Document qRBD37My3wX35085qM3xKQmE
T. H. Huffman
imvnniHe
Communication
From: Date:
Subject:
D. C. Skokna October 25, 1991
ABERDEEN MONTHLY PROGRESS REPORT SEPTEMBER, 1991
There were three first aid and two recordable (one MT and one RWC) injuries reported during September. For FY1991, there were nine recordable (four MT and five RWC) cases reported. The RWC involved a mechanic who sprained his back while lifting a valve. The MT case occurred when a mechanic fell on a grating and suffered a laceration of the lower right eyebrow and a contusion on the right cheek.
A Supervisor Safety Seminar was held during the month with forty
attendees. Topics included product safety, substance abuse,
supervisor responsibilities and liabilities, and safe job
preparation.
As of September 30, the plant's employees
completed 4470 days (5,984,039 manhours) since the last lost
time injury.
FY1991 Key Statistical Information
PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Productiion, 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
Operations
uf it
CAI
38.3 93.4 98.3 1.0412
5.6 98.5
3.2 95.5
1.5 89.4
4.6> 69.4 15.6
Y.T.D.
458.6 86.8 97.9
1.0247 59.2 97.3 52.1 98.8 18.3 84.7
< 10.3> < 202.0> < 278.7>
The resin production of 458.6MM pounds is a new all time annual record surpassing the previous record set in FY90 of 457.4MM pounds. The conversion of the Old Module to the VCSM is set to begin October 18.
Compound orders were good during the month. Dry blend quality concerns caused more than normal downtime and slower rates.
VAB.0001189534
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T. H. Huffman 10/25/91 Aberdeen Monthly Progress Report - September, 1991 Page 2
Costs
Variable costs were near budgeted levels.
Fixed costs were favorable due primarily to a favorable MM&C variance. However, an accounting error resulted in no contract costs being charged in September. This error will be corrected in October.
The Shipping Natural Team made its manage] ent presentation for a proj t that will improve safety and productivity in the finished goods warehouse.
The Plant Manager's Natural Team identified $403M in cost savings from their project to improve cash flow by $1MM. Some of the incomplete items will carry into FY92.
Chelsea Building Products visited the plant for a general overview, tour and a review of dry blend quality control procedures.
A two-day team management course was presented to sixteen employees.
The plant's average natural team score in FY91 is 17.2, up 72% during the year.
In FY92, the plant's natural teams had forty-four documented successes. Improvements were noted in
quality, productivity, environmental awareness, and safety as a result of these projects.
D. C. Skokna Plant Superintendent
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DISTRIBUTION Houston
J. D. Burns
COVER LETTER 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. Gamblin
Austin
C. R. Miller R. L. Poe
X
H. J. Hall
Oklahoma Citv LCVCM Plant
H. D. Garrison P. D. Carrico
LCCP Plant
J. Friend
LCLAB Plant
J. W. Ware
X
Baltimore
L. R. Bauer
X
Hammond
J. Pavao
X
Premiere
P. L. Foote
Aberdeen RWS/DCS (File Copy), TJA, JBA, JEB, JME DAM
ENTIRE REPORT
X X X X X X X X X
X X X X
X
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VAB.0001189536
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SAFETY - B. L. Trego
Sept.
Fiscal Y.T.D. 1991
Fiscal Y.T.D. 1990
First Aid OSHA Recordable
Total Injuries
3 2 5
Number of Restricted Workday Cases Number of Lost Workday Cases
1 0
Injuries bv Department
Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office
Totals
0 0 5 0 0 0 5
Injuries bv Type
Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other
Totals
3 0 1 0 1 0 0 5
Non-Occupational Injuries
Lost Workday Cases Days Lost
0 0
Contractor Injuries
First Aid Cases Medical Treatment Cases Lost Workday Cases
0 0 0
Safety Record
Last lost time injury - 7/5/79
Days since -
4,470
Employee hours since - 5,984,039
On September 30, 1991, the employees of the Aberdeen plant completed 4,470 days with no lost time injury.
VAB.0001189537
A
SAFETY - Continued
Topics for plant safety meetings during the month included: Operation Clean Sweep and Off-the-Job Safety. In addition, Vinyl and Compound shift workers conducted familiarization tours for emergency crews.
A Management/Supervisor Safety Seminar was held in October with over forty attendees. Topics included Product Safety, Substance Abuse, Supervisor Responsibilities and Liabilities and Safe Job Preparation.
A fire drill was held in the plasticizer tank farm. It required use of foam by Vista personnel and response by the Aberdeen Fire Department. Headcount was also evaluated.
Routine dosimetry results for the month were:
Chemical
VCM Lead Total Particulates
Monthly Injury Summary
PEL Number Percent
81 100.0
8 100.0 3 100.0
> PEL
Number
Percent
00 00 00
urv Class FA FA FA MT
RWC
Department Maintenance Maintenance Maintenance Maintenance
Maintenance
Description
Contusion and abrasion of left elbow.
Metal splinter in ''ring" finger of left hand.
First degree burn at back of neck.
Laceration of lower right eyebrow and severe con tusion of upper right cheek, below eye.
Muscle sprain of lower back.
VAB.0001189538
OTTAT.TTY HANACEMKHT PROCESS - T. J. Arbelter
All of the plant's natural teams met during September, Some of the teams' highlights for the month were:
The Shipping Natural Team made a presentation to Management on September 18. The problem the team identified was the lack of restroom facilities in the finished goods warehouse. The team identified numerous health, safety and productivity problems associated with this lack of a facility, including:
- Truck drivers traveling unescorted through the plant in search of a restroom.
- Warehousemen have no facilities convenient for washing their hands prior to eating lunch.
- No eyewash facility near the warehouse.
- Warehousemen spend too much time giving directions to truck drivers.
- Warehousemen must walk an excessive distance to and from the restroom - this takes time away from work.
The team identified five alternative solutions to the problem, selected one and solicited bids from four qualified contractors.
The Plant Manager's Natural Team identified $403M in cost savings from their project aimed at increasing cash flow by $1MM. These cost savings resulted from efforts relating to staffing optimi zation, energy conservation, inventory control, productivity improvement and administrative stream lining.
The Synergy Team continued selecting in on the brainstormed list of barriers to effective par ticipation in QMP/natural teams.
Chelsea Building Products visited the plant on
September 10. Attendees from Chelsea included Jeff
Miller, Vice President Engineering;
Gunther
Nitsch, Technical Director; and Phil Marshall,
Quality Control Manager. The purpose of the visit
was to provide Chelsea with a general overview of
our plant operations, a detailed demonstration of
the quality control of rigid compound, and to
discuss the use of SQC, SPC and DOE at the Aberdeen
Plant.
VAB.0001189539
onat.tty management process - Continued
The Quality Coordinator conducted a two-day team management course for sixteen plant employees. Bob Seymour, Doug Skokna, Bruce Trego and Steve Hillman volunteered to conduct modules during the course. Thanks for the help!
The average natural team score for FY92 is 17.2, up 72% during the year.
A
VAB.0001189540
GOST VARIANCES - D. C. Skokna
Variable Costs
Product
Sept.. 1991 Variance. $M
Efficiency
Price
Total
PVC Flexible Compound Rigid Compound Plasticizer
Total
<$52.4> 12.2 10.3 45.5
$15.6
$537.9 < 317.1> < 72.2> < 90,7>
$ 57.9
$485.5
< 304.9> < 61.9>
< 45.2> $ 73.5
PVC Resin
Energy use was above budgeted levels.
Flexible and Rigid Compounds
Both compound units operated near budgeted efficiencies.
Plasticizer
Raw material usage was favorable.
Malor Price Variances:
Variance - 8M
VCM Natural Gas Phthalic Anhydride m Resin to Rigid Compound Resin to Flexible Compound a Alcohols m Plasticizers m Other Price Variances
Total
$486.7 43.6 27.2
< 76.7> < 94.0>
<122.2>
<192.9> < 13.8> $ 57.9
Fixed Cost Variances
Variance - $M
Payroll and Benefits MM&C Miscellaneous TI&D Clearances
Total
<$ 2.8> 148.7
< 68.1> 0.6
< 9.0> $ 69.4
Payroll and Benefits - A $21.7M favorable payroll variance was offset by an
unfavorable benefits variance of $24.5M.
MM&C - An accounting error of some type showed contract expenditures to be <$21.7M>. Actual expenditures were approximately $100M. Therefore, this month's variance is incorrect.
VAB.0001189541
VINYL - J. D. Olson, D. E. Knittig
*
The Vinyl Department had no first aid case or OSHA recordable injuries during September.
The monthly safety meetings were held on shift with each shift supervisor leading discussions focusing on shutdown safety issues and other shift concerns.
General
1. VCSM project team prepared for an October conversion of the Old Module. The date has been moved to October 18 due to inven tory constraints. The conversion team focused on optimization and documentation.
2. The west incinerator installation was completed.
Testing
continues prior to shutdown and replacement of the east
incinerator.
3. Testing of a closed dump system was completed. The cleanwall and evacuation reactor modes were reversed in sequence to evaluate the effect of cleanwall on the condenser with no evacuation after application. PED is working on the design.
Seut.
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
%
38.3 1275.7
100.0 925.0
30.8 93.4 94.5 98.5 98.3
458.6 1256.3
98.5 10783.0
29.5 86.8 91.0 90.9 97.9
The fiscal 1991 production of 458.6MM pounds is a new fiscal production record exceeding the previous record of 457.4MM pounds in fiscal 1990.
Reactor Downtime
Hours
- Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, and dump conflicts).
308.0
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VAB.0001189542
VINYL - Continued
Reactor Downtime
Hours
Maintenance downtime (hydroblast D-744 condenser, New Module DCS download, hydroblast D-741 condenser, incinerator outage, D-745 rinse nozzle, D-300 Lenape lid replacement, ram valve on D-744, Install DCS patch and download D-743 programs, D-744 annual rupture disc changeout, PM D-300 gearbox, PM D-745 gearbox, D-745 cooling water valve, and replace RTD on D-741.
170.0
Dryer Time
% of Total Downtime
m Operational downtime (centrifuge plugs, dryer cleaning, flameouts).
39.7
Maintenance downtime (dryer PM).
7.7
m Reactor limited production.
52.6
Key Maintenance Items - J. B. Autrey/S. A. Truitt
1. The annual rupture disc changes were completed on reactors 741 and 744.
2. The emission recovery compressor's seal was changed when it developed a leak.
3. Reactor condensers 741, 742 and 744 were hydroblasted in an effort to control contamination.
4. Reactor 745 seal was changed after twenty-three months in
5. Maintenance assisted the startup on the west incinerator.
6. The critical instrumentation PM for the SA module was completed.
7. One major valve in Vinyl was changed out in September.
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VAB.0001189543
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COMPOUND - S. C. Hillman, M. &. Kane
The Compound Department had no OSHA recordable injuries in September.
General
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.
Compound Production
Operating Pars
Line I
30
Line III
30
Line V
7
Total
% Prime
Capacity Utilization Factor
Production M (Lbs.3
Month
Fiscal T.T.D.
1807 3526
274 5607 98.5 72.3
60 118
39 187
20076 35067
4069 59209
97.3 63.3
Downtime
Line I
- Product Changes - One Dicer Offline - Miscellaneous Maintenance
Line III
- Product Changes - Miscellaneous Maintenance - Quality
Line V
- Product Changes
Hours
118 56 8
59 16
5
33
*
VAB.0001189544
COMPOUND - Continued
Operating Dave
Rigid Compound
30
% Prime
Capacity Utilization Factor
Production (M Lbs. 1 Month Avg./Dav Fiscal Y.T.D
3213 95.5 46.9
107
52108 98.8 70.0
Downtime
- Running One Blender - Product Changes - Quality - Miscellaneous Maintenance
Operating Davs
Plasticizer
30
% Prime
Capacity Utilization Factor
Hours
93 93 77
11
Production (M Lbs.3
Month
Fiscal Y.T.D.
1494 50 18307
89.4
84.7
70.9
76.1
Key Maintenance Work - J. B. Autrey, S. A. Truitt
1. PM procedures on #5, #6, and #9 dicers were completed.
2. Line I and plasticizer critical instrumentation lists were completed.
3. The search coils on #5 and #6 metal detectors were replaced due to
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VAB.0001189545
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ENGINEER TUG - J. E. Nickerson, M. L. Carter
PROJECTS IN DEVELOPMENT - GENERAL
VCSM
Movement of common equipment from the old control room to the new DCS equipment continues as operation requirements allow. Turnaround for conversion of the Old Module is scheduled to start October 18.
Drv Blend Oversize Problems
Dry blend screener replacement startup is complete. An evaluation of product quality improvements and troubleshooting new equipment problems continues. Design work and testing for new cooling equip ment continues with plans to start up a rented water chiller next month.
Incinerator Replacement
The new west incinerator startup is complete and on line. The east incinerator was shut down and the replacement startup is scheduled for November.
AT&T Scrap Recycle
Preparations are complete for a scrap test run on Line I which will be conducted when the production schedule permits. The trial will attempt to produce several types of products from the scrap material.
MSA RrM>nded Test Rim
An extended test run is in progress to determine if methane sulfonic (MSA) is a viable substitute for PTSA as the catalyst for plasti cizer production. The objective is to reduce organic loading to the ponds without affecting product quality. Thus far, product quality has not been affected by the use of MSA, however, no substantial improvements in organic loading have been noticed either. Further test runs are planned for mid-October.
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VAB.0001189546
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ABERDEEN CHEMICAL PLANT APPROVED CAPITAL PROJECTS
EN6INEERIN6 - H.L. CARTER
AFE NUMBER
A519 A649 A909 C591 0511 0550 D570 0580 0600 0749 D049 D899 F551 F650 F660 G560 G561 0610 G630 G659 G839 H500 H501 H510 H531 H541 H571 H581 H601 H620
PROJECT DESCRIPTION
PLANT ELECTRICAL UP6RADE VINYL CONTROL SYSTEM MODERNIZATION INERTS REMOVAL MODIFICATIONS DRYBLEND SAMPLE LINE VCM UNLOADIN6 MODIFICATIONS RAILCAR ACCESS PLATFORMS OLD MODULE RECOVERY SYSTEM ACCE5S RECOVERY VACUUM PUMP PRESSURE REL. PLASTICIZER LOADING. 1 UNLOADING. MOD. LEAD HANDLING AND EXPOSURE REDUCTION COMPOUND LINE 3 SEMI-BULK LEAD HANDLIN6 RAILCAR CLEANING RACK DRY BLEND SCREENER REPLACEMENT 5305 RESIDUAL VCM REDUCTION DECALCIFIED NATER TC SPILL CONTAINMENT WASTEWATER INFLUENT EQUALIZATION TC COMPLIANCE PROJECT REACTOR SLURRY STRIPPING OPTIMIZATION NEW DRYER BA6H0USES PLANT WATER RECYCLE PLANT WATER SYSTEM MISCELLANEOUS CAPITAL PROJECTS < I15M WEST INCINERATOR REPLACEMENT BOILER FEEDWATER TANK REPLACEMENT PVC GEARBOX REPLACEMENT D-745 RX DRIVE SHAFT REPL SPARE LARGE RX A6ITAT0R MOTOR GAS CHROMATOGRAPH UPGRADE EAST INCINERATOR REPLACEMENT
STATUS
PROJECT HAS BEEN COMPLETED AND TARGETED FOR FIELD CLOSURE 10-15-91 N.M CONVERSION WAS MADE IN JULY T/A - O.M. CONVERSION SCHEDULED FOR OCT. PLACED IN OPERATION B-91, TAR6ETED FIELD CLOSURE NOV FY 92 CONSTRUCTION IS IN PR06RE55 TARGETED PLACE IN OPERATION 12-91 CONSTRUCTION IN PROGRESS, MISC. MATERIALS STILL ON ORDER. PLACED IN OPERATION 8-91f TARGETED FIELD CLOSURE NOV FY 92 PREFAB WORK HAS BEEN COMPLETED, PLANNED FOR OLD MODULE OUTAGE IN OCT. N.M. WORK NAS COMPLETED JULY T/A - O.M. WORK PLANNED FOR OCT T/A PLACED IN OPERATION 8-91, TARGETED FIELD CLOSURE NOV FY 92 PROCESS ENGINEERING IS MONITORING MODIFICATIONS. MODIFICATIONS HAVE BEEN MADE, A TEST RUN HAS BEEN SCHEDULED FOR OCT PLACED IN OPERATION 8-91, TARGETED FIELD CLOSURE NOV FY 92 SCREENERS ARRIVED AND WILL BE INSTALLED IN OCT. TAR6ETED COMPL. IS OCT PROJECT IS TAR6ETED TO BE PLACED IN OPERATION IN OCT 91 NEW FILTERS DUE TO ARRIVE IN OCT. TARGETED COMPLETION NOV. FY92 PROJECT HAS BEEN COMPLETED AND TARGETED FOR FIELD CLOSURE 10-15-91 CONSTRUCTION IS CURRENTLY IN P0R6RESS, TARGETED OPERATIONAL MID OCT.FY 92 PROJECT HAS BEEN COMPLETED AND TARGETED FOR FIELD CLOSURE 10-15-91 N.M. WORK WAS COMPLETED JULY T/A - O.M. WORK PLANNED FDR OCT T/A MODIFICATION OF MEMBRANE BACKING IS SCHEDULED FOR OCT OUTAGE. PROJECT IS TARGETED TO BE PLACED IN OPERATION IN 11-91 I & E ENG. IN PROGRESS, CIVIL AND SITE CONSTRUCTION IN PROGRESS 36 PROJECTS APPROVED, 22 COMPLETED, ENG.IS IN PROGRESS ON 14 PROJECTS. INCINERATOR INSTALLED. PROJECT COMPLETION TARGETED FOR 10-91 PROJECT HAS BEEN PLACED IN OPERATION, TARGETED FIELD CLOSURE DEC FY 92 PROJECT IS TARGETED TO BE PLACED IN OPERATION IN 0CT FY 92 PROJECT IS TARGETED TO BE PLACED IN OPERATION IN OCT FY 92 CURRENTLY NORKING WITH VENDORS ON PRICING PROJECT WAS APPROVED IN JULY FY 91
INCINERATOR DELIVERED. PROJECT COMPLETION PLANNED FOR 11/91.
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VAB.0001189547
ENVIRONMENTAL - K. G. Akins
Water
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All wastewater discharge parameters were met for the month of September.
Samples of stormwater were collected from unpermitted outfalls during a rain event on September 24. Three to four weeks are required for analysis. This information is needed for the permit applications.
DuPont Environmental Remediation
(DERS) completed
sampling of the deep wells. The wells were being checked
phthalates that appeared during the last sampling. Results
expected in late October. The MDEQ was on site to observe
sampling.
the for are the
Conoco's Subsurface Environmental Assessment Lab (SEAL) attempted to delineate the vinyl chloride plume detected in shallow groundwater south of the New Module. The SEAL unit located the boundaries of the plume but did not pinpoint the source. This will probably be done with further SEAL work. The sewers will be visually inspected during the October shutdown.
Waste
Waste shipments during the month included:
Eighty drums of plasticizer filter cake to Fisher Industrial Service in Gadsden, AL.
A bulk load of storm water solids to M&D Industries in Alpine, AL.
VAB.0001189548
ENERGY CONSERVATION - J. R. Ganc
I. Energy Conservation Data
Sept.. 1991
Fiscal Y.T.D.
A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU
II. Boiler Operation
< 5.8%> < 4.6%>
2666.0 130.2
< 11.1%> < 10.3%>
2772.9 1624.1
Boiler
No. 1 No. 2 No. 3
Contmstlon Efficiency % Sept.. 1991 Fiscal Y.T.D.
83.2% 83.2% 82.7%
83.2% 83.3% 82.8%
VAB.0001189549
HUIOUy RESOURCE REPORT SEPTEMBER. 1991
Paraon^al - J. E. Beall
None.
Pgoioti^iif/T^pgferg
J. E. Nickerson - Operations Superintendent - Transferred to Chief Process Engineer (replacing Rendell Newton).
Steve C. Hillman - Senior Process Engineer - promoted to
Operations Superintendent
(replacing J.
E.
Nickerson).
Judith A. Frossard - Analyst Payroll - promoted to Production Scheduler (replacing Amy Bagwell).
John D. Hull - General Mechanic "A" -- promoted to Maintenance Supervisor (replacing Charles Smith).
RETIREMENTS
None.
None.
TO/FROM T.R1VB n ABSENCE
None.
VAB.0001189550
ABERDEEN PLANT
90 50 80 52 23 1 10 1 20 62 4 7 18
60% 45% 20.5% 20.8% 59% 30% 40% 37.8% 9.3%
0 0 0 8.3% 2.6% 3.0% 0 2.4% 24.0%
0 0 1 0 0 0 0
0 1 1 0 4 0 0
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VAB.0001189553
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ADMINISTRATIVE SERVICES - D. A. Barclay Safety
There were no reportable safety Instances this month.
tty
The Shipping Natural Team made a management presentation on their project In September.
OASIS Progress
Closing of the OASIS system in September improved by approximately fifty percent.
Statistics
Processed
Month
Y.T.D.
Processed Invoices Working Fund Checks Written Cost Savings Through Bid Process Raw Material Purchase Orders Issued MRO/AFE Purchase Orders Issued Spare Parts Purchase Orders Issued
1199 12
$ 255 120 216 167
11544 154
$28845 1117 2202 2098
Packaged Finished Goods Ending Inventory
Aug..'91
Compound "A" 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 Warehous e
4,309,548 85,626
365,738 182,848 117,408 537,998 356,699 731,450
100 172.939 6,860,354
Sent.. '91
4,240,156 107,846 293,590 202,380 119,045 593,244 431,162
707,450 100
180.759 6,875,732
(Decrease)
%
/Increase
Change
<69,392> 22,220
<72,148> 19,532 1,637 55,246 74,463
<24,000> 0
7.820 15,378
< 1.61> 25.95
<19.73> 10.68 1.39 10.27 20.88
< 3.28> 0.00 4.52 0.22
VAB.0001189554
ADMINISTRATIVE SERVICES - Continued
Bulk Finished Goods Ending Inventory
Aug.. *91
*91
Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade
Total
643,615 177,500 2,984,939 1,112,560 11,179,589 1.775.473 17,873,676
1,142,715
0
1,368,843 1,112,560 13,407,612 1.827.100 18,858,830
(Decrease) /Increase
%
Change
499,100 < 177,500> <1,616,096>
0
2,228,023 51.627
985,154
77.55
<100.00>
< 54.14>
0.00
19.93 2,91
5.51
VAB.0001189555
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VAB.0001189556
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VAB.0001189557
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ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS SEPTEMBER 1991
-SHIPMENTS BY PRODUCTS-
PUBLIC
MONTH IPT/ITC
EXCH/TOLL
PUBLIC
YTD IPT/ITC
11:09 AM 11-Oct-91
EXCH/TOLL
RESIN-BULK RESIN-PACKAGED
18,533,320 387,178
15,059,000 254,200
0 0
230,867,502 154,164,110
3,648,011
2,596,150
1,777,400
0
FLEXIBLE COMPOUND-BULK FLEXIBLE COMPOUND-PACKAGED
516,660 2,837,347
1,964,950 1,500
0
0
7,177,555 36,404,594
17,082,490 833,970
0 0
NEW BUSINESS
5,771
00
141,346
00
RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED RIGID COMPOUND-PELLETS
2,699,390 495,886 0
499,300
0 0
0
0 0
36,441,670 4,799,827 38,022
7,393,296 906,801 0
0 0
TOLLING - BULK TOLLING - PACKAGED
0 00
0 00
0 0 1,401,960 0 0 33,600
PLASTICIZER
42,420
581,220 369,200
993,810
3,190,830 4,572,010
11 H
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TOTAL
-SHIPMENTS BY MODE-
BULK:
* --------------
RESIN
*4FcPrTiFcMfiRdFcRii *
FLEXIBLE COMPOUND
RIGID COMPOUND PLASTICIZER
25,517,972 18,360,170
=== ==== = = = =
369,200
RAILCAR
144 11 12 5
CUSTOMER PICKUP
32 0 0 0
COMMON CARRIER
53 11 28
2
320,512,337 186,167,647 7,784,970
TOTAL 229 22 40 7
11
TOTAL SEPTEMBER
172 32 94
298
*YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
TOTAL YTD
PACKAGED:
SJLErPT1 EtrMwBtEnR*
RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
1,850 125 229 33
2,237
CUSTOMER PICKUP
457 0
27 29
4
513
s===sssssas
COMMON CARRIER
3 19 22 72
1 17 00
II II II
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492 60
183 39
774
TOFC AIR/UPS
00 00 00 00
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It
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2,799 185 439 101
3,524
sasssaasssa
TOTAL
23 95 18
0
TOTAL SEPTEMBER
26 108 0 0
2
136
*YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
38 176 0 0 292 895 0 0
11 181 0 0 0 300
53 82
4 0
267 1,269
196 3
TOTAL YTD
341 1,255 0 0 139
1.735
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VAB.0001189558
LABORATORY - J. M. Edvards
A. Safety
There were no safety incidents in the Laboratory during September.
B. Customer Contacts
Mike Kane, Randell Jackson and Jim Edwards visited Dayton Extruded Plastics to make several presentations to their entire plant on Vista's Quality Management Process and the product we sell them.
C. Customer O.C. Problem Reports and CNR's
9/04 Vlcoa. Glassoort. PA
The customer complained of a late shipment due to a problem with the carrier.
9/04 Vinyl Building Products
The customer complained of inconsis tent RP-20 varying in gloss level, slow fusion and causing streaking. R&D Technical Service developed a new test which may detect future vari ability .
9/06 Vinyl iwi
The customer complained that four board pallets were being used instead of the requested three board pallets.
9/06 TextHeather. Toledo. OH
A railcar of 5385 resin was routed in error and went to the wrong destina tion. This was the second time in three months that a shipment was de layed to Textileather.
9/12 Textileather. Toledo. OH
The customer complained of high brown contamination in a 5385 resin railcar. Jim Edwards visited the Toledo plant to learn how Textileather does their contamination testing and what specifications were needed.
LABORATORY - Continued
C. Customer O.C. Problem Reports and Cfflfs - Continued
9/15 Central Industries. Evansville. HI
The customer complained of "threads" in compound which jammed their equip ment. Samples showed the "threads" to be streamers.
9/15 Central Industries. Evansville. IN
The customer complained of being invoiced for 3000 pounds of product but only received 2600 pounds.
9/29 Essex. Marion. IH
The customer complained of receiving a truck of 5416 resin two weeks early.
D. Product Waivers
Customer
Product
Reason
Available Dayton
80273G WHT 110 RP-152 WHT 140
Long Fusion 40 Mesh
Thermal
RP-159 BGE 347
Color
Vycom
RP-461 WHT 110
40 Mesh
No. 1 H/T 1 H/T 1 Lot 1 H/T
E. RVCM Summary
RVCH of In-Process Samples
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 September, 1991.
Number of Samples Average RVCM, ppm
911 72
Drier 5265
14 0.786
5305
110
0.672
*
VAB.0001189560
LABORATORY - Continued
E. Rvcnc finwMrv - continued
RVCM of Shipment Samples
The following is a summary of the residual VCM analysis of shipment samples for the month of September, 1991.
Product
Number of SamDles
Average RVCM. ddid
5225 5265 5305 5325 5385 5395 5415 5465 Debox Pond Dry Blend
0 31 161
6 44 12 80
4 12
4 5
0.053 0.145 0.045 0.139 0.029 0.010 0.002 0.187 0.334 0.009
F. Resin Process Capabilities (based on dryer "regulars")
5265
5305 5385 5395 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
0.67 0.63 0.16
--
3.61 8.33 2.00 1.50 ------1.31 --
--
--
150
0.92 0.83
--
0.79 1.93 4.67 2.44 1.00
--
0.99
--
--
--
146
1.20 0.33
-- --
1.43
--
2.17 1.33
--
1.65
-- --
20.5
171
1.39 0.33
--
--
2.75
----
2.33 0.60
--
0.76 3.15
------------------ -------
28.8
154
1.17 0.30
--
--
2.33
-------------------------
6.33 0.74 0.02 1.54 3.67 1.78
0.3
172
VAB.0001189561
LABORATORY - Continued
Flexible Compound
Hardness Color Hard Particles Heat Stability Contamination Dicing Cross Contamination Mischarge METS-IR
Totals
Adjustments M Lb*31.0 <0.55>
31.0 <0.55>
Quality Summary
Rejections M Lbs . m
------
7.7 16.2
1.0 17.4
2.3 1.0 11.6 12.0 69.2
------_
<0.14> <0.29> <0.02> <0.31> <0.04> <0.02> <0.20> <0.21> <1.22>
Torque Rheometry & Color Torque Rheometry 6c 40 Mesh Color Color A 40 Mesh Contamination 40 Mesh
Total
I. Miscellaneous
Rejections M Lbs, iii
14.3 7.0
18.2 6.1
21.2
70.7
<0.43> <0.21> <0.54> <0.18> <0.63> <0.12> <2.11>
1. The lab data entry and report programs are all complete for the Vinyl computer VAX information system.
VAB.0001189562
*
SAMPLE SHIPMENTS SEPTEMBER 1991
RESIN
Ship Date 9/06/91
9/06/91 9/10/91 9/11/91 9/11/91 9/12/91 9/12/91 9/16/91 9/18/91 9/19/91
Product 5305 5385 5465 5305 5325 5395 5416 5225 5415 5225 5385 5415
Amount 50 lbs. 50 lbs. 2250 lbs. 150 lbs. 2250 lbs. 2250 lbs. 2250 lbs. 50 lbs. 100 LBS. 5 lbs. 50 lbs. 50 lbs.
Customer Baerlocher USA
Vinylex Corporation PROVEEDOR QUIMICO Sliverline Plastic Corp. LaGrange Molded Products Essx group Inc. Gary Chemical IUSA Carlon MARCOTECH
COMPOUND
Ship Date 9/06/91 9/26/91
9/26/91
9/26/91
DRYBLEND
Ship Date 9/09/91 9/26/91
Product 452-147 WHT 380 57121 WTCL 327 58031 WTCL 328 462-20A BLK 462-20B BLK 462-20A BLK 462-20B BLK
Product RP-461 WHT 110 RP-34 WHT 141 RP-91 WHT 110
Amount
500 lbs.
500 lbs. 500 lbs.
1000 lbs. 1000 lbs.
100 lbs. 100 lbs.
Customer Sunbeam-Northern Co. United Technologies Corp.
Deckerville Plastics Inc.
John Levardsen
Amount
15 lbs.
50 lbs. 50 lbs.
Customer Vycom PPG Industries
VAB.0001189563
r i.... |
j- i-
\
4
NUMBER OF INJURIES
25
20
15
10
5
0
M J S N J'89 M M J S NJ*90M M J S NJ'91M M J S MONTH
TOTAL INJURIES --*-- OSHA RECORDABLE
I I i>
rI 1' '
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'
VAB.0001189564
# 4
MONTH
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VAB.0001189565