Document wD740YwYQ5jzZJ6pwq6qbyMk3

A VINYL - D. W. Hollis, J. M. Edwards Safety The Vinyl and Yard Departments had one first aid injury case in December. Shift safety meeting topic for the month was the Subpart V Compliance Training. Production .1 Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. .5. Reactor Stream Factor 6 Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days December 38.8 1251 948 30.6 94.1 9748 66.8 31 Y.T.D.(Fiscal 87) 107.6 1171 2665 29.0 89.1 10158 60.2 92 Vinyl Department production for December was 38.8MM pounds which sets a new production record. The previous record was 38.7MM pounds set in March, 1986. Reactors The reactor stream factor for December was 94.1%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 84.0% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size information before charging, reactor inspections for 5415 test runs and delays due to four 5415 coarse batches. 2) Maintenance Service Downtime: Accounted for no downtime because the cleaning of the reactor AMS injection ports and inert vent lines was accomplished while the reactors were normally down for other reasons. 3) Maintenance Repair/Revision Downtime: Accounted for 16.0% of the total downtime and was due to changing D-600 and 744 reactor agitator seals, cleaning the sewers in the old module, changing the new module dump Sweco screen and a major electrical short in a new module starter bank. Dryers The dryer stream factor for December was 66.8%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 88.8% of the total down time. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 5.0% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems. VAB.0001186821 VINYL - Continued Dryers - Continued 3) Maintenance Repair/Revision Downtime: Accounted for 6.2% of the total downtime and was due to repairing the fluid bed blower, welding on #7 outlet supports, working on #4 activator instrumentation, working on #5 exhauster and explosion door, preventative maintenance on the fluid bed south Bird centrifuge, and #7 activator valve replacements. Product Quality Summary Resin Type Prime % of Total "B" "H" Production 5265 5305 5385 5415 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 2,273,116 3,816,440 23,179,058 6,207,369 1,800,860 - -- -- -- 37,276,843 -- -- -- -- 998,360 176,220 -- 223,580 1,398,160 -- -- -- -- -- -- 98,888 -- 98,888 5.9 9.8 59.8 16.0 4.6 2.6 0.5 0.2 0.6 100.0 EC CM O Quality performance for December was 99.7% customer grade with grade production. A total of eleven railcars were shipped as "B" grade during the month which represented 9 .6% of the 115 total resin hopper cars shipped. Load Date Ship Date Car No. 11/10/86 12/01/86 VIPX 45258 10/22/86 12/01/86 VIPX 45708 11/30/86 12/11/86 PLCX 43854 12/05/86 12/16/86 VIPX 45260 11/26/86 12/16/86 ACFX 55814 12/16/86 12/29/86 VIPX 45261 11/17/86 12/29/86 VIPX 45782 11/19/86 12/30/86 PLWX 44720 12/01/86 12/31/86 PTLX 41841 12/10/86 12/31/86 PLWX 44291 11/15/86 12/31/86 PTLX 41592 Customer Product Intermax, TX Debox T. Brewer, FL Debox Wexford, CA Debox Vulcan Plastics, AL Debox Westernag, TX Debox Silverline, NC 5385 Cont. Plast., CO Debox Wexford, CA Pond Resin Wexford, CA Debox Wexford, WI Debox Wexford, CA Pond Resin Reason Quality Quality Quality Quality Quality Cont. Quality Quality Quality Quality Quality VAB.0001186822 VINYL - Continued The Vinyl area received twenty short lead time emergency type orders comprising 7.4% of the 272 Aberdeen resin shipments in December. Monthly Variable Cost Performance Variable costs for the month were unfavorable at $487.3M resulting from an overall unfavorable price variance of $412.8M and an unfavorable efficiency variance of $74.6M. Resin variable cost for the month was 18.643 cents/lb. versus the budgeted 17.336 cents/lb. The $412.8M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $446.6M. The $74.6M unfavorable efficiency variance can be attributed mainly to the unfavorable efficiency variance of VCM, $67.7M; and calcium stearate, $16.2M. VCM efficiency for the month was 1.01402 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. YTD variable cost efficiency variances in the Vinyl Department totaled $103.3M unfavorable. Energy Performance/Progress 1. Plant energy performance for December was 2263 BTU/lb. General 1. Resin raw material in the 0744 account totaled $262.5M. 2. Commercial production of 5415 resin started in December using temporary facilities. A VAB.0001186823 A COMPOUND - P. J. Kober, J. E. Nickerson Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line V Line III Total 31 17.5 31 2676 1029 3815 7520 86 59 123 7348 2544 11524 21416 Line I operated thirty-one days during December at an average rate of 86M pounds per day. Major items affecting production efficiency were: product changes, 72 hours; quality problems, 15 hours; resin blower maintenance, 11 hours; housekeeping, 11 hours; cooling water contamination, 6 hours; Banbury problems and maintenance, 6 hours; and dicer system problems and maintenance, 5 hours. Line V operated 17.5 days during December at an average rate of 59M pounds per day. Major items affecting production efficiency were: product changes and startups, 40 hours; quality problems and reblending, 17 hours; pelletizer problems and maintenance, 7 hours; and plasticizer system maintenance, 4 hours. Line III operated thirty-one days during December at an average rate of 123M pounds per day. Major items affecting production were: product changes, 66 hours; scheduled and unscheduled mill and hydrotherm system maintenance, 20 hours; dicer system problems and maintenance, 14 hours; delays due to silo scheduling and rail switching problems, 9 hours; and FCM maintenance, 6 hours. Quality performance for flexible compounds was 1,3% off-grade of which 95% was due to mill scrap. "BC" production was 0.6%. The raw material requirement for flexible compounds was 1.01599 pounds of raw material per pound of compound versus a 1.01081 standard (YTD is 1.00488). The variable cost variance for compound was $44.1M favorable with $10.8M favorable due to price and $33.3M favorable due to efficiency. The efficiency variance due to product mix was $36.4M favorable. There were no major compound raw material efficiency variances. The 7.5MM pounds of compound produced in December is a new monthly total production record. The previous record was 7.4MM pounds achieved last month. Total compound inventory rose 1.7MM pounds in December to 9.4MM pounds. Dry Blend Production, M Pounds Operating Days Month 5493 31 Average Operating-Day Rate 177 Fiscal Y.T.D. 13900 92 VAB.0001186824 COMPOUND - Continued Dry Blend - continued Dry blend operated thirty-one days during December at an average rate of 177M pounds per day. Production included 80172C, 80273G, 90172D, RP-200, 223-36, 196-198, 223-134, 269-12, RP-203, 269-67, 269-69, 269-80, and 269-66. Dry Blend production was hindered by: product changes, 28 hours; delays associated with quality and lab problems and normal Q.C., 17 hours; transfer system problems and maintenance, 21 hours; and Welex problems and maintenance, 10 hours. Quality performance for the month of December was 98.8% customer grade. The raw material requirement for dry blend was .99013 pounds of raw material per pound of dry blend versus a standard of 1.00489 (YTD is 1.00571). The variable cost variance for dry blend was $13.5M favorable with $30.9M unfavorable due to price and $44.4M favorable due to efficiency. The efficiency variance due to product mix was $18.6M favorable. Plasticizer Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 1882 31 61 - 5643 92 Plasticizer operated thirty-one days during December at an average rate of 61M pounds per day. Production included 61OP and 108P. VRP production totaled 124M pounds (6.6%). The raw material requirement for plasticizer was 1.24486 pounds of raw materials per pound of plasticizer versus a 1.09868 standard (Y.T.D. is 1.12585). The variable cost variance for plasticizer was $81,4M unfavorable with $17.7M unfavorable due to price and $63.8M unfavorable due to efficiency. Alfol 610 was a major efficiency variance at $57.3M unfavorable. Much of this variance was due to an accounting error which left last month unusually favorable. The efficiency variance due to product mix was $1.8M favorable. Quality Improvement All compound, dry blend and plasticizer operators participated in SPC classes in December. The course included training in statistical methods, involvement team concepts, and the quality improvement process. VAB.0001186825 COMPOUND Energy Continued Compound Dry Blend A 1665.7 689.7 1569.0 1783.0 730.0 1833.5 VAB.0001186826 VINYL - D. W. Hollis 9 J. M. Edwards Safety The Vinyl and Yard Departments had one first aid injury case in November. Shift safety meeting topic for the month was the annual fire fighting training. Production November Y.T.D.(Fiscal 87) 1. Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days 36.6 1219 917 30.6 92.9 10182 62.3 30 68.8 1128 1717 28.1 86.5 10366 56.8 61 Vinyl Department production for November was 36.6MM pounds. Reactors The reactor stream factor for November was 92.9%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 64.9% of the total downtime and was due to reactor recovery scheduling conflicts. downtime due to rinsing the chem wash tank and waiting on particle information before charging. 2) Maintenance Service Downtime: Accounted for no downtime because the cleaning of the reactor AMS injection ports and inert vent lines was accomplished while the reactors were normally down for other reasons. 3) Maintenance Repair/Revision Downtime: Accounted for 35.1% of the total downtime and was due to rebuilding reactor 742 gearbox, replacing reactor 743 condenser gasket, changing D-600 reactor agitator seal and changing 742 reactor sewer valve. Dryers The dryer stream factor for November was 62.3%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 94.1% of the total downtime. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 4.0% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems. 3) Maintenance Repair/Revision Downtime: Accounted for 2.0% of the total downtime and was due to repairing leaks in transfer lines, #4 centrifuge repair, #4 activator repair and #7 centrifuge repair. VINYL - Continued Product Quality Summary Resin Type Prime % of Total "B" "H" Production 5265 5305 5385 5425 5465 Debox Sifter Overflow Pond Resin Total 2,841,838 3,277,980 18,365,625 8,551,395 2,114,400 -- -- -- 35,151,238 -- -- -- -- -- 1,084,720 -- 252,760 1,337,480 -- - -- -- -- -- 75,451 - 75,451 7.8 9.0 50.1 23.4 5.8 3.0 0.2 0.7 100.0 Quality performance for November was 99.8% customer grade with 0.2% ,fHlf grade production. A total of six railcars were shipped as "B" grade during the month which represented 6.3% of the 95' total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 10/27/86 11/11/86 PLWX 44258 Cont. Plastics Debox Quality 11/03/86 11/11/86 PTLX 41594 Vulcan Plastics Debox Quality 10/04/86 11/11/86 PTLX 41857 Wexford Debox Quality 10/07/86 11/13/86 VIPX 45703 Cont. Plastics Debox Quality 10/01/86 11/14/86 PTLX 41603 Grifco Debox Quality 10/06/86 11/21/87 VIPX 45290 Wexford Debox Quality The Vinyl area received forty-three short lead time emergency type orders comprising 16.0% of the 269 Aberdeen resin shipments in November. Monthly Variable Cost Performance Variable costs for the month were unfavorable at $259.5M resulting from an overall unfavorable price variance of $251.2M and an unfavorable efficiency variance of $8.3M. Resin variable cost for the month was 18.074 cents/lb. versus the budgeted 17.336 cents/lb. The $251.2M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $275.0M. The $8.3M unfavorable efficiency variance can be attributed mainly to the unfavorable efficiency variances of 939 initiator, $13.5M; and Methocel, $11.2M, being offset by favorable efficiencies in Calcium Stearate, $17.8M; and Alcotex, $12.0M. VINYL - Continued Monthly Variable Cost Performance - continued VCM efficiency for the month was 1.00278 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. YTD variable cost efficiency variances in the Vinyl Department totaled $28.8M unfavorable. Energy Performance/Progress 1. Plant energy performance for November was 2277 BTU/lb. General 1. Resin raw material in the 0744 account totaled $274.4M. 2. A run of X-42 resin was made to supply trial material to customers. VAB.0001186829 COMPOUND - P. J. Kober, J. E. Nickerson Compound Production Line I Line V Line III Total Operating Days 30 14 30 Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. 2542 774 4070 7386 85 55 136 4672 1515 7710 13897 Line I operated thirty days during November at an average rate of 85M pounds per day. Major items affecting production efficiency were; product changes, 65 hours; housekeeping, 17 hours; Banbury maintenance, 12 hours; quality problems and blender adjustments 15 hours, plasticizer weigh-up system maintenance, 6 hours; and dicer system problems and maintenance, 5 hours. Line V operated fourteen days during November at an average rate of 55M pounds per day. Major items affecting production efficiency were; product changes, 31 hours; and quality problems, 6 hours. Line III operated thirty days during November at an average rate of 136M pounds per day. Line III production was hindered by; product changes, 61 hours; mill and hydrotherm system maintenance, 10 hours; and FCM maintenance, 9 hours. Quality performance for flexible compounds was 1.4% off-grade of which 78.9% was due to mill scrap. MBC,T production was .68%. The raw material requirement for flexible compounds was .98587 pounds of raw material per pound of compound versus a 1.01169 standard (YTD is .99888). The variable cost variance for compound was $118.8M favorable with $19.0M unfavorable due to price and $137.9M favorable due to efficiency. The efficiency variance due to product mix was $95.9M favorable. There were no major compound raw material efficiency variances. The 7.4MM pounds of compound produced in November represent a new total production record. The previous record was 6.5MM pounds achieved last month. Total compound inventory rose .7MM pounds in November to 7.7MM pounds. Dry Blend Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 3982 30 133 8275 61 A VAB.0001186830 COMPOUND - Continued Dry Blend - continued Dry blend operated thirty days during November at an average rate of 133M pounds per day. Production included 80172C, 90172D, 80273G,RP-200, 186-139, 223-36, 186-180, 196-198, 223-68, 223-134, 269-12, 269-15, RP-440, 223-204, 245-67, 269-48, 269-50, and RP-203. Dry Blend production was hindered by: product changes, 98 hours; delays associated with quality and lab problems and normal Q.C., 59 hours; m problems and maintenance, 17 hours; and screener problems and maintenance, 5 hours. Quality performance for the month of November was 97.5% customer grade. The raw material requirement for dry blend was 1.01416 pounds of raw material per pound of dry blend versus a standard of 1.00492 (YTD is 1.01690). The variable cost variance for dry blend was $2.6M favorable with $29.2M favorable due to price and $26.5M unfavorable due to efficiency. The efficiency variance due to product mix was $2.3M favorable. There were no major dry blend raw material efficiency variances. Dry blend rates were reduced by the high percentage of RP, experimental, and colored products produced and the numerous difficult product changes required. Plasticizer Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 1769 30 59 3762 61 Plasticizer operated thirty days during November at an average rate of 59M pounds per day. Production included 610P and 108P. VRP production totaled 151M pounds (9.3%) The raw material requirement for plasticizer was 1.05375 pounds of raw materials per pound of plasticizer versus a 1.09851 standard (Y.T.D. is 1.06531). The variable cost variance for plasticizer was $35.0M favorable with $6.1M favorable due to price and $29.0M favorable due to efficiency. r The efficiency variance due to product mix was $0.2M unfavorable. A VAB.0001186831 COMPOUND - Continued Quality Improvement Control charting techniques were introduced to operators in Dry Blend to aid in investigation of variation in the dry blend weigh-up system. Training classes for all compound, dry blend, and plasticizer operators are scheduled for early December. The classes will include training in statistical methods, involvement teams, and the entire Vista quality improvement process. Energy Compound Dry Blend Plasticizer Usage (BTU/Lb.) Actual Standard 1783.1 692.2 1604.9 1783.0 730.0 1833.5 A VAB.0001186832 VINYL - D. W. Hollis, J. M. Edwards Safety The Vinyl and Yard Departments operated without an injury in October. Shift safety meeting topic for the month was Back Injury Prevention. Production October Y.T.D.(Fiscal 87) 1. Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days 32.2 1041 800 25.8 80.3 10543 51.4 31 32.2 1041 800 25.8 80.3 10543 51.4 31 Vinyl Department production for October was 32.2MM pounds. Reactors The reactor stream factor for September was 80.3%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 22.2% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank and waiting on particle size information before charging. 2) Maintenance Service Downtime: Accounted for no downtime because the cleaning of the reactor AMS injection ports and inert vent lines was accomplished while the reactors were normally down for other reasons. 3) Maintenance Repair/Revision Downtime: Accounted for 77.8% of the total downtime and was due to drilling the condenser on reactor 500 while changing relief valves and safety discs, and maintenance on various reactor valves and actuators. At the end of the month, the new module had its annual shutdown at which time the 742 and 743 agitator gearboxes were rebuilt, reactors 741 through 744 were hydroblasted and die-checked, remote operated valves were installed at the VCM sphere, the fresh VCM receiver and west recovered VCM receiver, and the oil seal was changed in the duraseal units to Shell Turbo oil. Also, air and steam piping modifications were made to allow new technology additions without plant outages. The vent lines above the fresh and recovered VCM receivers were modified. Miscellaneous steam, cooling water and process water leaks were repaired, electrical equipment had preventive maintenance and compliance items were completed on valve actuators. A VAB.0001186833 VINYL - Continued Dryers The dryer stream factor for October was 51.4%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 94.0% of the total down time. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 3.0% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems. 3) Maintenance Repair/Revision Downtime: Accounted for 3.0% of the total downtime and was due to ifl dryer centrifuge repairs, changing out the filter socks in dryers #5 through #8, changing out the north centrifuge in the fluid bed dryer, and repairs to #7 dryer drive train. Product Quality Summary Resin Type Prime % of Total "B" "H' Production 5265 5305 5385 5425 5465 Debox Sifter Overflow Pond Resin Total 2,478,838 2,723,426 17,873,833 6,392,125 1,697,400 -- -- 31,165,122 -- -- -- -- 920,940 -- 62,700 983,640 -- -- -- -- -- 122,836 -- 122,836 7.7 8.4 55.4 19.8 5.2 2.9 0.4 0.2 100.0 Quality performance for October was 99.6% customer grade with 0.4% ?,HU grade production. A total of one railcar was shipped as ITBfl grade during the month which represented 1.2% of the 84 total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 10/16/86 10/31/86 PLCX 43013 Cont. Plast. Debox Quality The Vinyl area received fifteen short lead time emergency type orders comprising 5.4% of the 279 Aberdeen resin shipments in October. Monthly Variable Cost Performance Variable costs for the month were unfavorable at $105.9M resulting from an overall unfavorable price variance of $85.4M and an unfavorable efficiency variance of $20.5M. Resin variable cost for the month was 17.676 cents/lb. versus the budgeted 17.336 cents/lb. VINYL - Continued Monthly Variable Cost Performance - continued The $85.4M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $73.8M. The $20.5M unfavorable efficiency variance can be attributed mainly to the unfavorable efficiency variances for: VCM, $7.6M; initiators, $14.9M; Methocel F50, $8.4M; and a favorable variance for Polyvic 5202, $5.9M. VCM efficiency for the month was 1.00363 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. Energy Performance/Progress 1. Plant energy performance for October was 2291 BTU/lb. General 1 Resin raw material in the 0744 account totaled $287.9M. 2 The new module had its annual maintenance shutdown during the final week of the month. During this time, major software and some hardware modifications were made to the Modicon control computer. 3 The first SPC Employee Involvement Team was organized in October. The first meeting will be held in November. A VAB.0001186835 COMPOUND - P. J. Kober, J. E. Nickerson Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line V Line III Total 31 2130 69 17 741 44 31 3640 117 6511 2130 741 3640 Line I operated thirty-one days during October at an average rate of 69M pounds per day. Major items affecting production efficiency were: product changes, 63 hours; dicer system problems and maintenance, 18 hours; housekeeping, 18 hours; preblend scale problems and maintenance, 16 hours; quality problems and rework, 14 hours; plasticizer weigh-up system maintenance, 10 hours; and transfer system problems, 5 hours. Line V operated seventeen days during October at an average rate of 44M pounds per day. Major items affecting production efficiency were: product changes, 32 hours; quality problems and rework primarily due to hard particles, 43 hours; and intensive cooler maintenance, 21 hours. Line III operated thirty-one days during October at an average rate of 117M pounds per day. Line III production was hindered by: product changes, 92 hours; mill and hydrotherm system maintenance, 12 hours; quality problems, 12 hours; FCM maintenance, 10 hours; dicing system problems and maintenance, 9 hours; and resin valve malfunction, 5 hours. Quality performance for flexible compounds was 2.0% off-grade of which 87.0% was due to mill scrap. "BC" production was 1.1%. The raw material requirement for flexible compounds was 1.01363 pounds of raw material per pound of compound versus a 1.01175 standard (YTD is 1.01363). The variable cost variance for compound was $31.6M favorable with $5.8M unfavorable due to price and $37.5M favorable due to efficiency. The efficiency variance due to product mix was $37.3M favorable. There were no major raw material efficiency variances. Total compound inventory rose .16MM pounds in October to 7.0MM pounds. Dry Blend Production, M Pounds Operating Days Month 4426 31 Operating-Day Rate 143 Fiscal Y.T.D. 4426 31 VAB.0001186836 COMPOUND - Continued Dry Blend - continued Dry blend operated thirty-one days during October at an average rate of 143M pounds per day. Production included 80172C, 80273G, 90172D, RP-200, RP-200T, RP-421, 196-198, 186-139, 223-36, 186-80, 223-57, 223-68, 223-148, 223-166, 223-206, 223-134, 245-53, 245-60, 269-12, 269-13, 269-14 and 169-15. Dry Blend production was hindered by: product changes, 99 hours; delays associated with quality and lab problems and normal Q.C., 53 hours; transfer system problems, 18 hours; and filler system problems and maintenance, 9 hours. Quality performance for the month of October was 98.3% customer grade. The raw material requirement for dry blend was 1.01751 pounds of raw material per pound of dry blend versus a standard of 1.00492 (YTD is 1.01751). The variable cost variance for dry blend was $39.6M favorable with $20.0M unfavorable due to price and $59.6M favorable due to efficiency. The efficiency variance due to product mix was $62.9M favorable. There were no major dry blend raw material efficiency variances. Plasticizer Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 1993 31 64 1993 31 Plasticizer operated thirty-one days during October at an average rate of 64M pounds per day. All customer grade production was 610P. VRP production totaled 152M pounds (7.6%). The raw material requirement for plasticizer was 1.07558 pounds of raw materials per pound of plasticizer versus a 1.09897 standard (Y.T.D. is 1.07558). The variable cost variance for plasticizer was $13.2M favorable with $2.6M favorable due to price and $10.6M due to efficiency. The efficiency variance due to product mix was $5.7M favorable. Enefgy Compound Dry Blend Actual 1807.9 750.7 1524.2 (BTU/Lb.) Standard 1783.0 730.0 1833.5 A VAB.0001186837