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To: T. H. Huffman From: Dote: Subject: D. C. Skokna November 27, 1990 ABERDEEN MOETHLT PROGRESS REPORT OCTOBER., 1990 There were two first aid cases reported during October. At month's end, the plant's employees had worked 4,136 days (5,522,371 manhours) since the last lost time injury. FY 1990 Kev Statistical Information October 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 Operations 41.6 87.8 98.7 1.0222 5.5 96.8 5.1 99.3 1.9 91.7 < 2.9> < 7.2> <218.0> 41.6 87.8 98.7 1.0222 5.5 96.8 5.1 99.3 1.9 91.7 < 2.9> < 7.2> <218.0> The resin unit was shut down for half a day to investigate the source of a noise in the 13KV main feeder breaker. It was con cluded that the source was an arcing fault on the bus, and that it could not be immediately repaired. Repair will be made upon receipt of necessary materials. In the flexible compound unit, PLENEX polymers development used eighty-five hours of Line I time. Business was slow; and, as a result, Line V operated 4.5 days. Rigid compound demand remained steady through the month. Several test runs were conducted to determine the effectiveness of the product screeners. Plasticizer demand was high all month. Operations were very good during the month. VAB.0001189909 T. H. Huffman 11/27/90 Aberdeen Monthly Progress Report Page 2 - October, 1990 Coats Fixed costs were essentially at budget. Variable costs were unfavorable primarily due to some calculation errors. VCM usage was overstated by about 1MM pounds while the flexible compound variance due to off-grade was overstated by $49M. With these corrections, the efficiency was close to budget. SM All of the plant's natural teams met during the month. The Warehouse/Stores Natural Team made its man agement presentation. This team collected data to identify the causes of poor condition inbound raw material shipments and the associated costs. About sixty-five percent of the unacceptable loads were from one supplier. The team contacted this supplier and reviewed the data with them. A notable improvement has been noted since this contact. The Vinyl "C" Shift Natural Team made their manage ment presentation. This team revised the operator log sheets to improve routine equipment surveil lance and eliminate duplication of effort. The Quality Control Supervisor's Natural Team made their management presentation. They improved the way the brittleness test is run. Improvements include better repeatability, improved safety (two fires were caused by the method this team will eliminate), and lower costs. A miscellaneous capital project will be needed to implement the recommendations. The Laboratory "A" Shift Natural Team made their management presentation. They recommended the elimination of routine resin dry time testing (out of 3000 tests/year, none were outside specifica tion. ) This test will be run on shipments and special requests. Time savings are approximately 750 manhours per year; and, since this test uses lead compounds, potential exposures to lead dust will be reduced. +1 V T. H. Huffman 11/27/90 Aberdeen Monthly Progress Report Page 3 - October, 1990 OMP - Continued m The Vinyl "D" Shift Natural Team made their presentation to management. Their recommendations will improve surveillance of resin screeners. The benefits will be less off-grade resin and lower maintenance costs. PVC Compounders (a 5415 customer), part of Group Dekko, visited the plant for an overview of our operations. Times Fiber (a flexible compound customer) , visited the plant to discuss the corrective action we have taken to resolve quality problems Times' experienced with our 38525 compound. In discussions with the State, we learned that our new NPDES permit BOD and COD limits will be much lower than anticipated. We are reviewing this and will comment before the new permit becomes final. The remedial investigation of the plant's Superfund sites started during October. D. C. Skokna Plant Superintendent rah k mmmmm m VAB.0001189911 wm MUMP M* Houston J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson O. F. Harman H. R. Flammar R. R. Smith B. J. Bean R. H. Gerlach R. D. Gaablln D. L. Cohen Angfcfo J. P. Stokes R. 1>. Poe X H. J. Hall Oklahoma Cltv H. D. Garrison LCVCH Plant R. A. Conrad LCCP Plant J. Friend LCLAB Plant J. V. Ware X L. R. Bauer X Hammond J. Pavao X Blana Premiere C. R. Miller P. L. Foote 4 Aberdeen RVS/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 X X f VAB.0001189912 SAFETY - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number Of Lost Workday Cases 2 Q 2 0 0 Fiscal 0 0 Fiscal b 2 1 3 0 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 110 000 112 000 000 001 223 2 0 0 0 0 0 0 2 Lost Workday Cases Days Lost Safety ftecpyd Last lost time injury - 7/5/79 Days since - 4,136 Employee hours since - 5,522,371 On October 31, 1990, the employees of the Aberdeen plant completed 4136 days with no lost time injury. The topic for the October safety meeting was the conduct of a Walking/ Working Surfaces Survey. Following the training, every attendee par ticipated in a plant-wide survey. 4 VAB.0001189913 SAFETY - Continued A surrey was done to see if there was an increase in the use of seat belts since an earlier survey prior to Mississippi's new seat belt law. There was an increase in usage from 40% to 53% during the period. Routine dosimetry results for the month were: FA Vinyl Abrasion, 2nd left finger FA Maintenance Abrasion, 2nd right finger VAB.0001189914 - T. J. Arbeiter All of the plant's natural teams met during the month of November. Some of team highlights for the month were: The Warehouse/Stores Natural Team made their presentation to management on October 9. The team collected data on inbound packaged material and determined the amount of time and money being lost by the company due to various forms of unacceptable shipment conditions. Corrective action was taken by the team to help improve the performance of the vendor responsible for approximately 65% of all unacceptable loads. Preliminary data indicates a noticeable improve ment. Data collection will continue. Vinyl nCn shift made their presentation to management on October 11. The team's goal was to revise operator check sheets to improve the quality of the checks performed, reduce downtime, loss of production and cost of equipment repair, improve morale by having more meaningful check sheets, and increase operator productivity. A side benefit re sulting from this project is the saving of nearly 4000 sheets of a paper per year. Time studies indicate the process of completing the new check sheets is less time consuming and consensus is they are more meaningful. m The Quality Control Supervisor's Natural Team made their presentation to management on October 16. The team justified upgrades to the brittle point tester designed to improve safety and the repeat ability of the test. The upgrade will eliminate the need for alcohol reagent (we have had two fires in the lab caused by this hazard), and will eliminate the safety con cerns associated with the storage and handling of liquid nitrogen cylinders. It will also provide for greater temperature control (vital to accuracy and precision) and will eliminate delays in testing ex-perienced in the past while waiting for nitrogen cylinders to be delivered. The Laboratory ''A" Shift Natural Team made their presentation to management on October 17. The team presented data to support their recommendation that resin testing for regular dry time be limited to shipments and special requests only. - Continued The team's data indicated the lab performs approxi mately 3000 resin dry time tests per year. During FY90, not a single valid test result was outside the specification. The team's proposal will result in a savings of 750 technician hours per year - time that will be used for truly productive work) The Vinyl nDn Shift Natural Team made their presen tation to management on October 18. The team's goal was to identify the causes of sifter overflow and develop a cost effective solution. The team recommended two solutions: 1) Add a scanning unit to one camera and, 2) Relocate the fluid bed camera. The estimated IRRs for these proposed solutions are 87% and 35%, respectively (approximate $4000.00 total cost). These solutions will reduce the amount of off-grade resin and reduce maintenance costs through earlier detection of problems. Chief Process Engineer's Natural Team has begun preparing process flow diagrams for all processes in their department. Vinyl Operations Supervisor's Natural Team has begun gathering data to be used in updating operating procedures. The Plant Manager's Natural Team planned and conducted the Third Annual QMP Manager's Meeting for supervisory personnel. The meeting covered the following subjects: e Recognition for 1990 Performance, Q-Scorecard p e FY91 Q-Scorecard Review e Key Quality Issues and Customers, Challenges for 1991 State of the Plant (how we are doing) Barriers to QMP Employee Relations - EEO/Affirmative Action - Substance Abuse Situation - Shift Workers Starting/Quitting Time Continued The team also established a Bulletin Board. Process Improvement Team and conducted an MBWA survey to measure the effectiveness of the current bulletin board communication to employees. Another survey will be conducted in sjLx months to measure progress. John Greenlee, General Manager, and Mark Shire, Plant Manager, Kendallvilie, IN, both of PVC Compounders - Group Dekko, visited the Aberdeen Plant on October 17. John and Mark were given an overview of our operations, as well as a full plant tour. John Greenlee presented an overview of Group Dekko and PVC Compounders to the Aberdeen personnel in attendance. Group Dekko purchases 5415 resin from Vista as well as several compound formulations from Premiere. Bob Westrick, Quality Control Manager for Times Fiber, visited the plant on October 23. The purpose of Bob's visit was to discuss the action taken at the Aberdeen Plant to eliminate recent quality problems Times experienced with 38525 compound. Bob was also given a tour of compound lines I, III and V. A e* mm m vi mm T VAB.0001189917 - D. C. Skokna Variable Costs Product 1990 Variance. 221 Total PVC Flexible Compound Rigid Compound Plasticizer Total <$ 65.3> < 117.2> 15.2 < 50.7> <$218.0> <$844.6> < 76.3> < 34.4> ____^7.7 <$907.6> <$909.9> < 193.5> < 19.2> . < 3.0> <$1125.6> Note: Variances were calculated using the "old" format. (Production was the total of prime plus non-prime products. The new basis uses prime production only.) Since we were not able to get EDS to convert to the new basis for a reasonable cost, October's IPA is on the "old" basis. Starting in November, we will have the in-plant capability to calculate IPA's using the "new" production basis. Two errors (VCM was calculated about 1MM pounds low; the flexi ble compound variance due to off-grade was calculated $49.2M high) caused about $235M of the unfavorable efficiency variance. Fixed Cost Variances m Payroll and Benefits MM&C Miscellaneous TI&D m Clearances Variance - $M Total <$ 38.7> 14.0 47.9 < 27.5> < 2.9> <$ 7.2> The primary cause of the unfavorable variance was an unfavorable $23.3M benefits clearance. M. M. & C. Expenditures were somewhat below budgeted rates. * wr mm VAB.0001189918 !* Continued Outside Professional Services - $10.6M favorable Contract - Operating - $11.6M favorable Warehouse G/L - $13.4M unfavorable TX&D Tax clearances were above budget. This category will be above budget all year due to budgeting too low. VAB.0001189919 yiHYL - J. D. Olson, J. M. Vinoskl Safety The Vinyl Department had one first aid case during October. The monthly safety meeting topic was "Walking and Working Surfaces Survey". A half-day vinyl unit outage was taken to investigate a noise in the main feeder breaker for vinyl in the primary 15KV switchgear. It was concluded that an arcing fault exists on the bus of this switchgear and could not be Immediately repaired. A repair plan has been formulated and will be implemented upon receipt of necessary materials. 2. Mechanical design and material procurement are underway for the permanent charge water decalcification systems for the production of Klockner resin. 3. The resin raw materials in the 744 account were valued at $306.1M. - 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 % 40.9 1320.6 103.5 956.0 30.8 87.8 92.2 96.2 98.7 Downtime 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). Maintenance downtime (hydroblasting on D D743, D744, and D745, seal and condenser bottom gasket replacements on D743, gearbox repairs on D742, sightglass repairs on Old Module fresh VCM receiver, inspection of maiti electrical feed breaker for vinyl unit). XZD 40.9 1320.6 103.5 956.0 30.8 87.8 92.2 96.2 98.7 Hours 521.0 384.0 VAB.0001189920 V1MTL - Continued Drver Downtime % of Total Downtime Reactor limited production. 25.5 Operational downtime (centrifuge plugs, dryer cleaning, and flameouts). 30.8 Maintenance downtime (screener motor replacement, centrifuge maintenance, screw feeder repair, fluid bed blower breaker repair, electrical outage due to feeder breaker inspection). 43.7 J. B. Autrey, S. A. Truitt All belts and sheaves were changed out in the fluid bed dryer blowers. The demister pads on the scrubber and a ductwork gasket downstream of the burner were also changed. Sewer valves were removed and replaced with blinds on all + m The shaft seal and fluid coupling on 742 gearbox were changed and the unit aligned. Wear was due to vibration. Reactors 744 and 743 were brought down for annual rupture disc change and hydroblasting. Reactor 743 had a worn seal that was replaced. The old seal was rebuilt. Reactor 743 bottom condenser gasket was changed because it was leaking. A motor was replaced on the #5 Bird due to bad windings. m Four major valves were replaced in Vinyl. * Safety J.E. Nickerson, K.6. The Compound Department had no first aid cases or OSHA recordable injuries in October. The topic of the monthly safety meeting was "Walking/Working Surfaces Survey". PLENEX polymers production consumed, eighty-five hours of production time on Line I. Line V continues to operate on an as needed basis, running for 4.5 days during October. Demand for rigid compounds remained steady in October. Several test runs to evaluate the effectiveness of our finished product screeners were conducted during the month. The goal of these test runs is to ^provide information on how screener performance affects our customers and to identify future capital requirements if current screening is deemed inadequate. Plasticizer production continued to increase in October while quality remained high. October production totalled 1.86101 pounds. Both internal and external demands remain high and are expected to continue steady. Operating Monti! Ayg./Pty Line I 31 Line III 31 Line V 4.5 Total % Prime Capacity Utilization Factor 1955 3390 148 5493 96.8 .680 63 109 -22 205 Downtime Hours Fiscal Y.T.D. 1955 3390 -JSl 5493 96.8 .680 - PLENEX Polymers Production - Product Changes - Miscellaneous Maintenance - Quality Problems & Control 85 67 27 11 - Product Changes - Quality Problems & Control - Miscellaneous Maintenance - Roll Mill Maintenance - Blender Maintenance 35 33 26 12 12 i VAB.0001189922 COMPOPHD - Continued Doriwt:ime - continued - Product Changes - Start Up\Shut Down Quality Problems & Control 18 4 2 Operating Month Rigid Compound 31 % Prime Capacity Utilization Factor 5108 99.3 .925 177 5108 99.3 .925 Downt ime - Product Changes - Quality Problems & Control - Miscellaneous Maintenance - Screener Maintenance - Univox Maintenance - Air Pad Blower Maintenance Operating Hours 82 37 35 14 8 7 Plasticizer 31 % Prime Capacity Utilization Factor 1862 91.7 .989 1862 91.7 .989 Kev Maintenance Work - J. B. Autrey, S. A. Truitt Pulled and cleaned vacuum jets on reactors #1, #2, and #3. Maintenance work was necessary due to calcium carbonate buildup. Completed P.M. work on all five dicers. The sprocket on Line III blender gearbox was replaced due to wear. + The motors on #5 and #9 dicers were replaced due to bad windings and bearings. A current transformer was installed on the dry blend Welex motors to allow for accurate observation of motor amperage. A VAB.0001189923 R. E. Polk. S. C. Hillman, M. R. Kana Sampling throughout the month shows that consistent compliance with TC regulations Is being attained. Several point sources are being evaluated for further reduction. As part of the TC compliance work, TC/RCRA training was conducted for the vinyl operations personnel. This training emphasized the effects of TC compliance projects on the vinyl unit. Drv Blend Evaluation of the causes of oversized dry blend particles continues. Test runs have shown that some oversized material results from the transfer system after the screeners. Some oversized material passes through the screeners. Further testing is planned to quantify the relative contributions of transfer lines and screener inefficiency. Discussions with Klockner have indicated a potential market for a 5305 resin with ultra low contamination or "gels". Marketing, R&D, PED, and plant engineering have initiated meetings to discuss a project to make an "ultfaclean" 5305 resin. Aberdeen Engineering facilitated a Hazard and Operability Study (HAZOP) of the HF Safety Improvements Project at the LCLAB plant. The fizial report has been issued to the HAZOP team members for review. A test run was conducted to determine the capability of making rigid pellets for U-Brand on compound Line V. During the test, approxi mately 10,000 pounds of pellets were made. Actual production and physical appearance of the pellets was successful, though the accuracy of stabilizer weighup in a full production run is still being evaluated. Pellet samples will be tested for NSF approval and a trial will be made at U-Brand. PED and Process Engineering par ticipated with compound operations in the test. Steve Hillman attended leader/facilitator training on establishing employee and community advisory groups. The training was held on October 16-17 in Houston. HGIimiKG - 1.1. ra ft, S.C. H liU ttl, H.l. U II IS mumm MUR f s VAB.0001189925 h F. 6. Jeanson Water All wastewater discharge parameters were met for the month of October. h The NFDES permit application was completed and submitted to the State. A meeting was held with the .State to review the application. Upon review of the application, the State will send us a draft permit. We have an oppor tunity to comment on this permit before it becomes final. Our BOD and COD limits In the draft permit will be substantially lower than our current limits. Waste Shipments for the month included: One bulk shipment of API sludge to CWM in Entelle, AL. t m One bulk shipment of lead bags to CUM in Emelle, AL. m One drum shipment of plasticiser filter cake to CWM in Emelle, AL. Superfund * The remedial investigation (RI) was started this month. All shallow moni toring wells were completdd. Soil borings into the waste sites were com pleted. The deep wells will be1started in November. Peter Virden with the State was here tifice during the month) monitoring the Rl progress. The final draft on the <$rum removal plan is expected in November. C lement International was chosen to do further risk analysis for the plant. A letter was sent to Clement authorizing them to The initial two items they will be looking at include a risk analysis for people who live around the plant and a thorough investigation of risk factors for VCM - where they came from, what other states use, Training on RCRA and TC was completed for the Vinyl Department. Compound and Maintenance RCRA/TC training will be done in November. I attended CWM's Emelle landfill open house and regulatory update. Hosted Royal Flex, a potential offgrade customer for millscrap, vacuum/vent dust and pond resin. D. . Moore QfflftiSi 1990 Fiscal Y.T.D. A. Unadjusted EUI <2.8%> B. Adjusted EUI <2.9%> C. BTU/Lb. Product 2598.0 D. Total Energy Consumption MMM BTU 134.63 < 2.8%> < 2.9%> 2598.0 134.63 A There were ninety-six energy related items com pleted in October, 1990. Eighty of these items were steam leak repairs. The remaining sixteen were steam trap repairs. No. 1 No. 2 No. 3 82.9% 83.0% 82.8% 82.9% 83.0% 82.8% * VAB.0001189927 None Sherry Truitt - transferred from Mechanical Engineer to Maintenance Ehgineer. Joseph Hegwood - transferred from Maintenance Engineer to Mechanical Engineer. None None None VAB.0001189928 A 15 12 41 24 41 33 5 171 78 80 50 90 62 25 1 10 1 20 65 4 6 18 53% 42% 22% 25% 61% 30% 40% 38% 7.7% 0 0 0 8.3% 2.4% 3.0% 0 2.3% 23.1% 0 0 0 0 0 0 0 MW IMP VAB.0001189929 to a; to u SS*s CO CO a* CO a PIMf# $ * 5 iinn min 8 i i CM CM HKI NO*I KwMo jc rsi $ s CM s (A I Ss? 5! VAB.0001189930 - D. A. Barclay There were no reporcable safety instances this month. I attended a plant safety orientation and staff attended a walking/working surface survey training session. Warehouse and Stores Natural Team made a presentation of their process to eliminate unacceptable inbound raw material loads. Processed Processed Invoices Working Fund Checks Written Cost Savings Through Bid Process Month 945 15 $3116 Y.T.D. 945 15 $3116 (Decrease) Compound "A" Crade Compound Off-Grade (BC) Compound Off-Grade (H) Compound MSP - 90 Hillscrap Dry Blend NAW Grade Dry Blend Offgrade Resin Type I Resin Type III Vacuum Dust Total Packaged Warehouse 3,904,664 394,732 58,755 90,112 175,008 271,497 25,308 441,800 44,950 5,707,872 4,388,118 634,030 64,755 95,276 170,691 377,526 17,729 452,550 44,850 6,482,404 463,454 239,298 6,000 5,164 < 4,317> 106,029 < 7,579> 10,750 < 100> < 44.167> 774,532 FLEXIBLE & RIGID OFF-GRADE OCT.'80 THRU OCT.'90 A net mm mm mm arm a$m PKQTO PRODUCTS INVENTORY m r VAB.0001189931 t Mima ciuicu run SIIFTIK MiLISIS ocroon iih -SUPIIITS BI PIOMCTS- PUBLIC mu IPT/ITC IICI/TOLL P9ILIC HSU-MLI liSIl-PICUCII 26,171,799 6,767,179 111,Til 111,762 US, iSI 9p 26,671,790 169,762 runni comm-nu 747,730 1,946,759 runni comm-pieuro 2,616,949 14,til 9 9 747,739 2,111,141 in bisiiiss 19,263 91 10,263 mu coipoiimiu IIIII CMPOIIMICUIII 3,156,519 429,369 (ii,iu) 9 9 9 3,156,519 423,359 I0UIN - MU TOLLIK - PICKAIII 9 6 1,491,969 9 99 0 0 PUSTICIM 172,949 162,651 563,149 112,140 TOTAL 39,991,423 9,234,1ST 2,1S4,IM 33,996,423 SUPIIITS IT I0H* BOLI: tOCTOBtlt inn IU1IIU COIMOII mil couom PUSTICIM UILCAI 162 16 23 1 CDSTOHII C0U0I PICIIP can ii 46 59 92 9 21 13 7 TOTIL 0CT0II1 292 59 89 wit iisii rUIIBLI COflFOIlD mu conoin pusTicim 162 46 59 16 9 2 23 9 21 1 13 7 ii1ii1 TOTAL TTI PACUCII: lOCTOlllt IISII niliin coipmii mil comm pusTicim i*t* IIHII I1t9 I IM I I1 t o 91 292 ** r C0STOBII PICIIP COttOI cmiu 4 17 13 72. 1 14 09 89 me comiin 90 09 99 09 ii 1 1i if iM nH 11 11 iiiti ui/irs 2 14 9 9 TOTU OCTOBII Wl* mu FLUIBLI COIPOIII m comm PLASTICIIII 18 193 0 i , t ii 4 17 9 0 2 13 72 9 0 14 1 14 9 9 9 9 9 99 0 TOTU TTI 16 103 9 0 16 11 it 11 1 1i 11 11 1i i1 ii i 1i i1 It i TTI irt/ue EICH/TOLL 1,717,111 119,700 215,156 9 1,946,751 84,937 0 9 99 (13,196) 9 9 9 0 1.491,969 09 162,659 102,140 9,234,657 2,154,000 Ttm 251 11 44 21 341 258 18 44 21 341 TOTAL 23 99 15 9 - 137 ! lr 1- 23 99 15 0 137 VAB.OOOl189932 g f cn si r**i 9s iju a*. I s MX 04 oo rx rx 5| cn t LU Si <t (n cn to lu lu I UJ LU tjn co s s n 04 QO -H CD OO mO 04 04 CN CN 04 N I\1 04 iTk CXI cn CO &S CJ CO to h *o >o to m o** ro CN III O' OD -- CXI o m co m O 04 1*0 m LcUo cc h-- & I CO cc i co cn IK ^ h- cn ^ co st aux a -'> ~ 25 ux 3 s sCO <iqr iss 33 9 m 04 ^ W CD 3 SS g: CN ex* -* CN O* C4 04 WON rN ci m i ??? x <ww 8MX o- co co co $ 04 S C> <"* C' CD mo on m on CO CD CO m mx in k> m on 'O m m on on *x m mx -4) u*4 m n 04 MO * in CX| O' o- -o lO # lO O 9T OQ m on CO O* -^O M &* in m on 3 s CN CO cn c'nD <;n ;D CO cn cn cn cn cn + x_y :*s CO oo *n s in 3 cn m m --r CO CN O HIsi m m on co u_ 3 u cn cc* CN mm S hx x u") CN *>1 i ox cn *n mx 3 ux in ox ^ 43 CN MX CO CQ MX MX MX -** 04 CN t MX MX az rx *x cc ON III cn m mx m ox CO ox ox O MX o I -- ox CIO toI IOI IXI oI OI M ro n <> MX MX h*) K) 4* ^ ^ CO n r** :3 i rj Sfe cn Sfc* 3 CO CO 3i si CD co 3 3ac 3 CM *3C & ^ g Si S 2iE sE 2*1 U aaa to u u uco co co cn ua cn CO cn u u u LU LU 3 f" K- CO CU ca CO to tI 3 si V Q DC co to Q CO CO 3CO ^ LU UJ O U. LL LU LU o CO Lu Ll. Li. h* h* > 3 a ooooo O' O' hO n M IN CN CN A VAB.0001189933 tambatmy - j. m. Edwards, Jr. A. Safetr There were no safety incidents in the Laboratory during October. The monthly safety meeting topic was "Walking/Working Surfaces Survey" taught by Bruce Trego. Mark Shire and John Greelee with FVC Compounders Inc. visited the plant. Operations and quality presentations were given followed by a plant tour. Robert Westrick with Times Fiber Communications Inc. visited the plant. We discussed two recent quality problems with Vista's 38525 flame retardant PVC compound and actions taken to prevent Kelly Kinnett, Ken Brenis and Vijay Kotian with Furon visited the plant. Analytical testing methods and specifications were dis cussed and agreed to for PLENEX jacketing and insulation compounds. 10/3 Sarnafil reported seeing black speck contamination in a truck shipment of 108P plasticizer from railcar VICX 1621. The contamination was Isolated in this first truck and the remaining plasticizer in the car was used. Cus tome r reported excessive amounts of multi-colored particles greater than 15 mesh * in RP461 WHT 110 railcar VIPX 45263. Vycom reported railcar FPAX 890168, also RP461, ran inconsistently and caused plateout. Vycom also reported metal contam ination in a truck delivery from Aberdeen of RP421 WHT 110. Some of the samples of metal resemble the hold-down clips in the dry blend unit screener. A project team and a process engineer are looking into all of these problems. tameATOM - Continued 10/12 Marley reported a 5305 car being too coarse in September. Again in October, they reported another 5305 car being too coarse to use. Both cats mat Vista specifications but failed Marley's specs for particle size distribution. Three compartments in PTLX 41833 were greater than 28% (Marley's spec) on the 60 and 80 mesh combined. Vista has no such specifications. Specifications are presently being negotiated. 10/16 Times Fiber reported screen pak pluggage and poor tensile strength properties in 38525 black compound. The problem was traced to high moisture and oversized aluminum trihyrate. Q.C. testing of incoming ATH was started to prevent recurrences. 10/30 Vytron reported unfused pellets in profile samples made with 17561. Samples received from Vytron showed the contamination to be 36440 which was run in the plant just prior to the 17561 run. The cause of the problem was cross contamination due to inadequate cleanout. There were no waivers for the month. The following is a summary of residual VCM results on in* process samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of October, 1990. Number of Samples Average RVCM, pp 952 22 98 123 0.224 0.377 .............................................................................................................................................. *................ VAB.0001189935 !'......... ------------------------------- ------- tiKMAWT - Continued The following is a sunnary of the residual VCM analysis of shipment samples for the month of October, 1990. 5265 5305 5325 5385 5395 5415 Dry Blend Debox Pond 29 152 2 62 5 60 53 8 0 0.081 0.123 0.046 0.361 0.040 0.031 0.027 0.191 F. (based on dryer "regulars**) 5265 5305 5395 M15 Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle size, microns 0.92 0.38 4.60 3.83 3.00 1.13 ---0.25 --* 135 G. 0.89 1.73 0.87 2.13 8.67 2.11 1.78 ---0.90 ------- -- ---- 141 1.25 0.53 3.67 1.56 1.78 ---1.05 -- -- 16.6 162 1.16 0.14 5.83 2.17 1.67 -- - 0.99 2.40 ---10.7 147 1.38 0.62 6.17 6.00 4.22 0.89 3.64 3.65 1.74 4.5 174 Hardness Color Hard Particles Dicing Cross Contamination Mischmrge Total M Lbs. XU 22.0 <0.38> 17.0 <0.29> 39.0 <0.67> M Lbs. 44.3 70.5 1.5 33.0 <0.76> <1.22> <0.03> <0.57> 155.3 <2.68> VAB.0001189936 UBflBATqiT - Continued Torque Rheometry Color Total 2.7 12.2 19.9 <0.05> <;q , ?4> <0.39> 1. All six natural teams net during the month. Two teams made project presentations to management. .2 The head space analyzer used to xe residual VCM con- centratlons in slurry and product samples had several failures during the month. 3. Dave Cox worked with Administrative Services Department on "Time Card" and "Safety Shoe Recording" programs using Paradox. He also started converting the plant's IPA reports to a PC instead of using time share. 4. There were two viscosity analyzer failures during the month. VAB.0001189937 RESIN Ship Date 10/10/90 10/04/90 10/12/90 10/16/90 10/17/90 10/24/90 10/24/90 10/24/90 10/29/90 SAMPLE SHIPMENTS OCTOBER 90 Product 5305 5415 5265 5385 5265 5305 5265 5305 5385 5385 5395 5415 5265 5305 5265 Amount 10 lbs 2 lbs. 50 lbs. 5 lbs. 5 lbs . 5 lbs. 50 lbs. 50 lbs. 50 lbs. 5 lbs. 5 lbs. 5 lbs. 5 lbs. 5 lbs. 50 lbs. Customer Robbins Tire A Rubber Sumitomo Corporation Polycast Technologies- Uniroyal Ferro Chemical Vista - Austin Keysor-Century Corporation American Thermoplastics Extrusion Co. Penn Color Inc. Great Lakes Chemical Corp. COMPOUND Ship Date 10/05/90 ' 10/10/90 10/10/90 10/11/90 10/11/90 Product 17462 WHT 18162 BLK 17121 WAT CL 18031 WAT CL 461-119A WHT 461-119B BLK 461-120B WAT CL 38401 ORG 61 419-50 A 419-71 B 34862 GRY 546 OG 461-120A WAT CL Amount 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 100 lbs. 5 lbs. 5 Xbs 100 lbs 50 lbs. Customer Vista - Austin KREO Company E. I. DuPont de Nemours Co. Inc. KREO Company Vista - Austin VAB.0001189938 Sample Shipments/October 1990 Page 2 COMPOUND (Cont.) Ship Date Product 10/11/90 38401 0R6 61 10/15/90 38525 BLK OG 10/16/90 17121 18162 38531 38931 WAT GRY WHT WHT CL i0G 548 OG 818 OG 810 OG 10/17/90 38963 WAT CL 10/19/90 38525 BLK OG 34862 GRY 546 OG 10/19/90 38525 BLK OG 34862 GRY 546 OG 10/19/90 38525 BLK OG 34862 GRY 546 OG 10/19/90 38525 BLK OG 34862 GRY 546 OG 10/26/90 38401 ORG 61 Amount 100 lbs. 100 lbs. 100 100 100 100 lbs. lbs. lbs. lbs. 100 lbs. 100 lbs 100 lbs. 200 lbs. 200 lbs. 400 lbs 400 lbs. 100 lbs 100 lbs * 50 ;lbs. Customer Coleman Cable Systems Kreo Company Kreo Company c/o Superior Insulated Wire Corp. Master Halco Superior Plastics Inc. Hemisphere Plastics Polychem Kreo Company Coleman Cable Systems DRYBLEND Ship Date 10/01/90 Product 802736 WHT 110 Amount 1300 lbs. Customer American Maplan VAB.0001189939 NUMBER OF INJURES J"88 M M J S N J'89 M M J S N J'90 M M J S MONTH TOTAL MJURES OSHA RECORDABLE II VAB.000118994Q \\ \ l