Document wDZdZzVLKgGo4y2xgr1QBe9x6

JN 5P 1 3 Rtc- MONTHLY MANUFACTURING REPORT AUGUST 1976 1. FINANCIAL SUMMARY a. Results Plant Sales July Plant Sales August Plant Sales YTD b. Discussion Inter-Co. Trade Total $ 189,000 165,000 $2,039,000 $ 164,000 143,000 $1,371,000 $ 353,000 308,000 $3,410,000 Due mainly to a 6 day strike at the beginning of the month, sales were at the lowest level of the year thus far. Sales to Bethlehem Johnstown rebounded sharply or the monthly sales would have been even worse. 2. FUTURE VARIANCES a. Recipe The RM 265A free recipes continue to give forming problems. Work is under way to develop better recipes for injection machines. b. OSHA __ The dust control equipment is.in and-operating. Only minor revisions .remain to be-compl-eted-in the PREMIX area. c. Foseco Trucking . . #jl , uJPf Due to the strike, the cost per mile in August was a poor $.801 per mile. Savings were un oveT July however W <2.612.on at a total of $9,003.00. There were 48 loads or 70% of August shipments carried on our equipment. Accumulated savings to date are $86,936.80. d. Quality Control 02-Exothermics We had an average production scrap rate for July with no abnormal problems. The 926-IP for Latrobe Steel is under control and no complaints have been registered against the new EP6100 FEEDEX specifications. August showed some start-up problems with the EP1881 FEEDEX. We had trouble with the 1881 setting up during stoving which accounted for a higher loss on three different units. The rest of the operation was normal. 2442 -2- Z-l 06-Kalminex Asbestos free EP6130 Hot KALMINEX was instituted the second week of July, As anticipated, we had forming and green strength problems as we approached different units. Recipe adjustments were made and some success was possible except with the big 801-C and 10S2 units. Our scrap rate was high for the month using this recipe. Other trouble spots that remain constant are warped drying plates, burning and distorted one piece tops. The 1124 thin walled one piece was run using a new clip to hold the wall dimensions. Our next run on this unit should further evaluate the system. August scrap was reduced by 5% over July. We have a good hold on EP6130, except for the 801-C. We still form a good piece but stripping and tTansfeT account for poor production. A new design will be requested since all other size one piece tops are working well. Again distortion and associated out of square, out of round scrap pieces are high. This is a direct reflection on warped drying plates and no green templating. We aren't out of trouble with our asbestos free 06 KALMINEX, but improvements have been encountered. September will show what additional adjustments will be necessary to establish our new recipe. _ 07-Pro/Kal- Production. - - Our new. operator'-s' report.will need updated to-rinclude^'addition'all-r^J information. The scrap rates for this department for July and August were extremely low, at .9S and..57 respectively. We must report all scrap at the machine (cured and green), slurries discarded and adjustments. A new sheet will be issued in September to record these areas. .. 07-Packing Unreported scrap from the production area for July vs. packing was 7.75%, for August 6.37%. Although we pick up production scrap, much of this occurs from in process breakage, which is our highest scrap area. Effort must again be exerted on our supervisors to insure proper thickness and stoving times. Thick, thin, and poorly formed (new recipes) were out of line and must be corrected. 2443