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FILE NAME Firestone FIRE DATE 1982 DOC FIRE007 DOCUMENT DESCRIPTION History and description of Firestone Decatur Plant Ex 41 APPENDIX B Section POSTAGE METER RECORD BOOK Those departments that have their own postage meters are required by Federal law to keep a Meter Record Book Form 3602 showing register readings of metered mail on each day of operation of the meter Meter Record Books must be retained for at least one year from the date of final entry See 39 C.F.R. 501 et seg Updated 9/2005 Jackson 064432 Decatur Illinois Page 1 of 8 DECATUR ILLINOIS TIRES TUBES AND CAMELBACK 10/31182 History The Decatur Plant is located on North 22nd Street in Decatur It was originally constructed in 1943 as the Victory Ordnance Plant Major products were T87 Power Trains for Caterpillar D Tractors The Firestone Tire & Rubber Company purchased this facility in 1962 from the government The first tire was cured February 14 1963. The 1966 Expansion increased the capacity of the plant to 26,000 tires per day The 1969 Expansion Program provided facilities for the production of 10,560 radial tires with total capacity remaining at 26,000 tires per day In 1970 production equipment was purchased and installed to provide the facilities for producing 200 steel belted bias tires and 1,200 steel belted radial tires with the total capacity remaining at 26,000 tires per day The 1972 Expansion provided production capacity to produce 20,000 steel belted radial tires per day while reducing the total tire capacity to 22,350 per day A refinement to the 1972 Expansion Program provided for an additional 1,500 radial steel tires per day bringing the total to 21,500 while the total tire capacity increased to 24,000 tires per day Modifications to our truck tire building capacity increased our plant rated daily capacity to 24,600 tires per day The H.D. Expansion Program completed in fiscal 1978 increased plant rated daily capacity to 25,100 tires per day Phase I of a Light Truck Radial LTR conversion was approved and begun in 1979. Under this program the plant rated capacity included 2,500 light truck radials 20,000 passenger radials and 3,900 bias truck tires In 1980 a second LTR conversion program was approved Phase II Rev.1 This is a long range program ultimately giving Decatur the ability to produce up to 6,500 LTR tires Since both LTR's and passenger radials can be built on the same machines Decatur is flexible in its ticket mix It can vary from 6,500 LTR's and 14,000 passenger radials to -0- LTR's and 21,500 passenger radials day Decatur is in the process of a bias truck tire conversion program which will consolidate sizes and types of tires in certain plants increasing Decatur's bias truck production to 4,200 tires by January 1983 Acreage Floor Space Production Area Finished Goods Storage Raw Materials Storage Office Area 153.2 Acres 1,331,404 443,980 124,240 62,150 Total Area 1,961,774 Sq Ft Leased Storage Areas 185,000 Grand Total 2,146,774 Sq Ft Power Facilities 1 Boiler Capacity 3 units 1 Unit - 100,000 lbs Oil 500 P.S.I. 1 Unit - 100,000 lbs Oil 300 P.S.I. 1 Unit - 100,000 lbs oil 400 P.S.I. 2 100 Compressed Air 5 units 3 Instrument Air Compressor 14,500 CFM 400 CFM : 4 Deep Well Capacity =< None 5 Incoming Transformer Capacity 37,500 KVA 6 Refrigeration - 3 units 3,600 Tons Refrigerated Compressed Air Dryer 1 unit 70 Tons Jackson 064433 Decatur Illinois Page 2 of 8 Average Power Consumption - Average Month YTD through September 1982 1 M KWH Consumed per M Lbs of Production 2 Power Cost per M Lbs of Production 3 M Lbs of Steam per M Lbs of Production 4 Cubic feet of air per M Lbs of Production 5 Gallons of water per M Lbs of Production .6778 43.29 4.5924 30.1629 1.2094 Capacity- Daily A 4 A A Front Tractor A6 Radial Passenger - Radial Previous 1983 Approved Plant Capacity 180 Units 620 1,600 1,000 200 21,500 300 Units 800 3,100 - - 3,650 19,000 Total 25,100 Units 26,850 Units Total Tire Weight Camelback Weight Miscellaneous 682,676 Units 20,000 11,748 846,215 20,000 11,748 Total Weight 714,424 877,963 + Enrollment - Average 1982/83 Salary Clock 488 1,631 Total 2,119 MAJOR EQUIPMENT ITEMS Dept. 112 - Compounding & Mixing 2 - 60 Mills l - 11 Banbury Final Mix 30/50 R.P.M. 2 - 11 Banbury Mixer 2 Final Mix 30 R.P.M. 1 - 11 Banbury Final Mix 40 R.P.M. 3 - 27 Banbury Mixer 50 R.P.M. Master Remill 2 - Bale Cutter Spadone 3 - 20 Pelletizer 3 - 84 Mills 4 - 48 Batch Machines 3 - 48 Mills Belts soap tanks wig wags shifters Dept. 115 - Refiner Mills MN 11 20 x 32 x 36 Refiner 2 11 26 x 26 x 36 Cracker Jackson 064434 Decatur Illinois Page 3 of 8 Dept. 121 - Steel Cord Calendering l 4 Roll Inclined 2 Calender - 70 Y.P.M. 2 Creel Rooms 2,592 total spool letoffs 4 84 Mills 1 Dual Fabric Letoff Train Hydraulic Compensator 2 Automatic Slab Loaders Dept. 122 - Dipping & Calendering 1 Roll Calender - 70 Y.P.M. 1- Dip Unit Rayon - 75 Y.P.M. 84 Mills designed for revising to handle nylon Roll G.P. Calender 1 Roll Innerliner Calender Roll Contour Calender 12,000 Gal Latex Storage Tanks 4 2,000 Weigh Tank 1,500 Gal Mix Tank Automatic Slab Loaders Dept. 123 - Stock Cutting Banner Bias Cutters NRM 66-90-360 2 Banner Bias Cutters H.D. Bias Cutters NRM 66-45-360 8 Spadone 100 Bias Cutter Free Loop Guiding & Spindle Windups 1 Fabric Dual Surface Windups H.D. Gum Insert Calender with Single 84 Mill 1 Rotary Bias Cutter Fabric Ply Transfer Unit 2 Tread Ply Assembly Unit with Automatic Letoff 48 Liner Reroll Table 222 Chafer Assembly Unit 2 Cameron slitter Tread Ply Gum Wedge Application Table 2 H.D. Gum Insert Calender with 6 C.F. Extruder Dual Letoff Dual Windup Tread Ply Gum Wedge Application Table Dept. 124 - Bead Making 4 - Bead Wire Winders 14 Unit Letoff 2 12 Unit Letoffs 4 2 1/2 NRM Extruder 4 Side Lapped Bead Splice Press 1 Wire Sizer 17 17 - 612A Utility Bead Reinforcing Machine H.D. General Purpose Bead Reinforcing Machine 1 Mark II Automatic Bead Machine 2 Spiral Wrap Bead Machine Extruded Bead Filler Bead Assembly Machine single & dual 4 Continuous Strip Cutter Extruder Temp Control Unit 1 10 Unit Letoff Jackson 064435 { :- Decatur Illinois Page 4 of 8 ~ 4 , i Dept. 126 Tubing - Tread & Sidewall A.S.M. Tread Slitter 1 x10 Tread & Sidewall Tubing Unit x10 Tread & Sidewall Tubing Unit 3 60 Warm Mills 36 Cushion Calender 36 High Speed Tread Cutter 19 8 Rubber Extruder with Reducer 84 Mills 3 of which are equipped with WSW Blending Belts 6x6 Preassembled WSW Unit 1 x12 Cushion Calender Offline slitter 4 Slab Loaders 1 10 Extruder System Dept. 131 - Heavy Duty Tire Building 23 2310 5 80 T.A.M.'s with 180 Server 80 T.A.M.'s 80 T.A.M.'s T.A.M.'s with with 8 Ply Side Loader 180 Server Server 59 T.A.M.'s T.A.M.'s with 146 Server 46 T.A.M.'s with 146 Server Lot Conveyors 46 T.A.M.'s with 146 Server Ply Dept. 133 - Passenger Final Inspection 4 1313 Trimmers Dual Pin Vent Inside Inspection Machines Dual Station Cold Brander 332 Meath Spotters Winner Curing Stands Vita Heater Universal Vulcanizer Model 360 Single Station Cold Branders -- WSW Lathe 8 - Wolverine Benches - Tire Spreaders 1 - Single Trimmer -- Passenger Tire Changer - Lot Conveyors 5 - Tire Bead Inflation Stands Repair Presses Dept. 139 H.D. Final Inspection Single Trimmer Dual Trimmers 2 Micro Poise Balancers 2 Lot Conveyors Meath Spotters Steam 3 - Tire Spreaders - H D. Matic - 1191 Concentricity Machines 1 - H.D. Tire Spreader Single Station Cold Brander Dept. 149 - Pass Tire Final Insp Grading Correction & W.S.W. Grinding 16 18 4 15 2 2 Manual Tire Balancing Units Tire Uniformity Optimers Spadone W.S.W. Grinders Firwood W.S.W. Grinders Jay 4600 CARE Machines Automatic Belt Sanders 2910 Automatic Tire Balancers Passenger Matic Lot Conveyors T.S.I.S. Manual Inspection Stands Jackson 064436 Decatur Illinois . Page 5 of 8 Dept. 150 - H.D. Tire Final Inspection Grading & Correction 3 - 2910 Automatic Tire Balancer 2 - Light Truck Tire T.U.O. & Conveyor System Dept. 153 - Flap Curing 6 - Flap Presses 39 - Flap Molds 4 - Patch Presses aN Dept. 158 - Waste Control - Filler Wax Unit Waxer & Lathe - 63 Liner Reroll Table 134 - 48 Liner Reroll Table - 20 Liner Reroll Tables - Chafer Reroll Tables A - Poly Baler - Steel Stab Ply Trimming Table - Steel Stab Ply Reroll Table 6 - Fabric Trim Tables Liner Sewing Machines Dept. 161 Green Tire Storage 1919 5 5 - Radial Tire Splice Presses Plummer Doping Units Radial Lot Green Tire Conveyors H.D. Tire Doper H.D. Tire Splice Presses Green Tire Automatic Dept. 166 187 178 9 2 Passenger Curing - 40.5 Curing Presses NRM - P.C.I. Units NRM - P.C.I. Units Firwood - Mold Cleaners Dry Blaster e em Dept. 169 - H.D. Curing 32 - 46 Curing 24 - 55 B.O.M. Presses NRM Curing Presses McNeil 32 - 46 P.C.I. Units 25 - 55 P.C.I. Units 1 idle unit used for P.C.I 1 - Mold Cleaning Unit Wet Blaster 1 - Vulcanizer Dept. 171 - Radial Stabilizer Ply Stock Cutting 3 - Spadone Wire Fabric Bias Cutters 3 - Spadone Dual Fabric Letoffs 9 - Horizontal Splicing Tables Jackson 064437 i , Decatur Illinois Page 6 of 8 Dept. 174 Radial Tire Building 115 - 85B T.A.M.'s 13 - 85D T.A.M. 1 additional machine planned - Lot Basket ConveyoIS 110 - 280D Servers 18 - 280C Servers Dept. 551 - Bladder Building Curing & Inspection 36 x 30 Model 900 McNeil Bladder Curing Presses 17 Bladder Molds 4 inactive 9 Extra Bladder Cores 1 44 CFE for Bladder Slugs Dept. 561 - Cement Mixing 6 - 1 1 12,000 Gal Bulk Storage Tanks 500 Gal Struthers Mix Tank 500 Gal Chemineer Mix Tank 250 Gal Struthers Mix Tank 25 Gal Day Mixer Philadelphia Mix Tank Solvent Distiller Dept. 765 Quality Assurance 3 - Position Tire Test Machine > Position Bureau of Standards Machine 1 - Bead Cutting Machine 1 - Tread Stripper Band Saw 1 - Profilometer 1 - Manual Balancer - Centering Gauge Machines 2 - H.D. H.D. Tire Tire Test Machines Mounter - Passenger Tire Mounters - IHI Model K248 Holograph Unit 1 - Picker Manual Ray Unit - Picker AID Ray Unit - Monsanto 1027 Ray Unit Dept. 791 - Warehouse & Shipping 2 - Passenger Tire Unitizing Machines - Signode l - H.D. Tire Compression Unit - Brainard 3 - Tube & Flap Insert Units Jackson 064438 Decatur Illinois 1 Page 7 of 8 FORK LIFT TRUCKS - AS OF NOVEMBER 1 1982 ty QUAQUANN MAKEMAKE Clark 2 Clark Clark 3 Clark Clark 110 0 MODEL Fork Fork Fork Fork Fork Kalamazoo Kalamazoo Platform Kalamazoo Platform 12/2 - Hyster Fork POWER L. Gas L. P. Gas L. P. Gas L. P. Gas L. P. Gas Gas Gas Gas CAP OPERATOR 5,000 5,000 5,000 5,000 5,000 Rides Rides Rides Rides Rides 1,000 1,000 Rides Rides 1,000 Rides 4 3 , N W W HANN HANNN 16 14 1 10 10 2 > 60 Clark Clark Clark Baker Baker Baker Baker Baker Baker ELECTRIC FORK LIFT TRUCKS Fork Fork Fork Fork Fork Fork Fork Fork Fork Electric Electric Electric Electric Electric Electric Electric Electric Electric 5,000 5,000 5,000 5,000 5,000 5,000 5,000 5,000 5,000 Rides Rides Rides Rides Rides Rides Rides Rides Rides Baker Baker Baker Baker Fork Fork Fork Fork Electric Electric Electric Electric 6,000 6,000 6,000 6,000 Rides Rides Rides Rides Baker Baker Baker Baker Baker Baker Fork Fork Fork Fork Fork Fork Electric Electric Electric Electric Electric Electric 7,000 7,000 7,000 7,000 7,000 7,000 Rides Rides Rides Rides Rides Rides Moto Moto Platform Platform Electric Electric 4,000 4,000 Rides Rides Moto Platform Kalamazoo Platform Raymond Platform Electric Electric Electric 6,000 2,000 6,000 Rides Rides Rides DEPT 831 701 791 729 Janitors 701 749 166 701 791 166 112 128 149 161 791 701 112 122 123 126 166 831 112 122 126 123 124 128 128 831 128 Jackson 064439 Decatur Illinois " Page 8 of 8 QUAN 9 1 10 47254812 47254812 47254812 47254812 47254812 47254812 29 1 l 2 ADAM ADAM ADAM ADAM MAKE Baker Baker ELECTRIC FORK LIFT TRUCKS continued MODEL Fork Fork POWER Electric Electric CAP 4,000 4,000 OPERATOR Rides Rides Towmotor Fork Towmotor Fork Towmotor Fork Towmotor Fork Towmotor Fork Towmotor Fork Electric Electric Electric Electric Electric Electric 5,000 5,000 5,000 5,000 5,000 5,000 Rides Rides Rides Rides Rides Rides Towmotor Towmotor Fork Fork Electric Electric 7,000 7,000 Rides Rides Towmotor Towmotor Towmotor Fork Fork Fork Electric Electric Electric 3,000 3,000 3,000 Rides Rides Rides DEPT 791 831 128 133 158 166 701 791 122 112 133 791 124 ee e ne Jackson 064440 | an TO MR W. A. FERRING CORPORATE ENGINEERING FROM DECATUR PLANT DATE AUGUST 12 1982 REFERENCE SUBJECT | GENERAL PLANT DATA REPORT 954-005 F Firestone INTEROFFICE RECEIVED AUG 1982 W. A. FERRING Attached is the General Plant Data Report for the Decatur Plant ee i Buchanan PLANT ENGINEER RLB ac Att CC H. E. Powell RECEIVED AUG 1611982 1611982 3 MAILING DEPT MAILING AKRON . SisT8A Jackson 064441 ~ -2753 3-79 . a a . ATTACHMENT I ACREAGE PLANT 156 DECATUR YEAR 1982 I. . : a, FLOOR AREAS OWNED BUILDINGS SQ METERS SQ FEET A. RAW MATERIAL STORAGE B. PRODUCTION AREA C. PRODUCTION AREA IN THE OPEN , D. FINISHED GOODS STORAGE 7 E. F. OFFICE AREA VACANT OFFICE SPACE . TOTAL | 144,240 1,355 612 399,772 24,790 37,360 1,961,774 II LEASED BUILDINGS A. RAW MATERIAL STORAGE B. PRODUCTION AREA C. PRODUCTION AREA IN THE OPEN D. FINISHED GOODS STORAGE | E. OFFICE AREA _ TOTAL 185,000 185,000 185,000 | 185,000 REFERENCE DRAWINGS : PLOT PLAN __ 02-22 PROPERTY DWG 1924 LAB bj 10/6127 10/6127 Jackson 064442 we Firestone INTEROFFICE me / MR W. A. FERRING SUPERVISOR OF ESTIMATING AKRON DATE FROM REFERENCE | SUBJECT GENERAL PLANT DATA REPORT F OCTOBER 15 1981 DECATUR PLANT RECEIVED OCT 19 1981 W. A. FERRING Attached is the General Plant Data Report for the Decatur Plant R. L. BUCHANAN PLANT ENGINEER RLB ac Att 5 Pe 81273C Jackson 064443 & TO MR H. D. BOSSMAN AKRON FROM R. L. BUCHANAN DATE OCTOBER 7 1982 REFERENCE SUBJECT FLOOR AREA SUMMARY REPORT Firestone F INTEROFFICE RECEIVED OC1T1 1982 H. D. BOSSMAN for the Decatur Plant for 1982 Attached is the Floor Area Summary Report R. L. BUCHANAN PLANT ENGINEER . - rq ; ~ ioe het Ca a Meee SY s, ON, S1278 Jackson 064444