Document wKrOEppmkeGrvk44REjjROMKB
ABD00282797
VINYL - D. W. Hollis/M. L. Nathan
Safety
The Vinyl and Yard Departments operated without an injury in July.
Shift safety meeting topics for the month included Home Safety. Items such as chainsaw and boating safety were discussed.
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
July
36.3 1170.7
889.0 28.7 92.5
11222.0 54.3 31
Y.T.D. (Fiscal 1985)
345.5 1136.7 8435.0
27.8 89.4 9842.0 61.5 304
Vinyl Department production for July was 36.3MM pounds which was 102% of the Business Area's targeted level of 35.5MM pounds.
Reactors
The reactor stream factor for July was 92.5%. Downtime in the reactor area occurred as follows:
1) Operational Downtime: Accounted for 57.7% of the total downtime and was due to reactor recovery scheduling conflicts, no place to dump reactor slurry, downtime due to severe weather conditions, and a planned one-day outage in the new module. The outage was taken to complete shutdown type maintenance work including installation of a conductivity meter in the new module dump tank, repairs to the new module dump screener, and replacement of the hot water charge tank discharge valve.
2) Maintenance Service Downtime: Accounted for 3.6% of the total down time and was due to cleaning reactor AMS injection parts and slow vent lines.
3) Maintenance Repair/Revision Downtime: Accounted for 38.7% of the total downtime and was due to ten reactor valve changeouts, agitator seal replacement on 400, cooling water jacket repair on 743, agitator kicker blade installation on 400 and 600, and solenoid relocation project on 700.
Dryers
The dryer stream factor for July was 54.3%. Downtime in the dryer area occurred as follows:
1) Reactor Limited Production: Accounted for 89.1% of the total down time. Dryers were shut down when possible for energy conservation. Advantage was taken of the downtime to perform shutdown type work such as dust collector sock changes.
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ABD00282798
VINYL - Continued
Dryers - continued
2) Operational Downtime: Accounted for 9.1% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning, transfer activator problems, and downtime due to power outages.
3) Maintenance Repair/Revision Downtime: Accounted for 1.8% of the total downtime and was due to activator, centrifuge and screener repairs. A screw feeder and modified centrifuge chute were in stalled on #6 rotary dryer during the month.
Product Quality Summary
Resin Type
Prime
5265 5305 5385 5425 5465 Debox Sifter Overflow Pond Resin
Total
3 ,506,575 3 ,564,201 21 ,145,071 5 ,964,686 1 ,336,235
-
-
82,420 35 ,599,188
"BC"
-
127,560
-
127,560
"HM
-- -- -
103,967
-
103,967
% of Total Production
9.8 9.9 59.0 16.6 3.7 0.4 0.3 0.3 100.0
Quality performance for July was 99.7% customer grade with 0.3% "H" grade production.
A total of five railcars were shipped as "B" grade during the month which represented 3.8% of the 130 total resin hopper cars shipped in July.
Load Date Ship Date Car No.
Customer Product
Reason
6/20/85
7/10/85 PTLX 41821 Grifco
Resifted Sifter Quality Overflow
6/22/85 6/17/85
7/10/85 7/22/85
PTLX 41591 Grifco PLCX 42994 Vulcan
5385 5385
Contamination Contamination
7/03/85
7/24/85 PLCX 42303 Vulcan
Resifted Sifter Quality Overflow
7/13/85
7/31/85 PLCX 44730 Silverline 5385
Contamination
The vinyl area received twenty-eight short lead time emergency type orders comprising 10.0% of the 279 Aberdeen resin shipments in July.
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ABD00282799
VINYL - Continued
Monthly Variable Cost Performance
Variable costs for the month were favorable at $2679.2M with $2363.6M due to price and $315.6M due to efficiency. Resin variable cost for the month was 17.184 <?/lb. vs. the budgeted 24.605 c/lb.
The $2363.6M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $2302.1M; VCM freight, $26.1M; Lupersol 223M initiator, $42.2M; and utilities, $11.3M.
The $315.6M efficiency variance can be attributed to higher than budgeted efficiency in VCM, $165.4M; utilities area, $56.5M; and Naugard 492, $27.6M.
VCM efficiency for the month was 0.98350 lbs. VCM/lb. PVC versus the budgeted 1.00500 lbs. VCM/lb. PVC. Year-to-date efficiency is 0.99774.
Year-to-date variable cost efficiency variances in the Vinyl Department totaled $997.5M favorable.
Energy Performance/Progress
1. Plant energy consumption for July totaled 2343 BTU/lb.
2. A total of twenty steam leaks and two steam traps were repaired during the month.
General
1. Packaging for the month totaled 537,400 pounds.
2. Resin raw material in the 744 account totaled $286.7M at month end.
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