Document x5yaroQGOGDBmw8d7OGw69kkb

MONSANTO.CHEMICAL COMPANY -----PLASTICS DIVISION ' SPRINGFIELD, MASSACHUSETTS OPALON-ULTRON PLANNING GROUP OPERATING MANUAL April 30, 1953 Distribution: 1. J. c. Garrels, Jr. 2. R. M. Morris 3. G. T. Barks 4. P. A. Klingsporn 5. L. A. Schroeder 6. H. W. Barber 7. R. A. Holmes 8. Vinyl Planning IT n 9. 10. T. S. Lawton, Jr. 11. D. S. Plumb 12. M. G. Caine 13. E. R. Tolies l4. A. C. Pamerleau 15. R. Higginbotham Prepared by: Approved by: Robert S. Young G. T. Barks A. G. Erdman T. S. Lawton, D. s. Plumb C. w. Roberts 16. A. G. Erdman 17. E. L. Bechard 18. D. Bouchard 19. 20. Standards n Dfmet *pt. 21. R. S. Young 22. Extra 23. Extra 24. Extra 25. Extra This is copy No RSV0026857 0FAL03! -ULTEOK PLANNING GROUP OPERATING' MANUAL TABLE OF CONTENTS Page No. I, INTRODUCTION ----------1 = Surrey Authority Si- purpose------------ 3= Scope ---------------- -4. Responsibilities 5. Organization ----- -1 -i -1 -1 -1 -3 II PROCESSING OF ORDERS------------- -- -- --..............-............. .............. 1. General Procedure--------------**,-- r----------------------- -------2. Shipment Promise & Re-promise -Procedure------------------- 3. Sample Order Procedure ,--~-- ------------ ---------------------- 5 4. Shipping Schedules --;--------------------------- -- ---------6 1 ' 5i Expediting------------------------------------------- ------------------------ 5. 5 5 6' III TRANSFERS------------------- ------------ -------------------------------------------- 7 1. Film'to Sheet Department -------------------------- ------------------7 St To Bondsville or Public Warehouses ------------------------ ----- 7 IV PRODUCTION SCHEDULING PROCEDURE 1. Monthly Scheduling Meetings -- So .Economical Scheduling of-Film 3= production Run Schedules ----- 8 8 9" 10 V RAW- MATERIAL PLANNING ----------- ------------ -- -- X1 1= Raw Material Forecast -------------- ------------ ---------- - n So Raw Material Usage Record - ------------ :--------- ;--------- -- 11 - 3,, Raw Material Requisitioning for-Current Meeds' -r------- 11 VI PLANNING RECORDS -----............... -------- -- ----................ -- 13 1. inventories------- ------------------------------------ ------------------------ -- 13 1 2. production Records ---------------- ---------- .--------------- 14 3. Shipment Records ---------------- --------------------- -------------------------- 14 Open order Records -------------- ------------------- 1--------------------- 14 5., History of Product Item Activity ---------- ----------------------- < 15 60 Planning Files ----------------------- --r--------------------------------------- 15 VII PERIODIC REPORTS ------------------------- -------------------------- ------------- - 16 .1. Open Order, Status Report ----------------------- ---,16 2 o Monthly Repromise Summary'----- --------------------------------------- 16 3. Other Periodic Reports ---- ------ ---'----------------- 1,6 VIII CLERICAL COST CONTROL SYSTEM --------------- ------- --------- 17 lc General -------------- -------------------------------- 17 2= Monthly Performance Report --------------------17 3* Maintenance of System ----- -------------- --<------------- - 19 RSV0026858 INTRODUCTION 1 . Survey Authority This operating manual' has been prepared as a part of a general survey of the Opalon-Ultron Planning Group conducted by the writer 'in response,to an Initial request toy Mr. G. T. Barks, Manufacturing Superintendent, and authorized by Mr. R. M. Morris, Plant Manager, on November 25* 1952. 2. Purpose The purpose of this manual is to provide a detailed description of the procedures'and policies governing the conduct of produc tion planning activities in the Opalon-Ultron area. since such matters are not static, nothing in this manual is to be con strued -as limiting in any way the future substitution of im proved methods or policies`upon approval of the proper author ity. 3.. scope Specifically, this manual covers the operation of the Opalon-" Ultron Planning Group only, with occasional reference to Sales, Shipping, and Accounting Department- function which directly' affect" Planning. Also included' is a description of the clerical cost control system developed during this survey a an aid to evaluating the clerical workload of the Planning Group. 4. Responsibilities a. The Planning Group is -responsible for? 1) Proper production scheduling. 2) Routine processing of orders. 3) Determination of shipment promise and re-promise dates. 41 Maintenance of' necessary files and records. 5J Availability of current inventory and open order status in detail. 6) Expediting of production and shipments -as required. 7) issuance of periodic reports pertaining to plan ning and production activities. 8) Maintaining continuous contact with Sales, Produc tion, and Shipping in order to act as a focal point' for current information regarding production,- inven tory, and shipment status. b. The Sales Department is responsible for? l) The expediting of customer orders to the Planning Group. RSV0026859 -2- 2} The'' supplying'of cmplt# instructions to th# Plan ning Grodp regarding specific customer requirements for Materialo 3) .."Knowledge of market' 4<ari for the various specifio product, and assignment f 'priority t Individual orders for purpose @f production scheduling. 4) The determination of' specific items and'quantities to he produced for' inventory. 5) The designation of.product specifications for us# as criteria forshipping purposes. 6) Furnishing Planning.each month, prior to am esta blished deadline, with the 'test possible forecast of complete production requirements, by formulation, for the coming, month for use in preparing the raw material forecast. c. The shipping .Department is responsible ffor.s ' 1) The shipment of orders as scheduled by the 'Planning Group. 2) The prompt notification to- Planning of any scheduled shipments which are to be delayed as soon as such information becomes, available. 3} The provision of reasons for the delay of. any Items not being shipped as scheduled. d. The production department lb responsible- fors 1) Adherence to' the production schedule issued by the Planning Group.. 2) The prompt notification to planning of any failures - to meet production schedules as soon as such in formation "become available. This includes not Iflo cation of the date and .duration of ell trial rums, etc., which may affect production schedules. -.Reasons shall be given In all cases. ' 3) The proper, taking and delivering, of test samples to a .designated pick-up point in' accordance with the established schedule. .e. -The Plant Accounting Group is responsible forg 1} Cooperation with the Planning Group with regard to production, shipment, and Inv ntory figures ,and, in formation ..essential to the maintenance of accurst# and up-to-ddt .planning records. At pr sent,' close contact betw en these two groups is essential ini order to promote the proper exchange `of mutually- RSV0026860 needed information., and to reduce duplication of work to a minimum. 2) The provision of weekly raw material inventories and usage reports to -planning. f. The Plant Laboratories are responsible fors 1) The prompt' pick-up of test samples from designated points in accordance with the established schedule. 2} The transmission of test results for those character istics which affect 'shipping to the .planning Group by 300 p.M. each day, or by such other time as may be agreed upon through negotiation. 5, Organization The planning Group reports to the Manufacturing Superinten dent, 'through the operating Superintendent of the OpalonUltron 'Production area. The group's 'personnel is divided into three positions with duties and responsibilities as outlined belowg 'Position Is Chief Planning Clerk This Individual is in direct charge of -all operations of the Group, and is responsible for all actions performed by the Group. His specific duties are -as-follows% a. Receives all orders and assigns promise dates for ship ment in accordance with established procedure. Also Issues repromise reports dally. b. .Develops operating procedures and policy proposals when necessary, and reduces these to writing for approval by higher authority. c. is contact man for the group on all matters concerning the relations of the Group with other groups or depart ments, and on all procedural or policy matters affect ing the Group. d. .Is responsible for the proper performance of all func tions of the Group, as outlined in paragraph 4a. above, and for the prompt reporting to higher authority of any and all conditions which may arise to prevent proper performance and which are -beyond his power to correct. Supervises and assigns work to the other members of the Group (Positions 2 and 3) with due regard to proper balancing of the workload, and following the principle that all possible work of a routine clerical nature should be assigned to Position 3= RSV0026861 Position 2i - Assistant planning Clerk The individual* or individuals* in' this -position work under the-. direction of the 'chief planning Clerk. The primary function of this position is that of expeditor* with specific duties and responsibilities as outlined below? a . Maintains close contact with such groups as the Order Department* Research* Technical Service* Production supervision, Warehouse personnel* Shipping* Traffic* . etc. in order to keep currently informed on the status of specific items which may require special attention by Planning or by any of the other groups involved. b. Acts as expeditor on special items* and keeps those con cerned* including the Chief Planning Clerk* informed of their current status. c. prepares shipping schedules* participates in production scheduling meetings* prepare periodic reports*' and per forms such other duties a may be assigned by the Chief planning Clerk. Position 3s Clerk This position handles all routine clerical work of the group under the direction of the Chief planning Clerk. .Specific duties are as followsg a. Maintains current inventories on all product items. b. Maintains open order records. c. Keeps records of production and applicable test results. d. Determines raw material requirements for current pro duction* and prepares the necessary requisitions to insure an adequate supply within the production area at all times. e. Prepares the monthly Raw Material Forecast. f. Assigns blend numbers* and issues paokout. Blender* and Banbury schedules. g. Distributes order copies according to established routin . h. performs all routine filing operations. 1. prepares special analyses* reports* etc. as may toe assigned toy the Chief Planning-Clerk. RSV0026862 PROCESSING OP ORDERS -5- General Procedure The' regular routine for processing orders.-and releases is shown in Plow Chart So. 1, Appendix A-. This chart is large ly self-explanatory except for the symbols and color codes which are identified in the key given on the tabbed title sheet for Appendix A. 2. Shipment Promise and Re-promise Procedure The current procedure and policy regarding the. establishment of-promises and- re-promises is covered in the'bulletin given in Appendix B-. This procedure was made .-effective as of April 1, 1953* 3 Sample Order Procedure, Sample orders. arS- ordinarily received by mail on Form Mo. 2^0, but- may be t'eletyped if urgent. The- procedure is somewhat different from that for regular orders* and. is outlined as follows% a. A promised date is entered as on the regular orders. b. The copies are distributed as follows; Original and copies 3 and 4 - To the Color Lab Super visor or Sampleman. Salmon (Ho. 2) - Retained in Planning open order file according- to promise date. All other copies - To Order Department. c. The sample is obtained from the sample room and delivered to the Parcel Post Department with the original copy of; the order by the Color Lab Supervisor. At the same time the yellow copy is returned to Planning. d. If the desired sample is not available in the sample room, a Material Handling Requisition (Form No. 433) Is" initi ated to move a roll, from inventory tp the sample room. e. Planning pulls and, destroys the: salmon copy, and files the yellow copy in the "completed" file. f. It-, is to be- empha-Eized that Planning is still responsible for follow-up on sample - orders to ensure their shipment on or before the date promised. If delays are encounter ed, the reasons therefore must be obtained from Production,.and a re-.-promise issued in accordance with standard pro cedure . RSV0026863 -6- 4 o Shipping Schedules Shipping schedules, are'prepared daily for each product. In order to insure that no orders are over-looked* the practice1 has been established of reviewing all open orders each day, 1 -It :is imperative ,that the schedules be completed at 3s30 P.M. in order to provide .Shipping with time for planning the., follow ing day's activities and't arrange for carriers. 5,, Expediting Since definite limitations on routine shipping service have been established in order to smooth out normal operations (See' Appendix B.) It has consequently become even more im-^ portant that those items of genuine urgency be expedited'' to the fullest possible extent. The responsibility for such ex pediting rests directly with the Planning Group. It is ex pected that Planning will carefully relay all requirements and information regarding Items of an urgent nature to the concern ed parties without delay* and will follow-up to'insure proper completion of the desired action, in cases where Planning is unsuccessful in obtaining the desired-action*-or If"-success is doubtful* it will be Planning's responsibility to inform th party from whom the request for special handling originated so that he may be in a position to take additional action If deemed necessary. RSV0026864 -7- III. TRANSFERS 1, Transfer qfJTilffl to Sheet Department a. The Sheet Planning Group obtains information regarding the availability of desired items by telephone from "the Vinyl Planning Group. b. A Material Transfer. Requisition (Form 433} is initiated by Sheet Planning, .and is mailed to. Vinyl Planning. 1 c. vinyl Planning Issues written instructions to the Shipp ing Department warehouseman to place? the desired rolls at the loading platform, and forwards the Transfer Re quisition to the Materials Handling Foreman. d* The rolls are pieked up and delivered to the Sheet De partment by a Materials Handling truck. Two copies of the case tickets are removed when the material Is : loadd> and are distributed as follows; . dne copy to Vinyl planning (With a signed copy of the requisition). , ! One copy to Sheet Planning when material is delivered. e. The requisition and tickets are forwarded from Vinyl Planning to Plant Accounting for the information of that group* 2. Transfers to Bondsville Warehouse and to Public Warehouses' Complete procedures for these types of transfers are eover d in the bulletin given in Appendix C. s RSV0026865 -8- IV. PRODUCT I OF SCHEDULING PROCEDURE 1 * . monthly Scheduling Meetings a. Each month meeting will. he held to determine the best possible production schedule for each product for the coming month. These meetings are to be attended, by re presentatives of the? Product Sales-Manager Order Department Production Supervision Planning Group. b. The. above meetings will be held not later than four days before the end of the month, and In -no case less than four days before the runout date of the current schedul if this, precedes the month end. A definite date should be set at each meeting for holding the following month's meeting. The most convenient time for these meetings- from the stand point of Planning, is at 11?00 A.M. on Tuesday, Wednesday, or Thursday. e. Even though definite orders may not exist to cover the entire month, it is imperative that the full month be scheduled "-for "the rpurpos of "preparing the Raw'Material Forecast. If specific orders are not '`available,' a. forecast by formulation must be supplied by the sales Depariment for any unscheduled portion of the month. Planning, is responsible -for Issuing copies of the .production schedule, and all revisions thereof, to the following con cerned parties % : Assistant product Sales Manager Sales' Correspondent (temporarily) Technical Service office (temporarily) Manufacturing Superintendent Operating Superintendent Operating Supervisor--Film & Compound^ Operating Supervisor- Color Laboratory Foremen's Office Shipping Planning In addition to the monthly schedule meeting, there will be a weekly review of the schedule for the coming week. Formally, this review will Simply be in the form of a telephone -conversation between the Sales Correspondent and the Planning Clerk, and will be accomplished, on Thursday in order to tie in with the shipment promise procedure outlined in Appendix B. At this time,;-the production schedule for the coming week (Monday through Sunday) will be "frozen" against all Sales breaks, except those of a most urgent nature. All such emergency de viations will require the approval of the product Sales Manager and of the Manufacturing or Operating Superintendent. RSV0026866 -9- Planning will publish the weekly "frozen" schedule on Friday for prompt distribution to all concerned .. 2. Economical Scheduling of,Film a. Production Sequence ' There are, a great many factors which' govern the economical scheduling of individual product- items. It-is, therefore, ' important that all possible consideration be given to the scheduling of production items in the sequence which;wiil best minimize the costs involved c While less economical sequences may be dictated by customer priority requirements, it is the responsibility of planning, in conjunction with Production Supervision, to bring the approximate cost of such deviations to the attention of the Sales Department so that proper evaluation of their desirability may be made c Specifically, the following, factors-shall be given con siderations Color Changes Gage .Changes Formulation Changes Width Changes Embossing Changes These factors differ in their relative importance. Assuming that the average cost of one hour of down time is $80.00, - the approximate costs of the various types of. changes are given in summary form in Appendix F . It should be noted that the costs of two or more-types of change are-, not cumulative if they are performed at the same time. Tn such cases the cost is determined by that'of the longest single operation only. Analysis of this cost' summary indicates that. the; following general rules should be observed .in .production schedulings (1) Color sequences should be followed .-without lnterrup tion in order to minimize cleanout '"expense. (2) Formulation changes which involve a radical shift from one heat range to another should be mini mized. In this connection, the-running speed (a function of gage) must also be taken into con sideration. In general, the currently-used. formula tlons are divided as follows? Low Temperature; TJL-1, 2, 6, and f. High Temperature (Stiff) s UL-3, 4, 5, P82-5Q, and P82-51. (3) Gage changes between the heavy and light ranges should be kept to a minimum, based on the follow ing dividing lines Light g .003 to .006 Heavy? .006 to .010 RSV0026867 -1Gb. Run Length While production sequence is ofgreat importance in sche duling, the factor of run length should actually-receive primary consideration due to its. even more significant effect on costs. Any overall guide to economical sefa duling must therefore take this factor into account along with the sequence variables? Such an overall guide has been developed, and is described, in detail in Appendix I. Briefly, the system is based on three fundamental stepss (1) The establishment of an acceptable production standard for the cost of Iteni changes' per pound produced. (2) The evaluation of each week's schedule prior to "freezing* (See paragraph 1-4. above) to determine the approximate cost per pound of the changes con tained, therein for comparison with the standard. (3) If the cost.of the proposed schedule is appreciably greater than standard, the negotiation of sch duie revisions to reduce the cost to an aeceptabl level. This system ean be effectively employed only with th sincere cooperation of both Production and Sales, but if a conscientious effort is made ..substantial savings in production cost should result. 3 Production Run Schedules Based on the production schedules derived as described abov , Planning issues blend numbers, tickets, and schedule-sheets for each production run'in accordance with the procedure shown in Chart No. 8, Appendix A. RSV0026868 V. RAW MATERIAL PLAKKIMG X. Raw Material Forecast Planning is responsible for submitting a monthly forecast of raw material requirements to the Material Coordination (Jroup. The deadline for this forecast is noon of the 5th day of the new month, but the goal for Planning should be the 1st, if at all possible. The forecast must give not only the requirements for the coming month, based on the established production schedule, but must also indicate anticipated requirements for the two months following- making three months in all. This is neces sary in order to glye sufficient lead time to insure the availability of materials when needed. In view of the fact that production is only definitely scheduled for a month ahead, this means that Planning must estimate the requirements for the second and third months on the basis of the current pattern of production according to formulation. Planning will, therefore, maintain a running record of monthly production by formulation in order that trends may be observed. This should be reviewed with Sales at the time of the monthly scheduling meeting in order to obtain whatever long-range Information can be obtained from that quarter. The, detailed clerical procedure for preparing the Forecast is given in Flow Chart Ho. 6, Appendix A. Planning is further responsible for the immediate reporting, in writing, to Material Coordination of any changes in fore cast which may result from production schedule or formulation ' changes during the month. 2 Raw Material Usage Record A simple check against possible raw material shortage is main tained by the Planning Group. This is kept on the basis of weekly inventory and usage reports supplied by the plant Accounting Group, and is cheeked by the Chief Planning Clerk: after each posting to ensure that no critical items have de veloped. under current operating conditions, such cases may arise due to the fact that stock levels are maintained at only 30 days' supply, and this quantity might be used up in the first few days of the month if production happened to be concentrated on the particular formulation using a certain critical material. Expediting action by Planning through Material Coordination is indicated in such cases in order to bring the inventory up to a safe level as soon as possible. 3. Raw Material Requisitioning for Current Needs Storage space for raw material in the Ultron Warehouse and production areas is presently so limited that a day-to-day RSV0026869 -12cheek mast, be made fey planning to b sup - that suffici nt quantities are requisitioned from' primary storage areas and delivered by the Transportation and Materials Bepartment to keep Production supplied. For this reason, the procedure shown in Flow Chart No. 7* Appendix A, is followed at th present time. When adequate storage-space is available so that the build ing inventories can. be maintained on a "maximum-minimum" basis, this procedure can, of course., be largely eliminated. RSV0026870 **33-- VI. FUNKING RECORDS 1. Inv ntories a . tfltron Film - The. Springfield portion of the inventory record win consist of a daily IBK tabulation In summary form (I.e.; The total pounds of'each product Item will he consolidated In a single line item on the tabulation). The outside warehouse (Bondsville) portion will be iden tical except that the tabulation will fee nn less fr qhently, depending on the turnover rate. Currently, a weekly run off is satisfactory. Since certain items have defects which prevent their use by certain customers, even though they are classified as first grade film, it is neeessary that these items be' broken down in the tabulation by means of the coding system which appears in Appendix B. Further, in order to provide a complete record of the nature of the d fects, roll numbers involved, etc., it will be necessary for Planning to maintain a ledger sheet for each of th se items giving this information for reference purposes, The card decks for the inventory will be maintained by the Plant Accounting Group and by the Bondsville'Ware house Group, respectively. The Planning Group, through daily checking of production and shipment entries, will assist in maintaining accuracy, and will cooperate to the fullest extent in bringing any neeessary adjust nts to the attention of both parties. b. Compound and Dry Blend inventories Eventually, these inventories will be handled In a manner ' identical to that described above for film. In fact, the Bondsville tabulation I currently In us by Planning. However, until such time as the Springfield tabulation can be run on a more frequent basis, the Planning Group must maintain a manually-posted, periodically reconciled, inventory ledger in order to provide the up-to-date In ventory Information required. If run-offs cannot b ob tained on a daily basis. It will still be possible to post shipments and production to the latest tabulation sheet in order to keep the Information current until the next tabulation Is received. This method will at 1 ast eliminate the work of reconciliation, and will be the immediate goal towards which both planning and.Plant Accounting will work. c . Opalon Resin inventory This inventory Is not presently carried on tab card, but must be maintained manually under current conditions of operation. Due to limited warehouse facilities and the rapid movement of the stock. Planning must keep up-to-the minute on inventories In order to direct shipments properly. RSV0026871 -14- Furtherraore, quality difficulties'hav ra ant frequent shifts of stock from one category to another. For these reasons. Planning.-paintains an inventory file of the "production", or tissue copies, of the pallet tickets arranged according, to location and quality, and in numerical sequence within each category. An exc ption to this exists- in the ease of stock in public warehouse f03* which the tickets are kept in groups according to the lot numbers assigned by the public warehouse to each load received. A running balance of pounds in each inventory category is kept on the face of the separator cards dividing each category. 3\ Production Records The procedure for summarizing and recording daily production for the various products is shown graphically in the follow ing Flow Charts, Appendix A; Chart Ho. 2 - Compound and Dry Blend Chart No. 3 - Opalon Resin Chart Ho. 4 - nitron Film lb will be noted that In the case of Ultron Film, Planning works entirely from a production summary prepared by plant Accounting rather than from the original production tickets. This is done in order that the early morning work of summa rizing production tickets may tee distributed between the two groups with the result that the final figures are available sooner than they otherwise would be. 3. shipment Records The procedure for checking and recording shipment Information is shown graphically in- Flow Chart Ho. 5* Appendix A. This work is next in priority to that of the production records In the daily work routine. if. Open Order Records a. Compound and Dry Blend - All orders are entered in a single1 Open Order Record book as soon as received. A sample of the form used appears In Appendix E. The sheets" are arranged' in numerical order according to formulation. They are kept up-to-date at all times in accordance with the procedureshown in Flow Chart Ho. 1, Appendix A. b. Opalon Resin - The Open Order. Record is maintained in the same manner as for Compound except that the sheets are arranged according to quality category. RSV0026872 c. nitron Film - In the ease of film. Open Order records ar maintained in a slightly different manner due to the large amount of clerical work which would otherwise remrltr if all orders were entered in the r cord. Consequently^ only tKose orders held for customer release are enter# ora. the open order sheets, which--are arranged first alphabetically by customer name and then.by item description# The Plann ing copies of these orders are filed in a separate folder in .'alphabetical order# To advise order copies are filed In another folder in al phabetical order for "reader reference until such-time as they are scheduled for production. Released Orders for which shipment J promise dates have bee.m established are placed In a- third folder in order of prbktse date for daily review at the time of preparation' of the .shipping schedule# 5. History of Product item Activity A tabulation of total production and shipments, by product code and item description, is received each month from.the Tabulating Department, these figures are posted to record books set-up in such a way that the month-"to.-month activity on each item may be readily reviewed for purposes of production planning, and scheduling and for such other purposes, as review of in-' .ventories, selection f material for transfer to outside warehouses, etc# 6 # planning Files The principal files, with the required retention period for each* are tabulated below% name of File Retention Period a # Completed orders b. Production Summaries c. Shippers and Tickets d. Shipping Summaries e# Shipping Schedules f. Blender, Banbury, & Packout Schedules g#. Raw Material Foreeasts 1 year 5 years* 1 year 2 years 2 years 6 months 1 year This period Is specified in view of the possibility of dis continuance of the individual roll.Inventory, In which case the Production Summary would be the only ready source of roll number Information. RSV0026873 -16yil o ' PERIODIC -REPORTS 1 p ope a Order Status Report `An Itemized open order and.inventory status report for each 'product will' be prepared monthly immediately prior to the date set for the monthly scheduling meetings Copies of these're ports are distributed tog Production Supervision, Sales Dept-, and Order Dept, 2,, 'Monthly Repromise Summary in this report the total repromises issued during the month will be summarized according to the reasons which necessitated them- Distribution will be tog Production-Supervision, Sales Depto, and Order Dept* 3. other' Periodic Reports A list of the reports covered elsewhere in this manual is given below, for the sake of completeness, with references to the section of the manual in which they are describeds Daily shipping Schedules (Appendix A - Chart 1) Monthly Raw Material Forecast (V - 1) Dally R^promise Reports '(Appendix B) Weekly Report of calendar Change-over Cost per pound Scheduled (Appendix l) Clerical Cost Control Reports (VIII - 2) RSV0026874 -47- VIII H CLERICAL COST CONTROL SYSTEM 1. General A simplified Clerical Cost Control system has been developed as a means for % (1) evaluating the current clerical work' load of the planning Group as a basis for determining' the necessary.staffing requirements* and (2) providing a con tinuous measurement of the workload in order to maintain a constant check on group performance and staff requirements. The first step in setting up this system was to break the various clerical operations into basic-steps a indicated on the Flow charts in Appendix A. It 1 important to note that only position 3* or strictly clerical* Jobs are in cluded in ohis control plan. The operations performed by the Chief and Assistant Planning Clerks* positions 1 and 2 are not readily measurable,, and ar.e not included in the plan or in the standards in any way. Each of these operations was then time studied to determine a standard unit time for each. Personal allowance and rating factors were included in the final standards so that they repres nt the time which should be required by the average operator with.normal time off for personal needs, fatigue* etc. H _ Each of these operations was then related to the production count which best measured the output on that particular operation* and which* at the same time* could be obtained conveniently on a month-to-month basis. A tabulation of the major production*counts and their sources a finally established is given in the "Summary of Major Production Counts and Standards"* Appendix (3. Also shown in this summary are the so-called "pattern" quantities for each count. These quantities represent the average level of activity over approximately the past four month, and were derived from actual analysis of available office records. Extending these quantities by the standard unit time gives the standard hours, of work at the pattern level* and by adding this column the total average clerical workload of the group is obtained (227=07 hour per month). This may be interpreted* dividing by the standard 173 hours per month per person* as indicating that the current clerical workload requires the services of 1.3 average persons. 2. Monthly Performance Report Each, month the Planning Group :wlll submit a control report consisting of the following two sheets: H A-78- "Monthly Job Summary @f Standard Hours" A-76- "Office Performance Report" Appendix H contains completed forms for th "pattern" month and for the actual month of March* 1953 The method of making the computations involved in these reports is ex- RSV0026875 plained In the following? a . Monthly Jot Summary of standard. Hours (A -78) 1) Measured Workload The monthly production figures for the 13 'major pro-, duetlora counts are first obtained and entered in tfa column headed "Actual Monthly Units" on FormA-78 These figures are then extended by multiplying'! by the Standard Unit Times s and the products are entered In the column headed "Standard Man Hours". Finally, the column Is totalled'to obtain the "Total Measured Work", which appears on Line A* 2) Work Belated to Measured Work This Item, which appears on Line B, covers th$t class of work which does not vary in volume with any single production count,;'but which is inore directly related to the general level f office 'activity as a whole-. The computation is performed by multiplying the standard ;(0.11154) by the figure on Line A- "Total Measured Work" . 3) Constant Work This item, which appears on Line C, covers that class, of work which does not vary appreciably regardless of workload. A constant allowance of 16.400 hours p r month is, therefore, entered-for this item. 4) Total Department Performance The Standard Hours on Lines A, B, and C are then totalled on Line B. The. "Actual Man Hours" are next entered from the "Office performance Report", on which they are computed as explained in b. below. Finally, the difference between these two figures and the per centage of Standard Hours to Actual Hours .Ibv ent r d in the last two columns as indicated. b. Office performance Report (ik-76) 1) Hours Paid For .. The regular and overtime clerical hours actually paid for are first entered on Lines 1-A and B. "Borrowed" and "Loaned" time Is then entered on Lines l-d and D. The total is entered as indicated. 2) Adjustments S ction 2, Adjustments, is then filled out as indleat d, b ing certain that the figur s ntered tally with those on the we kly payroll time cards. RSV0026876 3") Met. Available- Hours This- is simply th sum of the totals of S ctions 1 and 2 o 4) Standard 'Hours This figure is brought forward from Line D of th "Monthly Job Summary of Standard Hours". The remaining items on the report are self-explanatory. 3 ,, Maintenance of Clerical Cost Control' System In vie* of the fact that the clerical operations perform d by this .group will undoubtedly change over a period of time, it will be -necessary to make revisions in the standard unit times, and possibly in the production counts, to take such changes into account. This Is especially"true when, new duties' are added or old ones are eliminated, although re visions may also be required if methods or procedures ar simply revised. In all such cases, the-writer, or his successor, should be contacted to make whatever revisions may be needed. % RSV0026877 LIST`OF APPENDICES A. Flow Charts (See Tabbed Sheet for Key t Symbols) No. 1 - Order Processing" No. 2 - Compound & Dry Blend Production po. 3 - Resin Production No. 4.- Film Production No. 5 - Shipment Records No. 6 - Raw Material Forecast No. 7 - Raw Material Requisitioning No. 8 - Production Run Schedules- B. Promise and Re-promlse Procedure Bulletin. G. Procedure Bulletin for Transfers to Bondsvllle and to Public Warehouses. B. I.B.M. Code for "Substandard 1286 Material". E. Open Order Record Sheets. F. ' Summary List of Costs of production changes. G. Summary of Major production Counts and Clerical Standards. .. . B. Clerical Cost Control Reports. I. Production Scheduling Guide. RSV0026878 APPENDIX A KEY TO FLOW CHART SYMBOLS Initial receipt of, or creation of, a paper work item. A clerical (position 3) operation. An operation performed by other than clerical (Position `3) personnel. Temporary file. Permanent file.. V Movement out of department or to another chart. Destroy Flow of paper work. papers brought together for checking, posting, etc. RSV0026879 Opalon-Ultron Order Processing -HART No, I : n o>. _ Iieo.se (8 Copies) Recei Vc] Ly Teletype, ^roiri Or A e.r Dept. 1 r ;tntcr\/ C he c h C cl Ck i n j t~ c- u. i sinp!.< ;f, li o\S ot C C sal Stoop Ta cl - T ~ r rvnne t f Some, N ol ck a f e Jo 1st ocy y . ("Wsrt K* - < s n F y { e r s p >' r- iv% i s e O rit r S &rt p r ' -v S t u( by p h r, h e. w t f h * r. C r\ (J. hour fit rC&('pt.) ^ e.'t Che r. ke-d With inventory and WI t h Pi t'clucf' i ON Sc he dtlie -for availability Scn-^cJ ftCt.fr ii. |r/i}y IyI (No sake dfd/e, for KesRi r} . x_____r1 f4 > 1 R e i k co s e. N | \t RroJ;j.ce.ai / ?/. t4 h f-f ' * > >Vwate a. of e r i t k.p r N a n tc. r?,{ b *. * e d on f. rod Hi t |c>`. "S c. k F d. n ! <2. . I f~ hot Sch t J n,li? d , ' To A.hvist1 Vi editor cJ. Oy>en Order Ret. Ord --=:-i ' t .CoPf No.7 j 1 t c i c a 0 f -t ."per OnPr} p n Film C n i All Other: X rnm t je ( n f '-r rn ,-.x t 1 <i t> r< 11 i f r r r -e J fo Oc>p iCrSy or d cap>ci a^-e- i epor itei ctr^-A d. r 51 r > fcuTed, XHl. Copy N'o'i, 2, 3 j 4 ,5 X Co Py No. I .0--- J f iseiener S\\Jf tilt by <Aoite-. /If" ter 3 M o nvtk To 0 rcl e a Deph _ , Posted to Order Record, ' / EXcept F1 11^ eders ) To Shi joptna R FiIren Coders po&fed ^ ) To Cyem Order Record, 7 Meld m 6per Sie 6 vvjo.*t"mq release T / '., R"leu se i~r c * .v eP. n r, d. ! 2.3 t-n 10 : sled to 6p.c,s XX.- ft e. c r> r c( . i 3 11- t J o 1 K r IO i t SO r-1 d 0.i.i-orcJini fO r O d la C t i O F STattAi [Held* far C m,js t o tvs e r PcUui e.~| <- &r te d ky states . Prirvrse. Date Set jJfijt Si h dw I C d p r Vr CT d KOIf cin -( tl j ; In-, Orrrv 5 erti j : l.) If p.1 r~ti a! r e ic a sd , p.o h ifpib, i) c.py ts reTaint*^ In Open File ttmcl nreen rUe 7) is r*l/n, .,) lr rcf^Bie ^, "irtWi 5 ^e^Tv-o^eidL u^<i p i ^ is j [ C o m p \ eTe- X RcVcctuicd psundi pasted tc swtnfof'j ton F s 1 m only to cRv; iifi.s.ti-,t c&,- msirreal -far tr- *- i p Cr \ t aP, y .. c-rnf t-jid On, B i ~ , aR Ft Sty r ty fifed 1 r. fit ki!> order* } n G '; ^ djZ. i". RSV0026880 Opalom-UltroN' Order Processing Chart No, 1 RSV0026880 CmzesKD A THJuction f'o.Met Tickets 6ujfS--Pso-p^tion Picked t/p "front Accounting J^ Office at /Aarw. \ Sorted hy "fern'iwf'a,. Ci-lo*' ` t An A lAt '-iA > / q'\\ JcMimMAry, ^ T .Shoet p.-c pared _ Pro u.c.1"! o n -& U n' mo ry Sheet (Z. C- o p iCS)___ \T~\_ Pqlai-JIs, rJd cd ft rid____A ^ j ' post e d To 5U'm many, V ./ To A CCOUnt iv\^ >f k ce. ftoPJc by ooi or . 0 r I q > r a I < 1 >- i ? tiled, in Cat-bon CopY r i n g b i nd e r To Acoou *> tmff office. rv" \ kat? test rcsulh_______ j Laboratory C11V^ol by phone. ! Re port anc( posted to Summary^ CompoundJ & Dry B\e*<d Ins/ft ntory T"TP\ Pounds posted !---< /8"S 4T-_0 IInve nL.tto_rryi/., To produTpon iff'.CC. for- -fi'linp ~o Chav*i No, RSV0026882 Re5IN' ProdscfToN Chart No. 3 ip T Kfi uo L) (a.j . Office cot 8; iS' am. Sorted Cy tdctfe. , 2rye>", 2 ) Mesk , 6n`c/ prcol uaPic-r period - RSV0026883 Fi lm ProdiJctio.n1 f"- M o, I RSV0026884 Su i.PPiNfi .R.E C OSC5 .r..XLE_BiCA.L._pF;.OCE.URE._....... F y~Q m Accounting by SlG 0 0~ VY) \ Frc m /'See c u nl;?; o by I K C 0 an* T V (-- y r. C C S S t-11 pFPp I' r- 6 /,-1 - Sch^^uife ApAirtiT C p o r-1 EL ra T e V ^^ d i t f c. r~, ^---- O 'iT'i MOi'iici SS S h ', )- t n c ol by C- ^Vi &- of if e. v'i-i. Pcs.1 ; -r , ' 1' i- l 'r, .< ?_ I-, ' tn' ' \\ ^ T j, ( 10 SlilPPiWG Sc n c v l C I NlTUTOR I ..So. * K o . RSV0026885 kAW lx') AT Eki AL R ECU ! SlTiONm C- - ClERiCA iHlTT | KLPpW, i Cio, ! JA I ! pe 1 ft r r.~ <il C * |.. i-ABr cS: \ f, r, I.r) t W U! (_ f- .:R*J /' bJrO'P- ffiv A'i , *_ > y* c , .5 *,i > i- f c r /. { , it r J j., . fi If F I i-r N'l Ft* C-twC 1 .>/ L,l". ! f f J iv"* si,"ff>> ! V 5*^ t_T_- J^I .\^JE * * S / ri^ui re i Jr r^i i i r, 1 i * -,'TU | . : ^ I /C t# J I lx) A T f= F< I /\ . | VJur i^rr Ft /,d c n ^ . f t n- ^ ts'i i r. R v C ' '* l 0. R, ft f |J o 1 Ci^w pun \stu P* oC.vJt-7 IC N s~~ r-itA U- yf Iti'4 ULC , Nx// l( f *' c {"nr r < fe 'n . A RSV0026B87 RSV0026889 APPENDIX B OPALON * PLTROH PLANNING Apr * 1 SHIPMENT PROMISE AND REFROH1SE PROCEDURE 1953 A. Original Promises on Incoming Orders and Releases i. Material In Inventory If material to fill the order is is inventory (tested and approved), shipment will be promised for the following working day* subject to the following conditions: a. Orders received after 3:00 PM of a given day will be considered to have been received on the following work day for promise date purposes. d. Consideration asust be given to the scheduled Shipping Department workload to avoid unnecessary overtime or Punching up" of work insofar as possible. c* Wire Rush orders will be given special handling when their urgency demands it, but must be kept to & mini mum. In all such eases. Planning, will supply a promise date or status report to the Order Department within one hour after receipt of the order. 2. Material Not Yet Produced If the material has not yet been produced* It either will or will not be on the production schedule. These two cases are covered in the following paragraphs: a. Material On Production Schedule Here again, two cases exist, depending on how soon the material is to be produced. 1) If the scheduled date of production Is within one week of the day on which the order or release TeT* received a definite promise.- date will be given. 2) If the scheduled date of production Is more than one week in the future, the promise date given wTTX"be prSTixed''T>y & to denote that it- is a tentative date. This date will stand, regardless of subsequent changes in the production schedule, until the Thursday of the week preceding the week in which the item is actually scheduled reproduction. At this time, definite repromise dates for all items scheduled for the coming week will be given through 'the repromise procedure outlined in Section r'Bn below. RSV0026890 b* fis&teri&l Not Or Production Schedule In this ease, the order copies will b marked ''to advise51 &ja& the item will be scheduled for production at the nextschedule meetinge As soon as the Item is scheduled, a promise date will be issued by Planning thru the repromise procedure which follows* B, ReproBSlses On Previously Received Orders 1. When Issued Repromises will be issued; a. When 1 tease originally marked "to advise" are placed on the production schedule* As indicated in Section "A",, the date will be definite if scheduled for production within one week, and tentative otherwise. b. When Thursday of the week preceding the scheduled week / for production of a tentatively promised item is reached* 4See Section A, paragraph X&-2 above) At this time a definite date is given* e* Whenever changes occur affecting items on which definite promise dates have been assigned* (i.e* Items to be pro* duced within the next week) S. How issued Repromises will be entered on the daily "Qp&lon-Ultron Repromise Report" for (see sample attached)* This report will be prepared In three copies arid distributed as follows: Sales Correspondent Shipping Foreman planning File (to be routed through the Operating Superintendent and Area Supervisor) The Sales Correspondent*a copy will be delivered by special messenger by 3j3 PM each day* 3' Telephoned Repromises If the repress! se affects an item scheduled for ehipsaent on the current day,, the new date will be transmitted Immediately to the Sales Correspondent by telephone* This will be confirmed later by a written entry on the daily repromise report, Monthly Rcpromie Report The Planning Group wil 1 prepare a monthly summary of the number of repress! ses issued, classified according to reasoe for the in* RSV0026891 formation of Production, Order, and Sales Department supervision in order that undesirable trends may be high-lighted and corrected. B, Notification of Shipping or Production Delays If the above procedure Is to be effective in keeping all those con cerned informed on order statue, it is essential that the Planning Group be notified immediately by Shipping and by Production of any conditions arising In those areas which will affect in any way the schedules or promises Issued by Planning., Specifically, it will be Shipping's responsibility to notify Planning as soon as possible, and by 3:00 PM at the latest, of any scheduled shipments which are to be delayed. Likewise, Production must notify Planning of any failures to meet production schedules as soon as the facte become known". This includes notification of the date and duration of all trial rims as ,-oon a this information is available. % RSV0026892 RSV0026893 RSV0026894 Afmmix c PRQCmmE BtILLETXH FOB TMXSFBRB TO BQMSSVXLLF AH3> TO PUBLIC WAREHOUSES TUls bulletin is still in process of propagation and will be issued upon completion. RSV0026895 RSV0026896 ....--PPEIX "B" BLTROH FILM X.BcKt CODE FOR Tl SUB-STAMPARB 1286" MATERIAL le Cold Marks 2* veneer 3e Fisheyes 4. Contamination 5 6 pucker 6o Pick off 7. color Streaks 8. Off Color 9. Orange Peel 10c Wrinkles lle Gloss 12c Matte 13o Nn~standard Formulation l4e Nn~standard yield0 50o Check before shippingo RSV0026897 RSV0026898 RSV0026899 FfWM 559 ft.H B 9-151 ULTRON COMPOUND OR PREMIX - OPEN ORDER STATUS SAMPLE INVENTORY CODE 1264FORMULATION NO. 1018COLOR Rjrp ORDER ENTERED DATE TIME CUSTOMER NAM V* 3 Columbia Cable OUR ORDER NO. LBS. ORIGINAL ORDER DATE j SHIPMENTS \L-B5. DATE , LBS. DATE \ LBS. TOTAL LBS SHIPPED TODAY NET LBS. OPEN ORDERS W112410,0001/17 3850' 3850 6130 4/30 REMARKS >huij bJ HX |-d O'-i RSV0026900 town sfi? s.i*. FILM ULTRON GQ.V,POUN0I0Jl :TOI)( - OPEN ORDER STATUS INVENTORY CODE White SAMPLE FORMULATION NO. 4COLOR 4001 .POST 65 2.6 ORDER ENTERED iW 2/22 CUSTOMER NAME Jason J1765 TOTAL LBS] NET LBS SHIPPED OPEN TODAY ORDERS 7160 REMARKS Inventory H.P.C.R, 80)-! O r>: 'Lx: t1>< I?: QTQ RSV0026901 --APPENDIX F SUMMARY LIST OF COSTS OF i PRODUCTION CHANGE'S Description 1. Color Changes: a. Minor Change be Minor Cleanout Ce Major Cleanout 2. Formulation Changes: a. Within Range be Between Ranges 3 Gage Changes: &e Within Range be Between Ranges 4. Width Changes: (All) 5. Embossing Changes: ac Plain to Embossed be Embossed to Plslr Code NOo Loss Cost at $80 per Hour 1 100 lbs. due $ 10.00 Cross contarn. 2 2 hours 160.00 3 20 hours 1600e00 4 22*5 mins. 30.00 5 2 hours 160.00 6 30 mins. 40.00 7 1 hour 8o.oo 8 7e5 minsc 10.00 0 "^0 mins* 40.00 s o 3 mins e 10.00 % RSV0026902 RSV0026903 SBNH&Kr OF MOT FRWOTIOli 0BHTS ft Cod m. 1 Besoapiptlos of mMr * Ttat ft EeXe&eee seei^F#& FrlsoipiXAffPliefttlOB ' Tiers Mtifee^C-tgjftMdiltlilF Pigere^ib latr! Beport Ffe@sf Mer'Dept, (Mr, Tnrmerleaa) 'Fetter Oftar^ft 200 t Total Igtamti<g ft ff I Chsieges.. Hegel-eed 9 ^ # 3^@ 3 Total", Of fShgxSmet Item 8P osssit Items m @lly lists ft? gMpped*' f sMpmeste ft iM for total* % of spikes# ft lww3t@Vli Possets f Heels Fa@fee Out is Bege. . 6' Haasfeeg5 ` f Different Film Item Pf4me Pr#iuti B Biffistfii end :llep@rt ^ ,. Total @rftily Frodnetie Smmm&rleg @0t items m Fr@#m= t@. Seta#!.. 1*150*00 i15.000 ft5 7 RoUft of Film SMpped (isolssdisss feBsis) ft TmstBfmrFQii SMpmesta B fmii f @ipi:-:if j^Jlo Shipp# mi pomefegsei n 9 *&" ef Eeelm Steippei ft Fomsffesre# ftdd p emh <tay en'Belly reports es# t@tiil f@r momt&e Month .sjflfeeoJfcisg He- 3s X*ft7*0 port pirns total" of trussItrs ifm Belly Shipping .Eep@rt, ' * 3*100*00 ,`etd*. mit Time H!0 for 0,ft8S unit oOlftft Bait 0,05330 Unit 100 ,?. 1000 0*2S330 mat c066 mat 0c08ft 10 Dolit 100 Total Sta, Time. Bee'& m pftttftra 9.75-9 IcftftO 25,020 16*813 16,io 10,135 19c iSO 8,795 3ft.72 RSV0026904 Susasry <f Major ggstuctisa Counts fc Standards AFFBHPSE 6 fl, f ..................._ C@de K. Beeeripti of Major Count Principal &pplioatia Seure of the Hehthly Figure for the Cstr@l |^Re^pt -i Std. Hnit flat Fatter 0tr.,$ . 'Bonn" ; 'Pef 10 Total Founds of File, C&&pmm& Raw Material Morth end aeeeunfcihg Re 2:550,000 0.02960 2000 and IS* I* Produced port (s Ite 4 & Filn} 11 Unsafe r @f Compound. and E Xtens Production Count lines used in Blend Fr@imo#d .. Schedule Reek f@r the n@nth. v 30 0.OS46O Emit It fetal TT" received Orders Total of Coants 112 above* 30 0.0263 Unit 13 M&sb r @f Frwalati@ne @n Msthi7 R.M. Fore- Count n Work Sheets for Predueti Schedules east . Fils & Compound Material Forecast* 26 0.59000 Unit - Total Measured WmM - Tta2 Std. Hours Related to fetal Measured Werk -0.21100 lour Total...Constant WOrR -16*40000 Month Or&nd Total Standard Hours Total Sta* Tise Based m Fattep&. 30:380 2*520 4.890 9M3 189.625" 22055 15.40 227.076 RSV0026905 RSV0026906 Monsant^^iemical Company MONTHLY JOB SUMMARY OF STANDARD HOURS Deportment POSITIONS AND FUNCTIONS BASIS OF MEASUREMENT ' ' " '" r' ';!?: ' -' - ?' ).yr 4 71 P:.- : - s'-.vj i >1. 7. ` ' 7'-t' 7 - v.,, : ' tv ' f 1 trrvh : ; V f = ; 5 - -- 7~ - yp OF E- -ThtriP5.! 7 761 pn S ff ac 3 h y if,}? O f$ -FT--..; 3 .-'ynft, nns'1 p---R-Hi, $ \ O. ph'cl'Tfv-sfv _ T: 73 ? ' < .v;;. X- "ssUsypsr./,i * ; - V * f 1 r-^~ ~ - ' hf'.'i r- ~ ? t c. -\ .* '7" ' STANDARD UNIT TIME f.npngr 0 ACTUAL MONTHLY UNITS 200 100 1 r- '45 ;H- 470 :. Tixgt 1,150 C 7;ri'f 2,150 P, ! ;. 45 r: F-ftp. 3,000 h t 00840 1,047 ' PI 1.PF 3,100 7 . ai ngo 1,550 o.c34fc 0 .7-1 Si 0 30 300 STANDARD MAN HOURS Pattern Month Date ACTUAL MAN HOURS OVER (RED) OR UNDER STANDARD PERCEN OF EFFICIEN 9.760 1.440 ; 25.050 16.790 15.050 10.139 19.800 8.795 34.720 30.380 2.520 4.890 , 1 tIj--d? t h t> Jh 1 f- Cr 16 9.440 tfSTJ '7 7 Tf j,P-. \Q 'PvP x -7 0:4 ::ht .-a. r^px itA^avi qb - .......- t-iiis*. : C 77 ...... ......... . ---- ----188.774 - -- 21.055 16.400 226.229 203.20 +23.02S Ill , . -M ... - RSV0026907 CDa.6 Monsanto Chemical Company .VXHTL. HAKK28&. GBOO?. APPEK&ni S r flrfkiaejca 0 ffice Perform once Report For Month Of . POTOT .MOOT. I HOURS AMOUNT 1. Hours Paid For: (Average straia'ht time hourly rate $ )-- -- A. Rnaular hours ot straiaht time rate R. Overtime hours at straiaht time rate C. Overtime premium amount ^ 7 ^_______ -- D. Borrowed service (adtflrf*'** . **,*. .?ws5.r ww**4* ?$rw. \ fr didd'C J E. Loaned service (deduct-red) _________F. ____________ ______________________________________________________________________________ G. ............................. H. J. ......... 2. Less Adjustments For: A. Vacations B. Illness TOTAL C. Holidays D. Excused or other absence E. Overtime premium amount ............... F. G. H. I. S03,20 -- -- -- TOTAL 3. Net Available Hours (Item 1 less item 2) 4. Standard Hours (From job summary of standard hours) 5. Variance From Standard (Item 3 less item 4-loss in red) G 203,20 2S6,gfeb 6. Operating Efficiency (Item 4 divided by item 3) 7. Number Of Personnel CLERICAL MEASURED UNMEASURED SUPERVISION jr 2 iVifti CD TOTAL 8. Comments '"-T-td.? it-vs iff asspoEos f the fXlevri^g i T&nittm 5 {S&Tl&l/ wa&k time by n^eamix-^H IsaloMed. is? psttssrc wsHtlosiL ral; " dese 4urisi; t;ht a^d^td s pp^iad; TiepTmni.&e pMOsdurf e,S PdP Ud ipd' dPpOdtd Cs.b Kdt;i'Ud Cedtidd: VdpOP' _;>OC 'j'n'py ; , 69 Sir PC 3;. Dote 0/ Survey RSV0026908 Vo. 0E&67 Department POSITIONS AND FUNCTIONS BASIS OF MEASUREMENT T c-!.! V; fio. ' 'VvlvuoilifH a? 3 71" 7b Cssawgaa i - :==.v;i v pr^f r'; i fiTrippAti! r :- v 'f "0 7 -, ; - ~i' '.=' ?pW-iF n' fLliJ, p-;T p--; " '. -- - V V i f t-r, % U.K Itemf f - 1 v r?iri ariif.i 7v'?i:r;S;? ST `-i V : .. ?3C 3 .Vi,, fto al'ilppt'd t>`7 fshVTK r>1 asr'A'; 1'oi!' 5`i rj.]sH, -'i.SA.orV . :!v uj s.l.Vt, fm/wikw. J-i Vr y' -" ' -7 r^r; t- t^s 3f 3' r*.,'3 . 1 1'NrftM PT-T-'^^S-F)/!^' ;; v 'V-i;?o;v cvi-aF Tf: 7 ' F .7 = '3' />! 7rSi; _y 3\i'V l f,pij sv^rFAslT , V--7 - = F P--- . STANDARD UNIT TIME ACTUAL MONTHLY UNITS 3,4388*1 -*V f"-T fuJIji.i-' j*f;1 . 1 7?t tfl-r> 243 115 303 r.Flbb 826 0 ,r`^?C0 2,505 28 F; ... ri if'7i 3 1,793 "*, 0**8*) 0 932 CF 0.0.20 2,8g2 0-.01960' 948 0 -.gS&OO 21 i'V -.71.610 358 STANDARD MAN HOURS MARCH, .1953 D ate ACTUAL MAH HOURS OVER(RED) OR UNDER STANDARD 11,858 1.656 16.150 12*. 060 17.535 6.308 11.834 7.829 32.390 18.581 1.764 5.835 PERCEN' OF EFFICIENi r. PWF 13 7-670 - u v'Tmrsvrvrv 7.. A'U'Sf r- . s;afp,X flfMc Void's ;giJI .......... -- -- ----------------151.470 4>4U5* 1.6 <300 -- --- 163395 16,400 184.765 193.50 8.735 953 RSV0026909 i 1 A- It MONSANTO CHEMICAL L.OMPANT ............ .-. ; .V2KZL -PL^BtSHHWRSB':-................. Office Performance Report For Monf/i Of ... . (, .wSfco. 1. Hours Paid For: (Average straight time hourly rate $ ) A. Recmlar hours at straiqht time rate B. Overtime hours at straight time rate C. Overtime aremium amount D. Borrowed service (add) E. Loaned service (deduct-red) _________F. _____________________________________________________________________ __________________________ _ G. ........................ H. I. TOTAL ?. Less Adjustments For: A. Vacations B. Illness C. Holidays D. Excused or other absence K. Overtime oremiuin amount F. G. H. I. ( .......................... .. HOURS -- .....- -- pc. 201*^0 -- 6,00 -- AMOUNT -- -- TOTAL 3. Net Available Hours (Item 1 less item 2) 4, Standard Hours (From job summary of standard hours) O r. ' ^A C* V. .s4c' Zpl-. "rf-- 5. Variance From Standard (Item 3 less item 4-loss in red) 6. Operating Efficiency (Item 4 divided by item 3) if.. A'"' c- ^ ?, 7. Number Of Personnel CLERICAL. MEASURED UNMEASURED SUPERVISION L TOTAL #r_; V' 8. Comments *03?3&S& Sf" Oleric&l wests dene by sleptefr isel'a^ed ir* efe&ss&SJs& h-ur*&r but sey: E-otuslly 6,&n O r1 sj^M'sfa(vnisitiir r,,' C - Dote Of Survey RSV0026910 RSV0026911 APPENDIX I ULTRON FILM PRODUCTION SCHEDULING GUIDE The need for a systematic method of evaluating film produc tion sequences and the attendant change-over costs has long been felt. The following procedure is the result of an attempt to develop such a system which can be readily and simply applied to desired schedules in order to determine the change-over costs in volved for comparison with established cost standards. The first step in development of this procedure was to sim plify the classification of the change-overs on the calender as listed in Appendix F. This was done on the basis of cost per change as shown in the following table: Classification of Calender Change-Overs Change Code Number Types of Change Included in Class!* fication Code Unit Cost of Change @ $80/Hr. 1 Minor Color Change Width Change Embossed to Flain $10.00 2 Formulation Change = Within Range 30.00 3 Gage Change - within Range Plain to Embossed 40.00 4 Gage Change - Between Ranges 80.00 5 Minor Color Clean-out 160.00 Formulation Ch&nge-Between Ranges 6 Major Color Clean-out 1600.00 To determine the approximate order of magnitude of possible savings in this regard, an analysis of the first quarter produc tion schedules for 1953 was made. These schedules were evaluated in two ways, based on the above table of costs % First, the total cost of changes was determined assuming that the originally sched uled sequence had been followed; and, second, the"'Total' ost,r"of changes" rof~"the actual sequence of production was derived in the same manner. The"ciTff'erence""be'tween the two represented, of course, the additional cost involved as a result, of deviations from, the original schedule. The results of this analysis are summarised below; RSV0026912 -2- Cost of Film Schedule Changes First Quarter 1953 Actual Sequence Originally Scheduled Sequence Total Cost of Changes at $80.00 Per Hour $5,980.00 3,460.00 Change Cost Per Pound Produced (674,500 pounds) $0.0089 0.0051 Loss Due to Deviations from Original Schedule 2,520.00 O.OO38 The standard cost allowance for changes which has been estab lished for Accounting purposes Is 5$ of the operating hours. Com puting this in terms of dGll&rs, assuming capacity production and $80,00 cost per hour, we get: Standard Cost of Changes = $0,0042 per lb. produced. Comparison of this figure with the current change cost of $0.0089 per pound shown above indicates that changes are presently running at slightly more than double the allowed standard. The attached form for "Weekly Production Schedule Evaluation" has been developed as a means for ready evaluation of proposed schedules in terms of change cost per pound. This form will be completed by Planning and approved by Production Supervision on each Thursday prior to "freezing" of the production schedule as described in Section IV-l-d of this manual. All proposed sched ule revisions will likewise be evaluated in the same manner. By use of the data contained on this form, production sched ules involving high change-over costs will be high-lighted and im provements may possibly be negotiated with the Sales Department, Furthermore, the accumulation of such data will give an accurate indication of the trend of change-over costs so that appropriate corrective action may be initiated when deemed necessary. A third benefit to be derived is in the use of this data by Production for the explanation of cost variances. RSV0026913 ) R.SV0026914