Document qmwxbxrv93grNbg7wzG57jd9q

MW l^Mj INTER-OFFICE MEMO TENNECO SEP 1 6 1971 CHEMICALS, asuirmpa rgto SEP 7 t971. to M.W. Williams s From H.B. Carr at Piscataway at Burlington Subject QUALITY ASSURANCE AND TESTING SERVICES MONTHLY REPORT - AUGUST, 1971 RESIN PLANTS d*te September 3, 1971 copy to W.E. Beckman W.C. Champion J.C. Fisher P. Gawason H.R, Horton 'E.J. Hourihan C.W. Johnston E.L. Kanyok F.W. Kanzler M.C. Spalding W.D. Wesply File `j/li/w III 'Vfft &&L Raw Materials 1. Dow Methocel On 8/18/71 we met again with Dow representatives in Pis-, cataway to continue our discussion on metallic particle contamination in methocel. Dow assured us that all steps are being considered to remove this contamination includ ing installation of magnets at key'process points. Our test method was provided to their quality control people so that they may monitor their program. Final settlement on the Columbia complaint, to which Dow was a contributor, is awaited. 2. Shell VCM The first two cars of Shell VCM were received in Burlington the latter part of August. Analytical results and in-plant assessment will be reported on shortly. 3. DM Water As part of an extensive evaluation program to improve bulk density control, the three DM beds were acid washed and re sulted in increased bulk density in Copolymer. Tests nec essary to define properties affected by acid washing are being investigated including BOD and COD analyses. C.W. Johnston will be consulted for his thoughts. In-Process Testing P.E. Support Analytical support was provided the following P.E. programs: a. Improved Copolymer Bulk Density Analyses of light and heavy end impurities, as well as acetaldehyde, acetylene and phenol levels, were contin ued to establish a data history to assess correlation with bulk density shifts. COLOR!TE 011405 M.W. Williams -2- September 3, 1971 b. Improved Particle Size Control - Flemington Light and heavy end impurity levels in virgin and re covered monomer are being analyzed to establish a data base for P.E. evaluation. c. Oxygen in Dispersion Towers Continuous oxygen trace analyses were made to support P.E.-'s evaluation of the influence of oxygen on disper sion resin reaction kinetics. Finished Resin 1. Ferro Magnetic Contamination As a result of the Columbia complaint, extensive work con tinued to establish a meaningful test for metallic contam ination in suspension resins and to arrive at workable specifications. In a coordinated effort with Plant Technical Services, an in-line test magnet was set up for the Copoly mer Plant. Proper procedures utilizing the test magnet are being lined out and data derived will be coordinated with CSL to establish in-plant and customer specs - this has been given top priority. 2. Clarity Testing A program to define and to establish consistent and accur ate clarity testing was coordinated with the Surface Coatings Laboratories. Several changes in the QC test resulted and good correlation has been established with SCL. The test re sults generated now will provide more definitive support to' the plant in lining out the AR901 process and will provide assurance that only material meeting field requirements is released. 3. 315 Copolymer FDA Status Since there is a potential 1 M lb,/yr. FDA market at Mobil, gas chromatographic analyses were performed to establish re sidual TCE levels in six samples of 315. The levels were 825-975 ppm which are considered very high for FDA applica tions. Further Marketing justification is awaited before pro grams, that may be extensive, are pursued to lower this TCE level. Fluid Bed Drying ' In support of Engineering* s evaluation of Fluid Bed Drying potential in Louisville, Kentucky, extensive QC testing has been provided on several control samples. Results thus far indicate slightly increased dry blend time, higher volatiles and shifts in particle size. Testing support will continue as part of additional Louisville evaluations to confirm these observations. General 1. Computer Use Utilizing a program established by G.W. Leach, the Quality Control Monthly Summary Report has been programmed resulting COLORITE 011406 M.W. Williams -3- September 3, 1971 in a significant savings in time and,the potential for more rapid and meaningful data readback, not only at month's end but any time during a month. G.W. Leach has also been suc cessful in developing a program for control charts such that necessary statistical calculations are made from raw data input and also such that the data is plotted. These approaches which have already proven successful will lay the groundwork for use at other plants. 2. Personnel During the period, F.W. Kanzler was promoted to Supervisor, Resin Quality Control with H.R. Horton as Laboratory Super visor and R.J. Eckman as Junior Chemist in the Analytical Control Group reporting to him. Mrs. Else Gallagher will join the Analytical Control Group 10/1/71 as an Analytical Control technician. K.C. Entwistle resigned from his Junior Chemist position ef fective August 13, 1971. COMPOUND PLANT 1. Color Matches During the period, 9 color matches were completed leaving a backlog of 14 outstanding. 2. Color Control - Naturals and Clears' Color drifts in naturals and clears have been noted in the Compound Plant for some time. As part of an investigation, the effect of varying levels of recovered monomer in resin transferred to the Compound Plant is being considered. The plan is to establish maximum recovery levels for each lot. 3. Industrial Plastics Industrial Plastics complained of wall failure in thin sec tions utilizing 3164 gray 83. The particular lot in question was made at Cary Paige and was released by Marketing without proper samples being provided to Quality Control. Marketing has been advised of their blooper on this one and samples will be taken during the next run. 4. Fers^iiel Compound Quality Control personnel have been working under severe strain due to sev'en-day non-scheduled plant operations. The technicians have had four days off since plant start-up, July 19th, They are to be commended for their efforts under these circumstances. A&E 1. Compound Analyses During August a number of significant compound analyses were completed and among them were: a. Opalon 1420 Analysis of this competitive switchboard wire compound in dicates that the formulation is based on a 2.48 relative COLORITE 011407 M.W. Williams -4- September 3, 1971 viscosity resin and a polymeric plasticizer system. Good insight into the stabilization/filler system also resulted b. Geon 8830 Two lots of this compound and a single lot of Blane 2120 indicated substantially different resin systems. The Blane contained 94.5/ PVC as opposed to `98 to 99% for the two Geon compounds. c. Goodrich Floor Mat Compound Goodrich 83760 floor mat compound from Plasteck, Inc. was analyzed for CSL to contain a 2.40 relative viscosity re sin with 57 phr of DOP. The formulation was cadmium/zinc stabilized. 2. Ink Analyses In support of the Nixon effort in which there is sparse know ledge of inks and printing requirements at several key account A&E has examined several inks, among them Silcox-Miller, Guguler and Omni-Card. Analytical results provided, including sol vent type and base resin, will be utilized in conjunction with the Surf^analyzer and the recently received Gravure Proof Prin ting press to define customer requirements. 3. Physical Testing A considerable effort was allocated to rheological investiga tion of record compounds to support the effort to produce a record compound with melt rheology similar to the Keysor re cord compound. Thus far 26 different formulations have been examined and the data generated is being analyzed - 'a report will Issue. 4. Personnel During August the following personnel changes were made in A&E J.P. Bolcar resigned effective 8/31/71 and was replaced by V.J. Meyer who was transferred from SCL; M.C. Spalding assumed full time responsibility for Nixon Quality Control and was re placed by E.L. Kanyok who was promoted to Supervisor of Qual ity Control and R&D Services. 5. Auguafc Time Allotment Showtir below is A&E* s August time allotment versus the June and July levels: * June, 1971 July. 1971 August, 1971 CSL P.D. Nixon Q.C. P.R, Safety General Foam t 27.8 31.5 29.2 7.7 0.7 3.1 - 17.9 27.6 38.5 7.3 0.8 4.5 3.4 2 24.0 28.6 28.5 10.8 2.1 6.0 - 100.0 100.0 100.0 COIiORXTE 011408 M.W. Williams -5- September 3, 1971 NIXON 1, BUDRUG Early in August^, 47 registered letters informing key drug ac counts of our upgraded Master File were issued. Confirmation of receipt has been received from all of these accounts. We have not received inquiries as yet and,while it is a little premature, this appears to indicate endorsement of our Master File. 2. Specifications Specification reviews for both Mirrex and G.P, Vinyl are ur gently needed and plans are to hold them as soon as possible. In the meantime, critical accounts will be investigated by Quality Control and temporary changes in specifications' will be coordinated with Manufacturing and Marketing such, that a written sheet (CIS or other form) endorsed by all groups will be available on the lines. 5. Color Group During August,Color Group completed 7 production matches, 10 sample matches and 7 optical matches. 4. Fidelity Prestige Products This customer purchases VCR-1001 clear, which it uses to make pouches for identification photographs for Polaroid. Habit ual cracking has been a problem with this customer, but we found that the problem could be substantially solved if the pouches were formed by placing our product with a competitive flexible film at right angles. Such a procedure reduces crack ing while the mating of cards in a similar direction leads to excessive cracking. 5. Diebold This customer also purchases VCR-1001, and has also experienced cracking problems. The lots which we examined had substan tially low drop dart formulations and control sheets. We feel that the sheet which they received was not processed effectively since our analysis of the material indicates that it was made according to formulation. 6. Personnel The following personnel changes were made during August: Harold Hansmann retired after 46 years of service at Nixon. D.L. Franzyshen and 1.0. Kenen were transferred to other groups within Tenneco. Ken Langbauer resigned as a Quality Control technic ian. Miss Mary Jane Mercowitz left as Quality Control secretary to return to school and Mrs. Naomi Blum has joined our staff as the Quality Control secretary. 7. August Time Allotment Shown on the following page is Nixon Quality Control* s August time allotment versus the June and July levels: COLORITE 011409 M.W. Williams -6- Q.C. Plant Eng. Prod. Eng. Proc. Eng. Prod. Dev. Tech. Serv. & Marketing June, 1971 85.6 4.2 5.9 1.2 1.9 1.2 100.0 September 5, 1971 July, 1971 60.5 3.9 8.9 11.2 8.5 7.0 100.0 August, 1971 & 56.9 08 60 72 9.4 19.7 100.0 HBC/jt H.B. Carr COLORITE 011410