often used program, a complete backup was made of all important disks managing lab data. 3. Dave Cox met with Witco and Vista R & D representatives to discuss wax properties, wax QC and calcium stearate specifications. 4. Dave Cox examined and evaluated an on-line particle size tester marketed by Lazentech. The instrument failed to reproduce the data and could not tell the difference between resins of different Another precision test was done on the Sintech tensile and elongation tester. The results still indicate an assignable cause 6. Work was started (process flow written) to check raw material Certificates of Analysis against specifications and quarantine of non-complying materials. 7. The RVCM headspace analyzer failed once due to a black carbon dust buildup on the circuit boards. VAB.0001190065 LABORATORY - Continued 8. The Inherent Viscosity analyzer pneumatic mechanism was repaired twice in June. Major work and downtime on this instrument is likely to be needed soon. The Brabender computer went out during a power outage. It was out h for repairs for two weeks and still was out at the end of the month. The Caulter Counter particle size analyzer computer was used during this time which has delayed testing Austin R & D autoclave resin besides slurry samples from the plant. 10. Jim Edwards was trained in Houston to implement the Customer Needs Response Program. This program was activated 06/29/90. 11. The lab worked with Price Waterhouse personnel in determining resources and costs associated in analyzing each individual resin, compound, dryblend, and plasticizer product. 12. All 6 laboratory natural teams met once during the month of June. i,j* J- * VAB.0001190066