Document v669z985GzvgnVReXMdr41w0w

T. H. Huffman From: Date: Subject: D. C. Skokna September 20, 1990 ABERDEEH MONTHLY PROGRESS REPORT AUGUST, 1990 1 There was one first aid and one recordable (MT) cases reported in August. The recordable case involved a mechanic who suffered a small second degree burn to his forearm that occurred when he con tacted a steam pipe. As of 8/31, the plant's employees have com pleted 4,075 days <5,431,094 manhours) since the last lost time inj ury. Fiftfo FY 1990 Kev 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 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, $M Operations August 38.9 86.9 98.2 0.99527 5.7 97.5 5.5 98.7 1.5 76.3 < 4.1> 2.7 87.4 A ON 4 00 V Y.T.D. 415.9 88.5 97.5 1.0004 65.9 98.1 49.9 99.3 16.2 85.6 245.5 721.4 4f. 3 t y-TD - C" "I I-.. 9^7, P h0O<?K$' Final tie-ins for the cleanwall project were completed with start up set for mid-September. Flexible compound demand increased late in the month and produc tion schedules became tighter. PLENEX polymers development used forty-six hours of production time on Line I. Rigid compound demand was strong all month. Railcar production of high drop temperature 90172D for U-Brand began during the month. The higher drop temperature caused pluggage on the #2 Welex chute and until a modification is made, this product will be made at reduced rates. The modification is scheduled to be complete during October. VAB.0001189972 T. H. Boffaan 9/20/90 Aberdeen Monthly Progress Report - August, 1990 Page 2 Variable costs were favorable due to good raw material use and a favorable product mix in the resin unit and conversion of inter mediate (low value) plasticizer inventory to products. Off setting these favorable items were unfavorable product mix variances in the compound units. OMP 1. The laboratory NC" shift natural team presented a plan to reduce dry blend moisture tasting frequency to save about 900 employee hours per year. 2. The compound "D" shift natural team presented the results of their millscrap reduction efforts. Results year-to-date are a fifty percent reduction and $300M estimated annual savings. No investment was needed to accomplish this. 3. A.T.&T. (a flexible compound customer) visited the plant on 8/29/90 to see progress made since their 10/89 audit. They were very pleased with our progress. 4. American Mirrex (a resin customer) visited the plant on 8/21 and 8/22 for an overview of our manu facturing process and to learn about our RVCM re duction plans. Mirrex gave us an overview of their operations and products and their resin quality re quirements . 3. Bob Seymour visited Klockner and Marley Mouldings during the month. 6. One hundred percent of the plant's natural teams met during the month. D. C. Skokna Plant Superintendent rah VAB.0001189973 DISTRIBUTION J. D. Burns R. T. Ferrell T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin W. L. McClain Austin J. P. Stokes R. L. Poe H. J. Hall X H. D. Garrison R. A. Conrad LCLAB Plant J. Friend J. W. Ware L. R. Bauer X J. Pavao Premiere Aberdeen C. R. Miller P. L. Foote RWS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, MRK, DAB, DAM, RBN, JEN, JDO, REP, BLT X X X X X X X X X X X X X X * VAB.0001189974 l WRM VWHPMNMMI m WDHHI satott - b. L. Trego First Aid OSHA Recordable Total Injuries i Number of Restricted Workday Cases Number of Lost Workday Cases 1 1 2 0 0 Fiscal Fiscal Y.T.D. 1989 15 _ 24 3 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 0 0 2 0 0 & 2 2 4 14 1 1 JL 24 Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains Stings Other Totals 06 02 16 04 04 10 0 2 20 24 Lost Workday Cases Days Lost 82 201 42 Last lost time injury - 7/5/79 Days since - 4,075 Employee hours since - 5,431,094 On August 31, 1990, the employees of the Aberdeen plant completed 4075 days with no lost time Injury. Topics for the plant safety meetings during the month included Health Training, CPR and Contractor Safety. mmmmm VAB.0001189975 Continued Safety banquets were held on August 24 and 31 to celebrate eleven years without a lost tine accident. An emergency response drill was held in the V 1990. It included a VCM leak and an injury area on August 10, Routine dosimetry results for the month were: VCM Lead Total Particulates Cadmium < PEL ftymbeg Percent 75 18 3 6 _______________________________________________________________ EEL. 1 0 0 0 The single VCM overexposure was with benefit of respiratory protection. h Maintenance Insect bite, right forearm MT Maintenance Second degree bum, left forearm VAB.0001189976 - T. J. Arbelter 100% of the plant's natural teams met during the month of August. Some of our team highlights for the month are: Lab C shift made their presentation to management justifying a reduction in dry blend moisture testing and blender checks. These changes result in saving over 900 employee hours per year, re ducing turn-around time on samples, and improving productivity. Compound 0 shift presented the results of their millscrap reduction project to management. The team implemented new procedures that have reduced millscrap 50%. Estimated annual savings are $300M. The Plant Manager's Natural Team began planning Quality Appreciation Day III to be held September 24 at the plant. We will be recognizing teams that completed projects during FY90. The Quality Management Coordinator traveled to AT&T Omaha with Mark Washington on August 6 to discuss preparations for the AT&T re-audit held on August 29 at the Aberdeen Plant. AT&T was pleased with the progress made on the corrective action requested from the previous audit held October, 1989. American Mirrex visited the Aberdeen Plant on August 21 and 22. Our objective of this visit was to provide American Mirrex representa tives with an overview of Vista's PVC operation, with emphasis on RVCM reduction project work, plant reliability projects, low-mole resin quality and quality management processes applied at the plant. Mirrex also gave a presentation outlining their finished products and raw material quality requirements. The Quality Management Coordinator attended the quarterly meeting of manufacturing site coordinators in Houston on August 22 and 23. Topics included quality manuals, customer audits and ISO 9000 series quality standards. R. W. Seymour made MBWA visits to Klockner and Mar ley Mouldings with Mark Eramo on August 15 and 16. At Klockner, they met with Rolf Riesterer, Klockner's Plant Manager - a first In our relationship with Klockner. 'L s'*1******, !,i VAB.0001189977 imiiMf1 111 HW D. C. Skokna Variable Costs PVC Flexible Compound Rigid Compound Plasticizer Total $128.7 < 25.9> < 35.7> 20.3 $ 87.4 <$ 50.6> < 28.4> < 123.2> ___ 2&JL. <$166.2> $ 78.1 < 54.3> < 158.9> <$ 78.8> Raw material use was below budget and the variance due to product mix was favorable resulting in this month's overall favorable efficiency variance. Off-grade production was 47% below budget in August. Flexible Compound An unfavorable product mix was the primary cause of this month's unfavorable variance. The unfavorable variance was due to product mix. Plasticizer Inventories of lower-valued intermediate products were converted to products. Price Variances - 610P to Flexible Compound - Natural Gas - Alfol*Alcohols - Resin to Flexible Compound - VCM - Resin to Rigid Compound - Other Prices Variances Total $36.4 21.2 < 30.1> < 75.2> < 86.0> < 115.9> 83.4 <$166.2> VAB.0001189978 Continued Fixed Cost Variances Variance - SM - Payroll and Benefits MM&C - Miscellaneous - TI&D - Clearances Total $11.6 0.6 < 20.0> 5.5 < 0.4> <$ 2.7> Payroll and Benefits This item was somewhat below budget due to low maintenance and operating payroll. M. M. & C. Was essentially at budget. - Moving, Home Assistance - <$13.6M> - Outside Professional Services - <$27.4M>, due to VMS charges and modeling studies. "-`N VAB.0001189979 VINYL - J. D. Olson, J. M. Vinoski SftT The Vinyl Department had no first aid or OSHA recordable injuries during Augus t. The monthly safety meeting topic was "Health Training". A 1. Final tie-ins were completed and programming work was started on the cleanwall system. Startup is scheduled for midSeptember . 2. Mechanical design work began on the permanent water decalci fication system for Klockner resin production. This system will allow production of decalcified 5305 resin in both reactor modules. 3. The resin raw materials in the 744 account were valued at $567.6M. August - 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 % Reactor Downtime 38.9 1232.2 96.6 903.0 29.1 86.9 88.7 97.2 98.2 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). YTD 415.9 1239.1 97.1 9736.0 29.1 88.5 82.6 93.2 97.5 Hours 383.5 Maintenance downtime (Old unit charge header replacement, BUS-80 tie-ins on all reactors, New Unit recovery compressor seal repair, hydroblasting and condenser drilling on D700 and D745). 591.1 r Continued Dryer Downtime Reactor limited production. 49.3 Operational downtime (centrifuge plugs, dryer cleaning, and flameouts). 37.9 Maintenance downtime (activator, centrifuge, screw feeder and star valve repairs). 12.8 Intenance tfork - J. B. Autrey, J. B. Hegvood Reactors 700 and 745 were each shut down on two different occasions during the month for hydroblasting as part of the contamination control program and the BUS-80 startup. The condensers on each reactor were hydrobias ted during the first shutdown in order to get them as clean as possible before the startup of the new BUS-80 system. Reactors 600 and 744 were shut down during the month because of VCM leaks that were detected around their condenser bases. The base of each reactor was torqued down using the hydraulic torque wrench and the appropriate torquing procedures. The fluid bed dryer was shut down during the month so that the demister pads on the fluid bed scrubber could be cleaned. The spare Bird centrifuge was reconditioned during the month. New breakers and current limiters were installed on the west cooling tower fan, new unit water pump and the west chiller. The need for these repairs was identified by an HSB Infrared survey. There were nine seal failures in the new reactor unit that were caused by the collapse of the seal water filters that supply seal water to the seals. There were three major valves changed out in the reactor area during the month. Numbers 1 and 4 VCM unloading compressors were changed out during the month and replaced with spare compressors. The compressors that were removed from service will be rebuilt and kept for spares. n VAB.0001189981 COMPOUND - J. K. licktrton, K. 6. Akins Safety The Compound Department had no first aid cases or OSHA recordable injuries in August. Demand for flexible compounds Increased late in August. Production schedules became very tight - particularly for our clear and natural colored products produced on Line I. It appears the demand will remain steady through September. PLENEX polymers production consumed forty-six hours of production time on Line I. Demand for rigid compound was also strong in August. Production of railcar quantities of high drop temperature <220 F.) 90172D for U-Brand began in August. This production is only possible on Welex #1 until modifications to prevent pluggage on tfelex #2 drop chute are completed. A dump header with a steeper angle will be in stalled from the Welex to a cooling blender. This modification allowing the production of higher drop temperature compounds for U-Brand and other customers at full rates is expected to be com pleted in early October. Prime plasticizer production was up 30% in August as compared to July. We continued to devote more time than normal to VRP/RAE production to further reduce by-product intermediate inventories. I A plasticizer technology class was conducted in August for plasticizer operators. Topics for the half-day class included chemistry, kinetics, thermodynamics and environmental concerns as they related to our plasticizer operation. Operating Line I 31 Line III 30 Line V 17 Total % Prime Capacity Utilization Factor Month 1755 57 3152 105 45 5665 207 97.5 .710 21456 37936 6514 65906 98 .766 - Product Changes - PLENEX Polymer Testing - Miscellaneous Maintenance - Deboxing Export Order 97 46 35 23 COMhHJMD - Continued - Product Changes - Miscellaneous Maintenance - Mill Motor Replacement - Quality Problems & Control 87 49 29 16 - Product Changes - Miscellaneous Maintenance - Startup/Shutdown Operating __Pavg Month Rigid Compound 31.0 % Prime Capacity Utilization Factor 5533 98.7 .937 47 15 14 178 X,.T, P 49893 99.3 .844 - Product Changes - Miscellaneous Maintenance - Quality Problems & Control - Welex Motor Replacement - Resin Star Valve Maintenance - Screener Maintenance Operating __P*r Month Plasticizer 31.0 % Prime Capacity Utilization Factor 1502 76.3 .608 92 36 23 18 12 11 Fiscal Y.T.D. 16220 85.6 .677 Kev Maintenance Work - J. B. Autrey, J. B. Hegwood - The vacuum jets on plasticizer reactors R-l and R-2 were cleaned on two different occasions during the month because of an excessive calcium carbonate buildup. The vacuum jets on R-3 and R-4 were cleaned once during the month because of the same excessive calcium carbonate buildup. Dry blend blender "B" was shut down during the month for repairs to its sprockets and chain. The sprockets and chain were replaced because of normal wear. \ VAB.0001189983 - Cantlimed Number two Welex in Dry Blend was shut down during the month because of a wiring failure. New wiring was pulled to the motor because the old wiring had burned out. The dry blend control room uninterruptable power supply (UPS) was shut down for cleaning during the month. This is being done as part of a P.M. program to maintain the integrity of the UPS. VAB.0001189984 II A .* R. E. Polk, S. C. Hillman, X. R. Kama The BUS-80 cleanwall Injection system was completed and started up on all reactors. Reactor rinse water to the sewer has been elimi nated. Safety and mechanical audit items remain to be completed. The modifications which allow the batch water stripper water to be pumped to the blend tanks have been completed. The piping which will allow the water to go to the cooling towers will be installed by mid-October. The modifications will provide reductions in the water VCM concentration at the inlet to the wastewater treatment system. The TC regulations require that the VCM concentration at the inlet to the wastewater treatment system be less than 200 ppb. Training will be scheduled for all vinyl operators. The sessions will cover basic RCRA topics as well as new administrative pro cedures required as a result of the TC regulations. Resin The AFE has been submitted for this project which will provide permanent ion exchange systems in each reactor module. Production model building for OASIS continues. Customer specific activities are being added to the models. The models should be complete by the end of September. The tests of both new wells have been completed successfully. Both wells are more efficient than expected. Engineering continues with plant review of electrical drawings expected by October. FDA Good This manual was completed and issued. Training of plant personnel is 95% complete. Joe Ledvina and Bill McClain will conduct an audit of FDA manufacturing practices on September 18. VAB.0001189985 h st I I I I to I / I I to I i* m i IK 5 uit S i H to &m~ H H sU tt isisssssgii a I I m I :* 3 I I I II II i 2 * gill t I I I ai *: i 5R 33 S i|i| - Ui a 3 5! s I 8KSS illiiS cn m 3| SBgl "2gg sSi X cn 3 3U I gK Ui. 3 n SSilililiili 3 VAB.0001189986 L J d imp wm mm * ENVTROW*iw*T. - F. G. Jeanson Water All wastewater discharge parameters were met for the month of August. A bioassay test was completed during the month. No toxicity was found in our outfall. Work was started on preparing the NPDES permit renewal application. The application is dhe in October. Our current permit expires at the end of March, 1991. Waste Waste shipments for the month included: - One bulk load of separator oil to M&M Chemical in Gadsden, AL. One bulk load of stormwater solids to CWM in Emelle, AL. One bulk load of API sludge to CWM in Emelle, AL. Fourteen drums of stabilizer spill and three drums of PA spill to TES in LaPorte, TX. 4 DuPont Environmental Remediation Services (DERS) completed the final issue of the Remedial Investigation (RI) Plan. This plan was submitted to the State DEQ. A meeting was held at the State to review the plan. A repre sentative from DERS, Joe Ledvina, David Cohen and I attended this meeting. After review of the RI Plan, the State DEQ approved the plan. The only additional items the State wanted were a revised schedule and slug tests on two of the monitoring wells. A revised schedule will be issued to the State during September and the slug tests will be incorporated in the RI Plan. Work on the RI Plan is scheduled to start in September. Comments on the NUS report were sent to EPA and to the State. comments were prepared by DERS and reviewed by Conoco and Vista. These Work continued on air permitting issues. Several contractors were con tacted about risk assessments and fenceline monitoring. They are all sending proposals. Two additional dispersion model test cases were completed by Scott Environmental. Comments were gathered from Environmental, Legal and the plant on a new proposed air toxics policy that the State DEQ Issued for comments. These comments were sent in to the State before the public meeting on this subject was held. VAB.0001189987 f bmvjmommrTAL -- continuAd Miscellaneous The annua 1 CMA waste survey was completed and sent in. A waste minimization tax of $1500 was paid to the State this month for 1990. VAB.0001189988 snuffy AMgW. 1999 I. Energy Conservation Data A. Unadjusted EUI <3.7%> B. Adjusted EUI <4.1%> C. BTU/Lb. Product 2539.0 D. Total Energy Consumption MMM BTU 131.12 Fiscal Y.T.D. < 6.6%> < 6.8%> 2617.0 1445.49 A. Maintenance There were eleven energy related Items completed In August, 1990. Ten of these items were steam leak repairs. The remaining one was steam trap repairs. No. 1 No. 2 No. 3 (1) 83.4% 83.0% 83.4% 83.3% 83.0% Boiler number one was not operated during the onth. WWMIIM VAB.0001189989 OWMI + - J. E. Beall Holli Harris, New Hire Michael Schneider, New Hire A. C. Pettus -bid from Vinyl MAM Operator to P-l Operator. * Michael Johnson - bid from Compound Operator to Vinyl "A" None Allan Bodron Berlin Genetti Anthoney Deanes *1.- * VAB.0001189990 Aberdeen* Mississippi Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound Vinyl Plasticizer PAR 16 13 41 24 40 33 5 79* 171 250 AUGUST, 1990 MONTHLY PERSONNEL REPORT Minority Employees Salaried Hourly Total 1 65 72 % 38% 29% 0 Hourly Min. Hired 0 0 % Min. Hired 0 Hourly Min. Term. 0 % Min. Term. 0 it EMPLOYEES MIN. EMP. % MIN. NEW HIRES YTD TERM. YTD TURNOVER 15 8 53 0 16 5 31 0 0 00 00 4 ' 41 10 24 0 0 1 1 1 24 5 22 0 0 0 0 0 38 26 67 0 0 0 0 0 * 33 10 30 0 0 0 0 0 0 5 2 40 0 0 0 0 0 0 Number of Applicants: Month 0 Year to Date APPLICANT BREAKDOWN: # Minority # Female a 0 % Minority % Female 0 0 0 THIS FIGURE INCLUDES 1 SUMMER AND 2 CO-OP STUDENTS. Hires (Hourly): Month Year to Date Terminations (Hourly): Month 0 Year to Date 1 Overall Turnover .8% Projected Annual Turnover .5% VAB.0001189991 r- m LU a Hi >I< O0\ OK K v K I, ;-# * fi . :- ^*- ,-j -`l l, 1 f GO lift O IQ) ** |t^# #<* * 1* 1 1 Ui moitr. A ** p r. *Jh ,*J ,.- H r r%t> * .4-V r . -* l "#*.!( * * x Z*'.- *- : V-f * 4- , -* 1P C^T**4y^ * -'''K^I *., 4 S" r w 1 .' * .+ % * I i* + r * tel ** + 4 4 4' W VAB.0001189993 There were no safety instances for the month of August. At month-end, we had five natural teams with a total of thirty-eight points for an average score of 7.6 points. Invoices Working Fund Checks Written Number of Packaged Customer Orders Packaged Shipped Pounds Coat Sawiiwa 1185 18 162 4,794,462 12,083 208 1,476 45,032,405 Savings due to competitive bidding were $55,876.80 for August, and $161,160 for fiscal 1990 YTD. Per Controllers, the new computer system is not able to allocate invoice discounts taken back to individual plants. Therefore, we are not able to report discounts taken. For YTD ending July, we have taken $19,745. Obsolete and Prime Off-grade Dry Blend Prime Dry Blend Off-Grade (Scrap) Millscrap Vent Dust Sifter Overflow Total Obsolete & Overaged 1,465,253 lbs. 164,931 lbs. 77,819 lbs. 1,416 lbs. 328,349 lbs. 292,203 lbs. _____1,SO9 lbs. 2,339,280 lbs. Training Supervisors attended CPR training. All Administrative/Purchasing personnel attended Health Training, FDA Resin and Good Manufacturing Practices Manual Training. . : 11 ."I. H. mum cimcu pun SIIPPIK miisis imn itf -sunms n nun- PUBLIC flOVTI itt/iic IICItfOLL I1SII-MI BISIl-PiCUGU 21,151,031 1,524,141 171,950 411,14) 111,154 0 ruillll COffNIMIU 311,720 1,594,100 iuiihi comm-ncuai 3,392,139 191,400 0 0 in nsmss 1,445 0 0 licit CQ1P0BIB-BIII tun cMPNn-PAcum 4,M3,BIO 102,311 091,700 0 0 0 TOLHK - BQU mine - PicuGiD 0 0 093,050 0 00 Fusncnu 292,520 (21,111) 541,414 writ 2MIMT4 12,1(4,511 1,4)1,511 -SIIPIKRS BT RON- BILK: MOIST* IIS1I luinu comm HUB C0MPO9ID pusticihi BI1LCAI 154 10 29 2 CISTOHI COHBOO P1CI1P CHIIU 20 00 03 4 17 0 10 TOTH UNIT 195 30 90 *111* mil rmuucouom mu comm PLiSTICIIIl 1,030 200 029 113 11 47 205 21 100 23 0 01 TOTH TTD 2,057 320 903 TTI PBBL1C IPT/IIC IXCI/T0L5 222,111,192 113,131,141 2,307,050 3,307,920 2,212,411 0 14,599,500 11,111,211 34,730,102 1,093,071 0 0 71,410 00 34,002,070 1,113,211 2,211,141 211,121 0 0 0 0 7,033,740 0 0 114,515 1,820,909 2,254,311 2.241,111 311,511,111 131,551,414 12,555,205 TOTAL 240 13 50 to 321 2,553 191 452 04 3,209 P1CU6ID: tIHBSTt mil nnuu comm inn comm mnicini TOTH MOIST trot mu luinu comm mu comm FUSTICIIII T0UI TTD C0STO8XK PICK0P 1 23 2 0 20 COHIOI CIIII1I 24 09 0 0 121 h TOPC comim iii/ors 00 00 00 00 14 13 0 0 00 27 31 152 0 0 249 011 5 0 19 90 0 1 0 3 00 299 5 1 03 05 2 1 Tt OTH 39 125 10 0 174 200 1.131 112 4 1.512 i. J' VAB.0001189995 * TamirATQRT - J. M. Edvards, Jr. A. Safety - There were no safety incidents in the Laboratory during August. The monthly safety meeting topics were "Health Training", "FDA Status" and the "Good Manufacturing Practices Training" taught by Jerald Uptain and Doug Knittig. B. Customer Contacts - There were four customer contacts during August. Mike Quakenbush and Jim Edwards traveled to Gold Bond in Sardis, MS to discuss 5385 specifications with Robert Kwapisz and C. Lafayette Mason. During the meeting, several target specifications were set. We had an understanding that the specification sheet was a working document and as more information was learned, soec limits and windows would change. Carm Covais, John Blum and David Pullin from American Mirrex Corp oration visited the Aberdeen Plant. They toured the plant and par ticipated in a technical information exchange. 5305 and 5265 resin specifications were set during this meeting. Richard Williams accompanied the Pacific Western Resins Technical Team from Vista to the Pace Florida facility. The purpose of this meeting was for evaluation and to discover any technical issues that would prohibit us from entering into a toll/exchange agree ment with Pacific Western resins. Cheryl Cincetti, Vendor Certification Coordinator with AT&T, visited the Aberdeen Plant to perform an in-depth review of our quality systems which were found to be deficient in 1989. Six of seven areas audited were found to be "Adequate". Otto Grill from Formtech reported they were having problems identifying different ship ments of the same product. The lab started sending certificates of analysis by fax and putting the lot number on the bills of lading. Dixie Wire reported that drums of wire made with 2153A compound had a bad odor which made their customers' employees sick with nausea. The Aberdeen Tech Service Lab is investigating. mmmm VAB.0001189996 Continued 8/08 continued 8/09 Formtech reported that a truck shipment of RP-91 WHT 110 ran with lower melt viscosity than previous and subsequent shipments. This caused them to have 5% on part weight. Randell Jackson visited Formtech on 8/16 and presented torque rheometry data which showed no difference in material quality that would cause that problem. 8/15 Dayton reported that a railcar of RP-151 WHT 145 was full of "black regrind". The rail road shipped them a car of black compound pellets by mistake. Available Plastics truck loaded with 80273G in the plant had to be off-loaded because of problems with torque rheometry properties. The truck was returned to their plant empty. Vista supplied another truck of good material the next day. 8/17 Customer reported higher than normal per centage on the 80-mesh sieve on one railcar compartment of 5305. Although the compart ment was in spec, the material looked suspicious and therefore they asked us to double-check the sample from the car they sent us. The sample was indeed 5305 and Hark Washington relayed the information to Harley Houlding. It is assumed they used the material without problems. 2/2Q northern Electric. Laurel. MS The customer complained that five boxes of compound were labeled with the wrong Northern Electric part number. Ted Nicker son responded and said that we would be more careful in the future labeling their VAB.0001189997 mm LABORATORY > Continued The cus to complained that 18831 Vater Clear 10 x 1xo6 frliexibolie compound caused "fisheyes" in their flexible luggage strips. Aberdeen Technical Service Lab responded to the com-pollaaiinntt.. Retains showed no hard particle or gel problem. S ince then t Central Plastics has run some product from Blane with the same problem. Customer processing is suspected to be the problem in this complaint. There were no requests for corrective action during the month of August. E. Product Waivers American Mirrex 5305 Contamination Available Plastics 80273G WHT 110 Long Fusion Eagle Plastics Stylecrest 80273G WHT 110 RP-27 WHT 113 Short Stability n % on 40 Mesh Vycom RP-461 WHT 110 % on 40 Mesh No. 1 R/C 2 H/T 1 R/C 2 R/C 1 H/T and 1 R/C 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 August, 1990. Number of Samples Average RVCM, ppm 899 25 111 152 0.218 0.320 VAB.0001189998 J Continued RVCH of Shipment Samples The following is a summary of the residual VCM analysis of shipment samples for the month of August, 1990. Product Number of Samples 5265 5305 5385 5395 5415 Dry Blend Debox Pond 23 134 57 0 52 62 16 1 0.135 0.128 0.390 ........... 0.041 0.048 0.484 0.504 6. (based on dryer "regulars") 5165 5305 5385 5395 5415 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 1.01 1.58 3.19 7.33 5.67 0.42 -- 0.36 -- -- -- -- 134 Flexible 1.48 1.00 0.58 3.07 4.17 1.67 1.38 ---- 0.89 -- ----- 143 1.51 0.64 3.89 2.33 1.38 ---- 1.75 2.00 -- -- 3.0 163 -*---- - - ----------- ---- --------*------- -------- 1.12 0.61 6.67 6.33 1.89 0.22 3.20 1.67 4.86 2.21 0 172 />0m\ Hardness Color Hard Particles Heat Stability Contamination Dispersion Dicing Cross Contamination Mischarge Metal 26.0 <0.46> 15.0 <0.27> 14.0 <0.25> 7.0 <0.12> 62.0 <1.10> 35.6 <0.63> 19.5 <0.34> 7.8 24.0 24.4 7.4 1.5 12.5 <0.14> <0.42> <0.43> <0.13> <0.03> <0.22> 138.8 <2.45> VAB.0001189999 Continued Torque Rheometry Color Total 14.2 3.6 17.a <0.26> <0.07> <0.33> J. 1. All six laboratory natural teens met once during the month of August. "Cn shift's natural team made a presentation to management about their completed project. By changing sampling frequency and procedure, the dry blend lab tech nicians were able to trim 2 1/2 hours of sample result turnaround time which should increase the productivity of the dry blend unit. 2. Dave Cox completed software which creates certificates of analysis from the railcar shipment database. 3. A fifty-pound load cell and a die were ordered for PLENEX compound tensile testing. * VAB.0001190000 SAMPLE SHIPMENTS AUGUST 1990 RESIN Ship Date Product Amount 8/01/90 8/01/90 5265 5305 5385 5415 Pond * 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 8/01/90 5305 2250 lbs. 8/09/90 5265 5385 5415 50 lbs. 50 lbs. 50 lbs. 8/10/90 5385 (New Tech*) 2250 lbs. 8/10/90 5415 (Control) 50 lbs 8/10/90 5385 (New Tech.) 50 lbs. 8/10/90 5305 (New Tech.) 5385 (New Tech.) 50 lbs. 50 lbs. 8/14/90 5265 5305 5385 2 lbs. 2 lbs. 2 lbs. 8/15/90 5415 50 lbs. 8/17/90 5265 5305 5385 5415 50 lbs. 50 lbs. 50 lbs. 50 lbs. 8/17/90 5305 1000 lbs. 8/17/90 5385 5415 50 lbs. 50 lbs. 8/22/90 5305 50 lbs. 8/23/90 5385 5415 1 lb. 1 lb. 8/27/90 5305 10 lbs. 8/27/90 5265 5305 50 lbs. 50 lbs. Customer Tech Mark PANAMERICA DE PLASTICOS United Technologies Auto PIZABRENO S. A. Abitibi-Price Corp. Vista Polymers - OKC Gencorp Polymer Products Uniroyal Plastics Dar Chem Vicrtex Inc. 3M Austin Center Ristance Corporation CONDUCTORES LATINCASA Great Lake Chemical DAVID NETKA Robbins Tire & Rubber Dayton Extruded Plastics VAB.0001190001 COMPOUND Ship Date 8/02/90 8/02/90 8/03/90 8/15/90 Product 18961 NAT 15072 NAT 35852 NAT 18031 WAT CL 830 NAT 03 8/17/90 34643 NAT 8/20/90 8/23/90 8/24/90 8/30/90 8/31/90 8/31/90 38525 NAT 02 27121 NAT 15041 CB 50 16851 CB 50 38401 ORG 14331 WAT CL 27121 NAT 34311 NAT 18162 GRY 545 Sample Shipment s/August 1990'., Page 2 Amount 100 lbs. 100 lbs. 200 lbs. 100 lbs. 500 lbs. 50 lbs. 200 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 100 lbs. 200 lbs. 100 lbs. Customer Macklanburg-Duncan Tandy Cable Products Flexible Technologies Arizona Electric Fabricators Inc. ELECTROCONDUCTORES DE HONDURAS Tandy Wire IFER DOMINICANA C. A. Donnelly Corporation IFER DOMINICANA C. A. Tandy Wire Tandy Speciality Cables VAB.0001190002 NUMBER OF NJURIES ABERDEEN CHEMICAL PLANT INJURIES (FMlfi Month Running Totate) 40 35 30 25 20 IQ 10 5 O > > ii i ii ii i i i t t ^ i i i i i i i n i JASON OTOBF M AM J JASON OMF MAMJ JASON 0J*9OF M A M J J A TOTAL INJURIES OSHA RECORDABLE - -1'' # t*-n im- VAB.0001190003 ABERDEEN ENERGY CONSUMPTION Bi/niB PMM HI PR VAB.0001190004 wm r