Document qa4bjErG44NJ5nvDYX6yVNKZK

1 T. H. Huffman Interoffice Comm u nicotion From: Dote: Subject: D. C. Skokna November 25, 1991 ABERDEEN MONTHLY PROGRESS REPORT OCTOBER, 1991 There were one first aid and one recordable cases reported during October. The recordable case was due to a mechanic who suffered a sprained ankle. On October 11, the plant completed 6,000,000 hours since the last lost time injury, At month's end, the plant's employees have worked 4501 days (6,025,330 manhours) since the last lost time injury. FY1991 Kev Statistical Information Oct. Y.T.D. 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 29.4 65.8 97.0 1.0264 6.09 95.7 2.94 96.7 1.56 78.1 < 12.3> 24.7 < 24.6> 29.4 65.8 97.0 1.0264 6.09 95.7 2.94 96.7 1.56 78.1 < 12.3> < 24.7> < 24.6> An Old Module turnaround and conversion to the VCSM began on October 18. Both modules were down for three days to convert common equipment. All reactors were producing resin by November 7. The new dry blend screeners were installed and successfully started up. Schedules are tight on the flexible compound lines. A H--'H | l^riTT -ii i-. e khhimh r. - ................... 'I Ik -a.:4l -V. VAB.0001189497 'll `**I*I. + - .L. f T. H. Huffman 11/25/91 Aberdeen Monthly Progress Report - October, Page 2 1991 Costs Variable costs (efficiency) were above budget due to an accounting error for the PVC initiators. Above budget costs related to the VCSM conversion/turnaround in the Old Module were offset by a tax credit that reversed an estimated FY91 tax liability. Overall, fixed costs were slightly favorable. QMP Dayton Extruded Plastics (rigid compound customer) visited the plant to discuss product specif ications. Quality Appreciation Day IV was held to recognize team successes during FY91; thirty-nine teams received awards. Seven employees Mississippi". attended "Excellence in The Maintenance Area I Team made a presentation to management. Their project improved the safe access to equipment inside the VCM sphere dike wall. Vinyl "C" shift personnel presented a project to management that purges VCM from filter packs. This eliminates disposal of the spent filter element as a hazardous waste. The Copier Team recommended a new copier to manage ment that improves service and reliability at no incr/ef as/e-/ , in costs. n //f / /r // D. C. Skokna Plant Superintendent rah VAB.0001189498 IT l DISTRIBUTION COVER LETTER ENTIRE REPORT Houston J. D. Bums X R. T. Ferrell X T. H. Huffman X C. J. Matson X D. F. Harman H. R. Flammer X * X R. R, Smith X B. J. Bean X R. H. Gerlach X R. D. Gamblin X C. R. Miller X Austin R. L. Poe X H. J. Hall X Oklahoma Citv H. D. Garrison X LCVCM Plant P. D. Carrico X LCCP Plant J. Friend X LCLAB Plant J. W. Ware X Baltimore L. R. Bauer X Hammond J. Pavao X Premiere P. L. Foote X Aberdeen RWS/DCS (File <Copy), TJA, JBA, JEB, JME, SCH, DAB, DAM , JEN, JDO, BLT A >t-H iirihfcJi-M * 1- 1 l.'^l :iap;.,UK"rri.^ k ,i|^(Biiti.l..i 111 hk.iK lk ry WIM VAB.0001189499 > '-if.: SAFETY - B. L. Trego Oct. Fiscal Y.T.D. 1992 Fiscal Y.T.D. 1991 First Aid OSHA Recordable Total Injuries 1 1 2 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 1 1 0 0 0 2 Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 1 0 0 0 1 0 0 2 Non-Occupational Injuries Lost Workday Cases Days Lost 1 3 Contractor Injuries First Aid Cases Medical Treatment Cases Lost Workday Cases 2 0 0 Safety Record Last lost time injury - 7/5/79 Days since - 4,501 Employee hours since - 6,025,330 On October 31, 1991, the employees of the Aberdeen plant completed 4,501 days with no lost time injury. ildL rtqil \,m:> VAB.0001189500 A SAFETY - Continued The topics for the plant safety meeting during the month were "Hand Tool Inspection" and "Shutdown Safety". The Safety Department presented information about the plant safety programs to the Aberdeen C.A.P. Comments were very positive. Routine dosimetry results for the month were: Chemical < PEL Number Percent > PEL________ Number Percent VCM Lead Total Particulates 77 98.7 1 4 100.0 0 4 100.0 0 Monthly Injury Summary Iniurv Class Department Description RWC Maintenance Sprain, left ankle. Maintenance Laceration, left forearm. A T- 'I.J'ft'1 f:. . . / Irl<. i' : Ih1 'll'"' II -rt'lHIMrtt'-- lir-1 Eli Mr* HVilrVT i*|t " Fi+Jn ................ itr; n-| : ? -ii! n VAB.0001189501 P-T.-L-1-i I. . I. I | I-^I i-i ...J. Pj-H I . r H COST VARIANCES - D. C. Skokna Variable Costs Product _______Oct.. 1991 Variance. SM Efficiency Price Total PVC Flexible Compound Rigid Compound Plasticizer Total <$47.6> 24.1 < 1.5> 0.4 <$24.6> $ 50.6 < 184.5> < 141.9> < 44.5> <$320.3> $ 3.0 < 160.4> < 143.4> < 44.1> <$344.9> Resin The unfavorable variance was due to an accounting error for initiators. The "standard" showed zero initiator usage for some resins, which is in error. Assuming initiator use was at budget rates, the efficiency variance will be $95M favorable. Flexible Compound The variance was essentially at budget. Rigid Compound The variance was essentially at budget. Plasticizer The variance was essentially at budget. Mafor Price Variances: Variance - $M Debox Resin Phthalic Anhydride Electricity Micral 932 Natural Gas Alcohols Resin to Rigid Compound Plasticizers Resin to Flexible Compound Other Price Variances Total $ 65.8 23.0 14.9 14.8 < 34.7> < 70.6> < 84.7> < 98.3> < 106.1> < 29.5> <$320.3> Fixed Cost Variances Payroll and Benefits MM&C Miscellaneous TI&D Clearances Variance - $M Total <$ 14.7> < 0.2> < 2.6> 42.9 < 0.7> $24.7 VAB.0001189502 COST VARIANCE - Continued Payroll and Benefits - Maintenance and operating payrolls were above budget due to the Old Module turnaround and VCSM conversion. MM&C - Costs were at budget. TI&D - The favorable variance was due to a credit in the " Tax 'Other" category that reverses an estimated tax liability charged in FY91. Miscellaneous - Unclassified - Operating Supplies <$28.3> $18.3 The "Unclassified" variance was due to renting a water chiller to improve dry blend quality, and an invoice for physicals that was submitted in September, but not processed until October. A j ja |. I.J 4-- r! WH-* VAB.0001189503 I III r.( m |Mi-ri ^|- VINYL - J. D. Olson, D. E. Knittig Safety The Vinyl Department had no first aid case or OSHA recordable injuries during October. 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 conversion and shutdown in the Old Module began October 18th. Both Old and New Modules were down for three days for common equipment conversion. All New Module reactors except D741 were placed back in service after common equipment conver sion. D-741 was used as a water stripper until the batch water strippers were converted. Conversion continued as planned with all reactors producing resin by November 7th. 2. A leak was detected In the VCM transfer line from the sphere resulting in about 48 reactor hours of downtime in the New Module. The leak was in the VCM line under the rail track. Jumper lines were installed bypassing the leaking line. Oct. - 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 % 29.4 948.8 71.6 686.0 22.1 65.8 79.8 60.0 97.0 Reactor Downtime Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, and dump conflicts). i Maintenance downtime (hydroblast D-741 condenser, Old Module VCSM conversion/ shutdown, D-745 rinse nozzle, D-745 reactor seal, D-400 inert vent valve replacement, VCM transfer line leak, and VCSM common equipment conversion). YTD 29.4 948.8 71.6 686.0 22.1 65.8 79.8 60.0 97.0 Hours 381.0 2166.0 VAB.0001189504 VINYL - Continued Drver Tim** % of Total Downtime Operational downtime (centrifuge plugs, dryer cleaning, flameouts). 5.6 Maintenance downtime (activator problems). 3.5 Reactor limited production. 90.9 Key Maintenance Work - J. B. Autrey, S. A. Truitt 1. The 903 VCM compressor was changed out when the unit quit pumping. The internal heads were worn. 2. Changed out two major valves in the vinyl unit. 3. The east new unit charge water pump was overhauled. The following items were completed during the Old Unit shutdown which coincided with the VCSM conversion: 1. The studs for reactor 400 seal adapter plate were changed. 2. The studs and gasket for reactbr 300 seal adapter plate were changed. 3. Reactor 300 seal was changed; it had developed a slight leak. 4. Cooling tower PM was completed. New composite drive shafts were installed on tower 4A. The fan blades were adjusted to improve efficiency. Hot water basin covers were installed on towers 4A and 4B to reduce algae growth. 5. Annual rupture disc changes were completed on all Old Unit .6 The south fluid bed dryer Bird centrifuge was changed. The old assembly will be sent to Bird to be reworked. 7. Fifty-six relief valves were sent out for repair or replaced as 8. Leactor 400 dump s. was relocated to improve maintenance 9. A pipe stanchion column was eliminated to improve access to reactor 500 seal. A "'k -i:.................... -,k* r r 5,F- ^ i` HIT" ; i Ifcj. M.................. r-" iu-h+ i>*- -J-:: | i VAB.0001189505 VINYL - Continued Kev Maintenance Work - Continued 10. The fluid bed dryer demister pads were changed. 11. The Old Unit recovery line was completed on schedule. 12. Completed old reactor unit shutdown work. All reactors were hydroblasted. All reactor condensers, jackets, and exchangers in the Old Unit were chemically cleaned. 13. Jacket repairs on D-400, D-500 and D-600 were made when leaks were discovered during chemical cleaning. 14. Two condensers in the New Unit were hydroblasted. 13. A jumperline was installed at the VCM tank farm when the old line ruptured under the railroad tracks. 16. The following vessels were inspected: - North and south knockout tanks - North and south batch water strippers - Hot water charge tank - North and south VCM recovered receivers - Fresh VCM receiver - North and south emission recovery tanks - Three seal water coolers - The ERS coolers - All Old Unit reactors Minor repairs were made to one seal water cooler and the north emissions recovery tank. 17. All reactor condenser cooling water valves were rebuilt. 18. The level transmitters on the batch water strippers were up gr ade d. 19. The PIC heater control valve, cooling tower control valve, and back pressure control valve on the batch water strippers were rebuilt. VAB.0001189506 1 COMPOUND - S. C. Hillman, M. R. Kane The Compound Department had no OSHA recordable injuries in October. General The new dryblend screeners were installed and started up. Aside from a few minor issues, the system is working well. Some products have shown improve ment in the particle size. 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. Comnound Production Operating Davs Line I 31 Line III 31 Line V 13 Total % Prime Capacity Utilization Factor Production M (Lbs Month Ave. /Dav 1714 3925 418 6057 95.69 76.8 55 127 32 195 Downtime Line I - Product Changes - One Dicer Offline - Miscellaneous Maintenance Line III - Product Changes - Miscellaneous Maintenance - Quality Line V - Misc. Maintenance - Product Changes Hours 108 59 32 69 17 2 45 15 :i :i . r : : :i I . I . ,n.| : 4- . : 1 ! 11 " r- If M: M I !\1 -t:| ftilf'M1 li 1'- VAB.0001189507 COMPOUND - Continued Operating Days Rigid Compound 31 % Prime Capacity Utilization Factor Production (M Lbs.^ Month Avg./Day 2944 96.65 51.0 95 Downtime - Product Changes - Quality - Running One Blender - Miscellaneous Maintenance Operating Days % Prime Capacity Utilization Factor Hours 143 80 70 26 Production (M Lbs.) Month Avg./Day 1559 78.1 64.6 50 Key Maintenance ork - J. B. Autrey, S. A. Truitt 1. The #1 Welex chutes were cleaned for a test run. 2. The Line I mill Johnson joints were replaced. The old joints were leaking. 3. Line V twin screw motor was repaired when the windings went bad. 4. The picture tube was replaced on the Line I probatcher. VAB.0001189508 I ENGINEERING - J. E. Nickerson, M. L. Carter PROJECTS IN DEVELOPMENT - GENERAL VCSM Conversion of the Old Module to the DCS began on the 18th and should be completed by the first week of November. Recruiting . Major recruiting efforts began in October. Campus interviews were conducted at seven schools and the first plant trips were completed. Approximate fifteen plant trips are being scheduled for November. Ultraclean A dryer DOE using outlet temperature and air flow rate as parameters was completed. Outlet temperature correlated positively with con tamination and air flow correlated negatively. The first plasticizer conversion test run was completed. Work on new operating procedures to increase conversion and reduce monoester sent to the ponds was begun. AT&T AT&T recycled "fluff" was successfully compounded into several low grade products on Line I. A VAB.0001189509 4 ABERDEEN CHEMICAL PLANT MONTHLY PROGRESS REPORT CAPITAL EXPENDITURE STATUS M.L. CARTER OCTOBER REPORT 1991 CAPITAL EXPENDITURES (M$l VARIANCE ACTUAL BUDGET M$ % Month 507.6 773.0 -265.4 -34.3% 1st Qtr 507.6 1943.0 -1435.4 -73.9% YTD 507.6 773.0 +0.0 -34.3% Actual Expenditures - Expenditures in October were $ 265.4 M less than the plant's budgeted expenditure forecast approved in the First Quarter Budget. This underrun can be attributed to the following items: a.) delay in the T/A had a direct impact on several projects accounting for 43.3% of the underrun, b.) VMS errors found in September backed out of the actual in October accounted for 16.2% of the underrun, c.) inclement weather, delays in construction and material/equipment deliveries and procurement on the new water plant project accounted for 40.5% of the underrun. Quarter Budget - Current Quarter Expenditure Forecast as submitted and approved for the current quarter capital budget. YTD Budget - Total of current and previous quarter approved budgets. Forecasted Expenditures - The current approved quarter forecast calls for November expenditures of $ 712.0 M and Second Quarter expenditures of $ 1044 M. VAB.0001189510 i oo UOfI to UJ CO ooc (/> CO oLUr H OJ < H o o 1 I a u CM CO Ui o< CO I-- CO OCoUi u UI Ui iD iD a O' OC CJ O UI oc cd Q OCCO UJ Ui UI aCO a oUJ ui oaUJ Of oUi UJ CL a DC CO CO CQC9 CO Ui Ui CO CO DC Ui u19i Ui Ui CO < o UoJ oOocC H- k UJ UI UI UJ oCO CJ o* UJ CJ ^ DC Ui CJ Ui Q. O ui oac u. CJ o Ui Ui o DC a. a. CZ in i fO o to CM ro >o (VI o CM in so to o o >o OK to o CM itno o o'O 'mO ro in APPROVED CAPITAL PROJECT STATUa <1o i- 1 IX i <x 1 UJ i 1 oc i 11 i t CO CJ 1 CO *"* 1 UJ SI 1 Of i UJ t o i 1 o i 2E t o i oc CO < 1 CL 21 Ui 1 >- i Ui 1 i- o i 3Z i QC i J-- i UJ i 21 i miOi <i i i ii ai UJ O o a Ui o CO o UI CJ u. 2 o o Ui < o QC UJ t O. CL o oc C9 2 Ui in o 0 oo 00 1 CO to o iD Ui O' Uc*i XUJ o o C9 t ff . iii" 1 - --r; I I --I -..: i ittH-iftorr I .fu. ! Ml : t O^ S OC Qs Qn i W.00(1189511 1< Il 1 l_ z on <o Q- a. 1 UJ 1 OC - -i 1 1 CO o 1 CO 1 UJ 3E 1 QC i UJ 1 1 3 i i , CJ t QC * 4A i 1 a. i z1 * UJ 1 * UJ 1 i Q 1 sc OC 1 H i UJ 1 3C CO 1 o <1 i 1 1i 1 Hi O QC u o tu O' oCM O' O' UJ CO ui tf) osr cl u(/) O' w s C\J ru rvj oc a CO o UJ O' o UaJ oc oc 3 co UJ OC UJ QC 8 O' o & oo UJ u CJ CJ oo CO Q. o Os CM UJ QC CO 2 ^ ^ 3E H CO r> * Or 8 a Ui < ui Z I-- if* i % CO UJ </ oc oc & z Q UJ H UJ o oc 111 3 o UJ UJ o QC ui DC U O CM o o o o UJ UJ a oc 3 o--1 UI *4 U- o UI H UI cj QC o UI IL a UI 1-- UJ o oc o UJ uo UJ H" UJ a oc UI CL o UuI CO CO UJ CO UJ oc a. oc s CL oc oc o UJ UJ s CJ Ui o a UJ o o UJ UJ UJ ui sUi CD Ui Ui Si s s s s 2uoC CO UJ 3CO DC OC (/) Ui UJ Ui 2 OC sUi IK s s o QC CO Cl a_ u CO o UJ o oc CL M UJ QC 3 <D Ui o Ui oUI oUJ QC UJ Ol o UJ a Q3r u UJ CO u UJ ooc a* UJ UI CO u UJ o oc a. UJ |w UJ CL u (O o UI o QC a. ur UJ UJ 0- Q. u cj (O CO uu UJ UJ o oc a. CL < CO UJ UJ ** --J sc K *O* UJ OC 00 3 CJ a. oc UJ H oc icno CJ CJ CO Od CO cj UJ o QC oKl o UooJ co UocI 3 co ui oc UJ ~ --y CJ C3 OC UJ O CJ ooc a. oc UI UJ O' CO Os Os CM t I in in i ro * m CJ oc o K> UI u_ < CM in OCOs N- $ Qs CM in SO CM SO UJ o o UJ CO 3 UJ CJ z o UJ o oUcJ J Ol CL Os KI APPROVED CAPITAL PROJECT STATUS o S Kl in o oUocJ CJ OC CUaJI iiOrnno oUcJ ooc s <3 z a. CL CO UI OC UJ y 1" CO CJ UJ CO 3 CJ CO ac UJ oc o QC CO oc CO oc oc UJ UJ CO oc 1-- UJ DC > z o oc o fw CJ z z <z< UJ UJ oc z CL a. omSuO. o $u. ps u. osiGnO SO in CJ o4" SO o o fO SO o O' in SO CJ Omoos CJ in V CO H CJ h* UJ z o UJ 3E oc UJ CL CJ _J a. UI "4 oc CL o< oc CJ CO 3 oc UJ UJ z _J u z J *-- Ui uH (rt CO zUJ z UI X UJ CJ J Ol UJ oc y < oc UJ o UI UJ oc U, Jf o CO 1 5TAB.00(i&189512 k to ucoi z A (OM (ONl OOJ OoJ OoJ Of Of Of LU UI g s 00 o OUIf UOJf 88 88o oo * 2 09 2 CL a. CL CL < < UJ CO CO U_ CO CO <s O UJ uu a uo LU UI UI UI C3 UJI UI o o O Of o o Of Of Of Of Of o. CL a. H a. Chv OJ itno i CO o in O OJ cs OJ in in 1 m a. ro -- K>oo) OJ nj- oo o in o oj M oj in in ^ - OJ o OJ z n UX X u o(/) o IUi J 0Q C-JD JI Of o z; a co < UI OUIf rsi UI Op Of UI UJ Of CO C9 UI oo UI Of o X UI u o Of CO >"1 ' i . -1. - -*i: iph"`-M>l J .............' * CO UI Of CO CO II UI UoJj UJ u CO o u HII UI UI (X UI Of z oo zz UI O. Of z CL Op Q. *p X OJ 1 Of < UJ UJ Of u J-- UI Of u. UI 1< *-- u Of o CO 8 CL o Of z o a -J 1 LU a. CJ Of UI o CO <c o z < u *--t a UI 00 UI z -1 CO o ZS Of-J fppp pj H Of UI u h-- u o fH 2 o -J o -pj UI CO UI 3 z oa l-^i < OJ u oz o * UI Up li. CO o z CJ c/> u CJ u CJ 2 CO CO CO CO CO O0 fratf <o u CO 21 21 3E VAB.0001189513 r t' tA k. h-: : Hi. ^Lr. .1 ENVIRONMENTAL - K. G. Akins ater All wastewater October. discharge # parameters were met for the month of Sunerfond Results from DuPont Environmental Remediation Services (DERS) resampling of the deep wells were received. The wells were being checked for phthalates that appeared during the last sampling. The resampling did not find any phthalate contamination of the deep wells. DERS concluded the phthalates that were present during the one sampling event were due to laboratory contamination. Vaste Waste shipments during the month included: I Fourteen gaylords of filter cartridges to Laidlaw Environmental Services in LaPorte, TX. m Six drums of stabilizer spill to Laidlaw Environmental Systems in LaPorte, TX. Two bulk loads of waste oil to M&M Chemical in Attalla, AL. i A bulk load of empty lead and antimony bags to Chemical Waste Management in Emelle, AL. VAB.0001189514 ENERGY CONSERVATION - J. R. Ganc Oct.. 1991 Fiscal Y.T.D. I* Energy Conservation Data A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU < 13.0%> < 12.3%> 2784.6 111.4 < 13.0%> < 12.3%> 2784.6 111.4 II. Boiler Operation Boiler Combustion Efficiency % Oct.. 1991 Fiscal Y.T.D. No. 1 No. 2 No. 3 83.1% 83.0% 82.4% 83.1% 83.0% 82.4% Boiler #1 operated 29 days in October. Boiler #2 operated 30 days. Boiler #3 operated 21 days. A ilr - - 1 - 'J IH - f VAB.0001189515 .j.l T t--------- OCTOBER. 1991 Peraomifll - J. E. Beall Rp~i oyient Carolyn V. Wigginton - New Hire - Analyst Maintenance (replacing Debbi Lemmons). Promoti oTia/Trawafers > Reed Mackay - Lead Process Engineer - Promoted to Senior Process Engineer (replacing Steve Hillman). Debbi Lemmons - Analyst Maintenance - Promoted to Analyst Payroll (replacing Judy Frossard). Paul Allman - Compound Utility - Promoted to Compound RETIREMENTS Billy Paul Sizemore - Lab Supervisor - chose early retirement. Herbert Jackson - General Mechanic "A" - chose earlv TERMINATIONS/RESIGNATIONS None. TO/FROM T.EAVE OF ABSENCE None. VAB.0001189516 A 15 11 37 24 38 33 5 163 75 90 50 80 52 23 1 10 1 20 62 4 7 18 60% 45% 20.5% 20.8% 59% 30% 40% 38% 9.3% 0 0 0 8.3% 2.6% 3.0% 0 2.5% 24.0% 0 0 1 0 0 0 0 00 1 10.9% 2 6.5% 00 4 12.6% 00 00 . /ki / i M . .................. . ; -i . s| ::M:. \ .ii;- : - : i . j.! ^i-.........l-fl 1- : ,'C.U U I * I " ! ,--f \Z- . I .L't . . ............................................... ^ VAB.OOOl189517 V ...................... s H -i- .ni'-'-.r.. ---r- ---- h*ir i' :r-'fj^'i- VAB.OOOl189518 p P rin te d 11/06/91 DEPARTMENTAL SUMMARY HOURS REPORT ........... MONTHLY ............. A Z O' cM o*0 i. l*r ' -*l F H.I !--! ' I t f( I. 1 TN f ,h.-- VjI .-.I............ v* L t-n *!* r* - :h Tj'-ti-Lipn:. *>! -i ?>..a< =71 i-Wilr *em^-*i|iig>aiT--lliiJ>+ *I'.Tb+^^-f - -p*--- VAB.0001189519 ft '.-lb , .f 'I- ... - . ..,-Vp.: - |. -. ADMINISTRATIVE SERVICES - D. A. Barclay Safety There were no reportable safety Instances this month. Quality All teams met in October. OASIS Progress Due to extremely slow processing time, OASIS closing required seven days. 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 1105 12 $9603 86 207 198 1105 12 $9603 86 207 198 Packaged Finished Goods Ending Inventory Sent.. r91 Oct. Compound "A" Grade 4,240,156 PLENEX 107,846 Compound Off-Grade (BC) 293,590 Compound Off-Grade (H) 202,380 Millscrap 119,045 Dry Blend "A" Grade 593,244 Dry Blend Offgrade 431,162 Resin Type I 707,450 Resin Type "BC" 100 Vacuum Dust 180.759 Total Packaged Warehouse 6,860,354 3,561,429 117,522 427,778 190,380 227,315 703,045 318,312 693,500 100 208.767 6,448,148 (Decrease) % /Increase Change <678,727> 9,676 134,188 < 12,000> 108,270 109,801 <112,850> < 13,950> 0 28.008 <427,584> <16,06> 8.97 45.70 < 5.93> 90.95 18.51> <26.17> < 1.97> 0 16.40 < 6.23> VAB.0001189520 ADMHISTRATXVE SERVICES - Continued Bulk Finished Goods Ending Inventory Sent.. r91 Oct.. r91 Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade Total 1,142,715 0 1,368,843 1,112,560 13,407,612 1.827.100 18,858,830 1,629,815 0 2,142,742 1,255,040 14,088,907 1.865.800 20,982,304 (Decrease) /Increase 487,100 0 773,899 142,480 *681,295 ~ 38.700 2,123,474 % Chance 42 .63 0 56 .54 12 .81 5 .08 2 .12 11 .26 A - -'i . ,& I' ............................. nj*'" [Ttl-iilf-fTr' ' : i..-: . ; II-s-- !jA| --.L-iui -** ri : - VAB.0001189521 L,rv,i-' *' " ........... ' sTrilrTlrtifcmif- I era Kf% & CD Q OC Oc Cl Cl cn era era iii era era era era era era era ii cn cn UU uu CL era i OC oc I Lo era oc Oc i e_i cu uu era Sr eCJf 1111 ura ura in ira Ch O' O* O' cn 3K g o? UG s utr oc osc UJ CO sg o CD o uu CO CD cs oc & 4E 4^ K> i*ra fvO <D CD pc CH CN CH o< O CD ecno| Os ura i i CN CN eg i CN 40 * iai kOO* -ra ro i O' Mi i to i i i i i * era era cn l,B" UU LU UJ SE oo CD CO O CO o M D era <D o SET O1 O' ra CD h-> LU 22 LC WfJ <d A *** *H s S 3C |to a>to CD ^-- SC>i Li ftr* -ra M H CD Oi < to4 sCJ 1 f ( era O' O' Ui CO OO ea Ui ocxz ura tea m hra Ml LU rra Ml A lO ura ura it *"4 hra CCDH CD CH CD PH o CH O CD o- CD Po ^Jl O o ura CD CD t t ura t CO 'Oo OO CO *o i t CD H r-ra i ura ^r tTi ro CH i ura i i i i i era LU ! ^j X --5 A zd A ZD A CCOD Cr* Cr* r*- O- O' P***- * era3 m ura ura ura xX A* A* A>* A>< Oo <D H V--4 !x C DC 3V 3K 3C CM in CH ura PH ura CurHa toi i 1i A OC A A Ol CO Cl CO <4^ *4p* CM M> CM MmDtf PH vO UCH) --f *1 CH PH *ra h-> <D CD CH CH CD CD ura CO -ra rra to *oto A' i t i i i i i t i i i i ura oto CH era tn uu UJ CD CO A 3 era CO IN CD *H r-ra M) Co oo CH CO zer O' CH O' Nura) 1 CH OO -o **' o ura CH rra iqvfO* -o t-H* O' Ch CD CH CD I CD 1 CD 1 **oto 1 1 CM 1 1 1 1 1 1 t tn UJ ipuc o A 0 o-o s CH 3 era o ro ^pC *z 3K ro i A ura 1 ro N3 **a o CH <D 1 O 1 CD CD 1 CD CD 1 1 oto CO ra 1 1 rC-rOa 1 1 1 1 1 3 `Vf"' era CDO t*ra ^n4 to< s re hp*4 1 A A o f*ra CH o i oi oi to i i ura i G i i i i i y i ZD A -a ro CD O to ura r-. * 3 era X; E/ A in. CH O CH CD i Oi CD i CDto i i rs i i i i i i i A UJ O A CD CD* I*** m 3 era v*i M* K1 1 Cl ce CO ura A CM o CM i CM i i P*t*o i i A1 i t i i | 1 cn UJ A A CM to A m 23 A itot --f CH ura CD r*ra CH CH *D ZE A CM CM 1 1 sO 1 to 1 1 CM 1 1 11 1 1 1 cn Ui -*Q un to CM W to A Uu Mi ^o CO o 1 O' <D fO CoM CM tea 11 oI to 1 1 pn 1 ?o i 11 11111 l/) to M) m a cn cn UJ o A _L j MJ 55 I'D 1 Ol oc f^. 40 ura 2 u-a KVo-SF CM 1 o tea IP| y<"D> tn M3 |1P| tea **o -o 1 1IV1111 1 a cn __1 5 A M3 ImtMme3ap LJ CL iIiI (o If CQ 1J ^ Si ura nV11MII|<1T *-o M cp*nu * cn co cn cn era cn o& i So O CD era era VAB.0001189522 i ABERDEEN.CHEMICAL PLANT ANALYS OtlOBtfe 19$| -SHIPMENTS tit PRODUCTS- PUBLIC MOnth IPT/ITC EXCH/TOLL - PUBLIC Ytb IPT/ITC 11:39 AM '- '* * EXCH/TOLL RESIN-BULK RESIN-PACKAGED 14,469,500 11,825,450 263,000 205,750 0 0 14,469,500 11,825,450 263,000 205,750 0 0 FLEXIBLE COMPOUND-BULK 130,340 FLEXIBLE COMPOUND-PACKAGED 3,307,394 2,557,150 0 0 0 130,340 3,307,394 2,557,150 0 0 0 NEW BUSINESS 17.648 00 17,648 00 RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED RIGID COMPOUND-PELLETS 879,735 462,186 0 670,250 6,000 0 0 0 0 879,235 462,186 0 670,250 6,000 0 0 0 TOLLING - BULK TOLLING - PACKAGED 0 00 0 00 0 00 0 00 PLASTICIZER 0 674,250 544,650 0 674,250 544,650 TOTAL -SHIPMENTS BY MODEBULK: *nrTraPO* RESIN FLEXIBLE COMPOUND RIGID COMPOUNO PLASTICIZER 19,529,803 15,938,850 544,650 19,529,803 IS,938,850 544,650 tasagsasswasassaass==x=a:sssaaassaaasaaasasssaasascssssssssxssssssaasssas RAILCAR CUSTOMER PICKUP COMMON CARRIER TOTAL 121 16 45 16 0 7 6 0 12 7 00 182 23 18 7 TOTAL OCTOBER 150 16 64 230 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 121 16 45 16 0 7 6 0 12 7 00 182 23 18 7 TOTAL YTD 150 16 64 230 PACKAGED: OCTOBER* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER CUSTOMER PICKUP 4 25 1 0 COMMON CARRIER 14 97 10 0 TOFC AIR/UPS 00 00 00 00 AIR/UPS 0 2 0 0 TOTAL 18 124 11 0 TOTAL OCTOBER 30 121 0 0 2 153 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 4 14 0 0 25 97 0 0 1 10 0 0 0 000 0 2 0 0 TOTAL YTD 1 S DABr^|_C,.A* EV,JRF A v,. rt ' - | F! i:-' t : H-*-1-:. j,s t F<*t-: -. "* !I- -t-i nr-tsalrj^ifrKWi.|mPlgfc'tiPWHM-Hfl^I - t-+" ^aww*! +" VAB.0001189523 FLEXIBLE & RIGID OFF-GRADE OCT.'90 THRU OCT.'91 VAB.0001189524 LABORATORY - J. M. Edwards A. Safety There were no safety incidents in the Laboratory during October. B. Customer Contacts Jim Edwards and Terry Edwards (Lab Technician) visited Intex in Corinth, MS to show them testing methods for resin hard particles and contamination. C. Customer O.C. Problem Reports and CMR's 10/01 Formtech. Stow. OH The customer complained that product RP-91 was producing "shooting stars" surface imperfections in profile ex trusions. The line was shut down until another delivery of RP-91 was made. The customer complained that the makeup material was delivered four hours too late. The M.S. driver quit his route enroute. 10/02 Formtech. Stow. OH The customer complained that the lot of RP-91 that caused "shooting stars" was also too light in color. 10/02 Thermal Industries. Pittsburgh. PA The customer complained that a ship ment of compound in gaylord boxes arrived so damaged that they had to reject the shipment. The Aberdeen Plant has developed a new loading format to prevent future damage to gaylord box shipments. 10/03 Alenco. Peachtree Cltv. GA The customer complained that the 58162 Black compound produced poor swell and incomplete filling of die. A i' A * * ... .i - .i i- *h.| ' . ';r -|J- tint' -'*'*11 * VAB.0001189525 *z- 'I^-. E -J s: !' -I LABORATORY - Continued C. Customer O.C. Problem Reports and CNR*8 - Continued 10/09 Thermal Industries. Pittsburgh. PA The customer complained that a truck shipment of compound delivered one day early. 10/10 Peckervllle. Plastics. Peekerville. MI The customer complained of inconsis tent processing from box to box of 462-121-B1 Blk 464. This problem is not unique to this lot. 10/11 Chelesa The customer complained that 40,000 pounds of 489-100 WHT 144 was 2.0 b units too yellow. Aberdeen lab shows the material was on the blue side of the target. 10/14 Donnelly Corporation. Holland. MI The customer complained that they had severe processing problems related to thermal stability of lot 51L10 of compound 46234A Black. Samples of the problem material are being analyzed in Austin. 10/17 Pnlroval Chemical. Painesville. OH The customer complained that a 5305 truck order never shipped. A railcar arrived in time to prevent a shutdown at their plant. 10/17 Sunbeam-Home Comfort r T^nrel r HS The customer complained of beige and green pellets mixed in with an order of 27251 WHT compound. Better light ing was installed at the boxing hopper to help detect this problem in the future. A LABORATORY - Continued C. Customer O.C. Problem Reports and CUR'S - Continued 10/21 Thermal Industries. Pittsburgh. PA The customer complained of not receiving a shipment of RP-159 Beige that had been on order a month. Quality problems delayed the ship ment. 10/24 Donnelly Corn.. Holland. MT The customer complained of contamination in 48451 compound. Samples were Austin for analysis. metal Black it to D. Product Waivers There were no waivers for the month. E. RVCM Stmwmyy RVCM of In-Process Samples The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of October, 1991. Number of Samples Average RVCM, ppm RVCM of Shipment Samples 5265 16 0.106 5305 58 0.311 The following is a summary of the residual VCM analysis of shipment samples for the month of October, 1991. Product 5225 5265 5305 5325 5385 5395 5415 5465 Debox Pond Dry Blend Number of Samples 0 32 86 0 27 12 59 1 16 0 6 Average RVCM. ppm 0.033 0.083 0.461 0.122 0.043 0.011 0.474 0.068 VAB.0001189527 1 : j-.- *<*!+ .fH.'Vi : i i. IM:. : . u i r = '-f 1-HSlfl1- I -I i F> A tM-<. .Wist- -H1 >wp' i > * LABORATORY - Continued 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 "bw Color % on Pan (vs. 2% max.) % thru 140 Mets I.R. (vs. 95% of Control) Hard Particles, (% > 10) Average Particle Size, Microns 0.57 1.63 0.21 -- 6.89 8.00 6.00 0 0.16 -- -- 129 G. Flexible Compound Quality ginmuirT 3.40 N/A -- N/A 1.00 4.17 2.50 0.50 -- 0.50 ------- -- -- 123 0.77 0.61 -- -- 1 ..87 -- 1.44 2.06 -- 2.28 ---- -- 48.1 167 2.11 0.64 -- -- 2.83 ------2.67 1.13 -- 1.14 5.21 ------- 3.4 160 1.18 0.29 -- 2.83 ------5.67 2.47 0.47 3.31 5.32 2.67 11.5 177 Adjustments M Lbs. Hardness Color Hard Particles Cross Contamination Streamers METS-IR Totals 7.0 20.0 <0.12> <0.34> 27.0 <0.46> H. Rigid Compound Quality Stimwm-rv Rejections M Lbs m _. _M 27.6 89.4 1.6 4.8 6.0 129.4 __ v <0.47> <1.52> <0.03> <0.08> <0.10> <2.20> Torque Rheometry Color Pitting Total M Lbs. jC%1 3.2 28.8 2.0 34.0 <0.11> <1.02> <0.07> <1.20> > L * -rll L ilJ . H.| J-I.r li|-.l kl- A I lr*T ' J- 'S- VAB.0001189528 A SAMPLE SHIPMENTS OCTOBER 1991 RESIN Ship Date 10/03/91 10/09/91 10/10/91 10/10/91 10/10/91 10/15/91 10/16/91 10/17/91 10/18/91 10/31/91 10/31/91 10/31/91 Product 5395 5415 5325 5225 5325 5325 5415 5305 5415 5465 5225 5395 5415 5305 5385 5305 5325 Amount 4500 lbs. 100 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 500 lbs. 2250 lbs. 50 lbs. 50 lbs. 50 lbs. 100 lbs. 100 lbs. 5 lbs. 5 lbs. 50 lbs. 50 lbs. Customer Hoffinger Industries Inc. BACHMANN REPRESENTACIONES Group Dekko NIBCO Marley Mouldings I. U. S. A. Robbins Tire & Rubber Co. Aeroquip Corp. Cappus Plastics Perstorp Components Westchem Co. Armstrong World COMPOUND Ship Date 10/02/91 I 10/02/91 10/03/91 10/08/91 Product 55041 CB 50 16851 Cb 50 57121 WTCL 327 58031 WTCL 328 640-009-B NAT 55041 CB 50 35852 NAT Amount 100 lbs. 100 lbs. 100 lbs. 100 lbs. 500 lbs. 5 lbs. 5 lbs. Customer Flexible Technologies Macklanburg-Duncan Essex Group Inc. Vista - Austin l- ,j, ---h ,4- "`W it PUTT IFMEH 44-** ^ -|l,AitJ > t* ilvh MB**? iiiif4<OT -THS*jLi.iimii|| JH.WM1 i|i VAB.0001189529 '*! N I*-*-A* 'M-- :> ^i-i 1-i1-- ^^:.n,|Hj^| >^r,ail|iH.i COMPOUND (Cont.) Ship Date Product 10/10/91 14941 NAT 15072 NAT 10/14/91 34501 BLK 10/14/91 27121 NAT 10/15/91 419-50C NAT 419-50C NAT 02 10/16/91 17462 GRY 545 57462 BLK 10/23/91 38601 Clay 20 10/23/91 38552 NAT DRYBLEND Ship Date 10/09/91 Product RP-159 OG PLASTICIZER Ship Date Product 10/07/91 108P MISC. Ship Date 10/23/91 Product Vent Dust Sample Shipments/October 1991 Page 2 Amount 400 lbs. 400 lbs. 1500 lbs. 50 lbs. 10 lbs. 10 lbs. 200 lbs. 200 lbs. 10 lbs. 50 lbs. Customer Central Plastics Cast Film New Edgehill Company Vista - Austin Season All Industries Akzo Eng. Plastics Inc. Precision Cable Amount 1300 lbs. Customer Stylecrest Company Amount 2 lbs. Customer Americhem Amount 100 lbs. Customer Balcones Research Center University of Texas : J: hj.iIj . i n- ` VAB.0001189530 T- ; -ni - ------- A % NUMBER OF ...JURIES TOTAL INJURIES --OSHA RECORDABLE im irH -K- t'KH.H I !kv*-c-^+:d.,Ji-'rt*.- | d nr |r/rf 'w. i-F'-r1 fH .................... . Md^rirt-.--, i*-.-FTffc<. *- -Miiin-rttl j^"hf<H).i*^,iJ>yiil^iiriLiciffHii|-'' VAB.0001189531 w'MiHWwr-*lHfi|^in*frifr-F;rjt^''!*!ft***- +> 'f -v u.\wmFmn:i*:H*1 H-Mftii'fh.,... cn O' A* *K ABERDEEN ENERGY CONSUMPTION o cr> o CJ) m e<> cr LU cn o < oo cn oo oo oo oo oo o o K) m O O CM rO O O i-- rO O O O K) O O cn CM O O 00 CM O O r^ CM O O CD CM O o m CM o o CM O O rO CM O O CM CM an/rua t i i $ P> r!< *;ii --.'#7; -i . . I\ |. : * P I 1 I ' ip i-1 t .................. VAB.0001189532 l>