Document zQJqE1BQwEjyzK37r3nazojM6

T. H, Huffman To: From: Dote: Subject: D. C. Skokna April 22, 1991 ABERDEEN MONTHLY PROGRESS REPORT MARCH, 1991 Safety There were two first aid and one recordable (RWC) injuries reported in March. The recordable injury (RWC) involved an operator who suffered a corneal abrasion to his left eye. At month's end, the plant's employees have worked 4,287 days (5,726,980 manhours) since the last lost time injury. FY1991 Kev Statistical Information March Y.T.D. PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M Operations 39.4 86.0 97.6 1.0290 3.2 97.2 5.6 99.7 1.7 87.8 < 13.7> 53.9 < 2.6> 240.5 87.8 98.4 1.0243 25.6 96.7 28.6 99.6 9.6 85.0 < 8.0> 149.9 < 75.3> Three rotary dryers were successfully converted to the new VCSM system; the remaining dryers will be converted in April, Dump header modifications in the New Module significantly reduced 5385 hard particles from sixteen to one. In the compound units, costs and inventory control continued as high priority. Costs Fixed costs were $53.9M favorable primarily due to below budget benefits clearances and MM&C expenditures. Variable costs were essentially at budget for all units. VAB.0001189749 T. H. Huffman 4/22/91 Aberdeen Monthly Progress Report - March, 1991 Page 2 QMP All plant natural teams met during March. The Laboratory MD" shift made their management presentation. Their project will improve efficiency and improve the appearance of the lab to our customers. D. C. Skokna Plant Superintendent rah ..................in nwmmmmmm VAB.0001189750 Houston J. D. Burns X R. T. Ferrell X T. H. Huffman i C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblln Austin R. L. Foe X H. J. Hall Oklahoma Cltv H. D. Garrison LCVCM Plant P. D. Carrico LOOP Plant LCLAB Plant J. Friend J. W. Ware X Baltimore Hammond L. R. Bauer J. Pavao X X Blane C. R. Miller Premiere P, L. Foote Aberdeen RWS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, DAB, DAM, RBN, JEN, JDO, BLT X X X X X X X X X X X X X X VAB.0001189751 SAFETY - B. L. Trego March Fiscal Y-T,P, 199; Fiscal Y.T.D. 1990 First Aid OSHA Recordable Total Injuries 297 X _6 __3 3 15 10 Number of Restricted Workday Cases 0 3 2 Number of Lost Workday Cases 0 0 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 120 142 076 00 1 00 X _2 0 3 15 10 Injuries bv Type, Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 032 111 02 2 131 030 002 X _2 3 15 10 Non-Occunational Injuries Lost Workday Cases Days Lost 16 32 110 3 84 Safety Record Last lost time injury - 7/5/79 Days since - 4,287 Employee hours since - 5,726,980 On March 31, 1991, the employees of the Aberdeen plant completed 4287 days with no lost time injury. Topics for the plant safety meetings during the month were: Injury Reporting, Power Failure Procedures, 3-M Air Hat Cleaning, Hearing Pro tection, Respiratory Protection, Hazardous Waste Disposal, and Lab Lead Handling Safety. VAB.0001189752 SAj^n - Continued Respirator fit testing is being done by the plant nurse. This is being accomplished through the use of the new Portacount fit tester. Routine dosimetry results for the month were: Chemical <_________________________ Number VCM Lead Total Particulates 72 100.0 4 100.0 2 100.0 Monthly Inlurv Summary > PEL HuBk Egrcepp 00 00 00 FA RWC FA Adm. Services Vinyl Compound PVC resin, both eyes. Corneal abrasion, left eye. Contusion, left hand. * VAB.0001189753 OPAUTY MumaMf rancKgg . T. J. Arbelter All of the plant's natural teams met during the month March. The Laboratory D-Shift Natural Team made a presentation to manage ment on March 1. The team's goal was to reduce inefficiency and congestion in the lab and make the lab more aesthetically pleasing to visitors (i.e., customers). The team accomplished their goal by relocating test equipment, work tables and file cabinets, and by building a new resin work table from "scavenged" laboratory table tops (a new table costs $3,000!). The team also purchased a computer desk in order to locate the resin computer adjacent to the resin work desk. Quantitatively, the team estimates the relocation of items in the lab will save ten technician minutes per shift. Qualitatively, the n believes the improved work environment in our lab will have a very positive impact upon the men and women working there. Pro viding a clean, efficient work-place inspires people to be more efficient themselves. The Aberdeen Plant's Q-Scorecard performance as of March 31 is: Item Natural Team Activity Quality Goals Cost Control Safety Waste Minimization Work Unit Enhancement Linkage Wt. 20% 10% 15% 20% 15% 10% 10% 7 7.57 8.29 8.93 9.5 5.06 1.92 Points 1.4 .76 1.24 1.79 1.43 .51 7.32 The scores reported above are support card scores for each activity). the average of all departmental line item (except natural team ,.T VAB.0001189754 D. G. Skokna Variable Costs Product Product Mix PVC Flexible Compound Rigid Compound Plasticizer Total $ 86.2 34.3 213.6 < 0,1> $334.0 <$17.0> 2.2 8.0 ____4x2 <$ 2.6> $274.2 < 138.3> < 206.1> < 70.9> <$141.1> $343.3 < 101.8> 15.5 < 66.8> $190.2 Variable Costs: All units were essentially at budget. Price Variances: - VCM Natural Gas m Pigments, Colors m Phthalic Anhydride Plasticizers Alfol* 610 m Resin to Flexible Compound Resin to Rigid Compound m Other Price Variances Total $267.9 16.1 < 15.4> < 21.1> < 24.5> < 45.4> < 53.5> < 164.1> <$141.1> Fixed Cost Variances Payroll and Benefits MM&C Miscellaneous TI&D Clearances Total $ 23.1 43.7 < 16.6> 7.8 < >tl> $ 53.9 Payroll and Benefits - A favorable $59.3H benefits clearance was partially offset by an unfavorable payroll variance of $36.2M. MM&C - The favorable variance was a result of our continuing cost minimi zation efforts. VAB.0001189755 COST YAMAHA - Continued Miscellaneous m Moving, Home Assistance - <$14.1M> Outside Professional Services - $14.7M m Unclassified - <$31.9M> (This was due to the annual physicals) m Operating Supplies - $18.OM VAB.0001189756 Vltffl - J. D. Olson, D. E. Knittig Safety The Vinyl Department had one restricted work case injury during March. A vinyl operator scratched his eye on the corner of a box. An investigation was completed and the team presented recommended safety procedures. The monthly safety meetings were conducted by each shift supervisor instead of the one standard meeting by safety. These meetings focused on individual shift safety concerns. General 1. Dump header revisions in the New Module were completed. The revisions reduced hard particles in the 5385 from an average of about 16 to 1. 2. Dryers #1, #4, and #5 were converted to the new VCSM system this month. All dryers will be converted by the end of April. 3. The resin raw materials in the 744 account were valued at $370.5M. An early shipment of Alcotex that arrived prior to month-end caused a majority of the increase in this account. A test of a new rinse nozzle in D-745 was started during the month. The nozzle is designed to keep the reactor "ultra" clean and reduce hydroblast cycles. Preliminary results are encouraging with contamination numbers averaging about seven total contaminants. March - Production, MM Lbs. - Daily Rate, K Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime % 39.4 1270.9 101.2 939.0 30.3 86.0 89.4 92.6 97.6 240.5 1321.4 105.2 5612.0 30.8 87.8 92.6 96.3 98.4 m Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts and inventory control). Hours 395.0 wmmmmmmmmmmammmmmmrnemm mmm mm**** VAB VINYL - Continued Reactor Downtime a Maintenance downtime (X-ray VC line on D300 and D400, D500 seal change, gearbox maintenance on 0742 and 0743, dryer conversion to VCSM, power failure, D743 condenser drilling, New Module dump header revisions, installation of check valve in Old Module water line, 0745 rinse nozzle installation.) Drver Downtime Operational downtime (centrifuge plugs, dryer cleaning, flameouts). m Maintenance downtime (centrifuge maintenance, dryer conversions to VCSM). m Reactor limited production. Hours 644.0 % of Total Downtime 17.3 79.2 3.5 Key Maintenance Work - J. B. Autrey, S. A. Truitt The reactor seal on D500 was changed. The seal was not getting enough flow for flushing; the throttle bushing did not have the required clearance for proper flow. The old seal was rebuilt as a spare. Reactor 743 and condensers on D742 and D744 were brought down for hydroblasting to control contamination. m The safety discs on D745 were changed on the annual schedule. While the reactor was down, it was hydrobiasted. m The input shaft seal on D742 gearbox was leaking oil and was replaced. i The gearbox on 0744 failed and had to be replaced. The gear box on D741 was pulled and set under D744. The spare was installed under D741 because it required a different founda tion plate than what is under D744. A new gearbox is on order as a spare. The exhauster shaft on dryer #6 was replaced when a crack was discovered on the shaft. No major valves were changed in the vinyl unit this month. COMPOUND - J.E. Nickerson, M. R. Kane Safety The Compound Department had no OSHA recordable Injuries in March. The topic of the monthly safety meeting was "Housekeeping". General Control of costs and inventories continued to be a high priority during March. Lines were operated only on an as needed basis and operators from shutdown lines were utilized to cover vacations and other absences to reduce overtime costs. Repairs to the Line I Banbury motor and a Line V Orbitran (control system) failure were responsible for some abnormal maintenance downtime. Conoound Production Operating Psvs Line I Line III Line V Total % Prime Capacity Utilization Factor 22 27.5 6.5 Downtime Line I - Banbury Motor Maintenance - Product Changes - Miscellaneous Maintenance - Dicer Offline - Mill Maintenance - Quality Problems & Control - Waiting on Raw Materials Line III - Quality Problems & Control - Product Changes - Miscellaneous Maintenance - Mill Maintenance Month Av./Dav 1075 1856 237 3168 97.2 40.4 49 67 36 Hours Plscal Y 9492 14618 1469 25579 96.7 55.9 156 97 61 50 15 11 4 127 73 52 25 A VAB.0001189759 COMPOUND - Continued LineV - Orbitran Failure - Miscellaneous Maintenance - Waiting on Raw Materials - Quality Problems & Control - Product Changes Operating Daws Rigid Compound 29 % Prime Capacity Utilization Factor 5553 99.7 93.5 83 7 7 3 2 191 28583 99.6 80.9 Downtime Hours - Miscellaneous Maintenance - Quality Problems & Control - Product Changes - Waitine on Raw Materials 102 69 54 14 Operating __ Da Month Avg./DaT Fiscal T.T.D. Plasticizer 31 % Prime Capacity Utilization Factor 1653 80.6 87.8 9604 84.9 85.0 Kev Maintenance Work - J. B. Autrey, S. A. Truitt The drive end shaft on the Line III ribbon blender was reworked. The shaft was worn from bearing failure. The Line I Banbury motor was removed and checked to determine the cause of an overload situation. The motor was cleaned, bearing replaced and load tested. No problems were found with the motor, gearbox or Banbury. The cause of overload is believed to be related to product formulation and the Banbury operation sequence. The gearbox on Line III "B" blender was rebuilt and placed back into service. The rebuild was required due to worn gears. The motor was also repaired; it had bad windings and bearings. Line V Orbitran had the CPU board, 1.0. buffer board and the eight-bit 1.0. board replaced. VAB.0001189760 R. E. Folic, S. G. illlasn, M. R. Kane PROJECTS IH PEVELOFHEHT - GEHERAL Vlnvl Area HA2QPS A Hazards and Operabilities Study (HAZOPS) of the old reactor module was begun in early April. An initial two weeks of team meetings are scheduled in April. It is expected that four to six weeks will be required to complete the Old Module. Additional time will be scheduled later in the year. A project is being initiated to determine the capabilities of the existing vinyl area cooling towers. The project will determine the effect on cooling requirements o-f increases in production due to the cleanwall and VCSM projects and other production increases pro jected over the next two to three years. Reactor 745 Sorav Nozzle A new rotating spray nozzle is being tested in reactor 745 for washing the shell between batches. This nozzle replaced the old stationary, low impact nozzle. After one month in operation, the nozzle has performed well. The potential benefits are reduced resin contamination and reduction in reactor downtime to hydroblast the walls. Plans are to install one in D700 if this one continues to perform well. vcsm Conversion of all the rotary dryers was completed in early April. All dryers started up without any major complications. The fluid bed dryer will be converted in mid-April. Operator training on the reactor operations phase will be conducted in May. The project continues to progress as scheduled. foM Two ftectftjp We are working with Conoco to determine the feasibility of reclaim ing scrap resin from old pond #2. A preliminary design was com pleted by the plant to evaluate reclamation of this resin. This information was used for comparison to contractor bids. VAB.0001189761 NSINEERINS - ^ FOLK, 3.C. HILLHAN, M.S. KANE ABERDEEN CHEMICAL PLANT APPROVED CAPITAL PROJECTS AFE NUMBER A519 A649 A909 D511 D629 D749 D849 D859 DB99 F699 F779 6659 QB39 D570 0580 D600 F650 F660 6560 6610 6630 H500 H510 H620 H501 H521 * PROJECT DESCRIPTION STATUS PLANT ELECTRICAL UP6RADE VINYL CONTROL SYSTEM MODERNIZATION INERTS REMOVAL MODIFICATIONS VCH UNL0ABIN6 MODIFICATIONS COMPOUND REBLEND TRANSFER SYSTEM LEAS HANDLING AND EXPOSURE REDUCTION CQHPQUND LINE 3 SEMI-BULK LEAD HANDLING COMPOUND SILO BRIDGE BREAKING RAILCAR CLEANING RACK LON MOLECULAR HEIGHT RESIN EXPANSION DRYERS NO.4 & 5 CONTAMINATION REDUCTION NEN DRYER BA6HQUSES PLANT MATER RECYCLE OLD NODULE RECOVERY SYSTEM ACCE55 RECOVERY VACUUM PUMP PRE5SURE RELIEF PLASTICIZER LOADING AND UNLOADIN6 REVISIONS 5303 RESIDUAL VCM REDUCTION DECALCIFIED MATER TC SPILL CONTAINMENT TC COMPLIANCE PROJECT REACTOR SLURRY STRIPPING OPTIMIZATION PLANT MATER SYSTEM HEST INCINERATOR REPLACEMENT EAST INCINERATOR REPLACEMENT MISCELLANEOUS CAPITAL PROJECTS < $15M REPLACEMENT INHERENT VISCOSITY ANALYZER BOILER FEEDMATER TANK REPLACEMENT SOME ADDITIONAL CHANGES MADE, NILL CLOSE TO FIELD CHARGES IN HAY. DRYER CONVERSION ON SCHEDULE. HEN NODULE CONVERSION PLANNED FOR JUNE. HILL BE OPERATIONAL IN APRIL AND CLOSED TO FIELD CHAR6ES IN MAY. DESIGN IS SCHEDULED TO BEGIN IN JUNE. CLOSED TO FIELD CHARGES. PROCESS ENGINEERING IS MONITORING MODIFICATIONS. SYSTEM HAS BEEN TESTED MITK FILLER, MODIFICATIONS IN PR06RESS. NEN PARTS ARE IN, PROJECT NILL BE COMPLETED BY MAY. CONSTRUCTION IS IN PROGRESS. COMPLETION PLANNED IN APRIL. THE PROJECT HILL BE CLOSED TO FIELD CHARGES IN MAY. EN6INBSM6 IS IN PROGRESS ON MODIFICATION, PLANNED COMPLETION IN NAY. NEN MODIFIED SCREMS DUE IN MAY. THE PROJECT MILL BE CLOSED TO FIELD CHAR6ES IN APRIL. DESIGN IS COMPLETE. INSTALLATION IS PLANNED FOR 7/91. DESIGN IS COMPLETE. INSTALLATION IS PLANNED FOR 7/91. INSTALLATION IS IN PR06RESS. COMPLETION PLANNED IN MAY. PROJECT IS COMPLETE, NHL BE CLOSES TO FIELD CHARGES IN HAY. OLD NOQUIE COMPLETION PUNNED IN MAY, NEN MODULE COMPLETION IN JUNE. PROJECT NILL BE CLOSED TO FIELD CHAR6E5 IN MAY. PROJECT IS COMPLETE, MILL BE CLOSED TO FIELD CHARGES IN MAY. NAITIN6 ON ACCOUNTING CORRECTION, MILL BE CLOSED TO FIELD CHARGES IN ENGINEERING IN PROGRESS. PORTIONS OUT FOR BID. PLANNED COMPLETION EARLY-92 INCINERATOR DELIVERY PLANNED FOR 4/91. PROJECTCOMPLETION PLANNED FDR 7/91 INCINERATOR DELIVERY PLANNED FOR 4/91. PROJECTCOMPLETION PLANNED FOR 9/91 ENGINEERING IS IK PR06RESS ON 8 PROJECTS. 7 PROJECTS COMPLETED. CLOSED TO FIELD CHARGES. DESIGN IS IN PROGRESS. VAB.0001189762 ENVIRONMENTAL - K. G. Akins Water All wastewater discharge parameters were met for the month of March. The State responded to our letter of dissatisfaction on the new permit limits. They cited several reasons for no changes to the permit limits; the main one being that the City of Aberdeen was recently regulated at those same limits. The City of Aberdeen also discharges to James Creek. We expect to receive our new permit in mid-April. A test run of "superbugs" was completed in our wastewater treatment system. Results were somewhat clouded due to the mild winter this year. However, based on BOD data taken during the test run, "superbugs" will help decrease BOD during the winter. Superfund The draft remedial investigation was received. Comments were gathered from the plant and corporate environmental and sent to Conoco. A meeting to review the final report was set up for mid-April. A meeting was held with Conoco, Royal, Vista and Sun Polymers to discuss removal of pond #2. The most favorable option was for Sun Polymers to dry the material in Aberdeen. The only obstacle now is getting State approval. A meeting has been set up with the State for mid-April to dis cuss this project. The State has not yet confirmed that they will accept the lower risk factor. However, they have sent a letter to EPA in Washington asking for guidance on this matter. gaste No hazardous waste shipments occurred during the month. Use of the general plant trash compactors has resulted in savings of approximately $900/month. ENERGY CONSERVATION - J. R. Ganc March. 1991 Data A. Unadjusted EUI <14.6%> B. Adjusted EUI <13.7%> C. BTU/Lb. Product 2843.1 D. Total Energy Consumption MMM BTU 141.5 II. Boiler Operation Fiscal Y.T.D. < 8.5%> < 8.0%> 2757.5 830.7 Boiler March. 91 No. 1 No. 2 No. 3 83.2% 83.7% 82.8% Boiler #2 operated eighteen days during the month. 83.1% 83.3% 82.8% VAB.0001189764 WMXK KMOOTCE REPORT Beall None Jimmie Morgan - Maintenance Department - Employee progressed from General Mechanic "B" to General Mechanic "A". PD-TDIIMWyiWU Morris H. Williams - Maintenance Department - First Level Supervisor None fO/ranM TT**VB OF ABSEMCE None A Mnpwmm/m VAB.0001189765 EMPLOYMENT Salaried Hourly Temporary SUB TOTAL L.O.A. TOTAL 74 165 2 241 5 246 DEPARTMENTS #EMPLOYEES M I F NEg HIRES S alaried/Trans fe r Hourly Temporary TOTAL MO 0 0 0 0 YTD 0 0 1 1 %M %F 'L DEPARTMENT TURNOVER MO. YTD ANN. % J I'fl 9766 T \ A cn UJ <c a<rto <x a. UJ <o o to UJ <X CO r aero co rrt 05 $o+ o+ +<oz> 00 <D O CM UJ CO *<mn m <E> CD ro CM co U9 Lju ZZKCLU CO COCO CO VAB.0001189767 HP I I UJ u? ii it ! $ 0> i i CM i i in ro i i CM OJ CM i cm r- J CO CM I I i -o *r i CM in i s CM m5 CM ro 00 i ro i i i i i CM CM ii i i ii y^ i r- i M3 o tp in i i nO i CM i in i r i ev i i in i ro i in i i i nO ro 44 CP ro CM i I +r* i 'O i o i NO r- 1|1 1 **- 1 00 i in i OO i i ro i t i in in *r i oj i in i In i i >o O. 1 i NO i i 11 iro CO 1 1 u. i o1 A 1 o- 1 l 1 in 1 in 1 H-l <c t 1 in4 1 * 1 O' 1 'O 1 >o * CO J 1 <D 1 1 1 o *- t on I < I o 00 00 in <D UJ -j co <c UJ a. UJ <r a. UJ hcou JC CO '!>* Caen co ro X CO ui<ro co UJ CO UJ o UI CO Cd 1 <t 1 sin o- CM \ >o ao ro o* t CM no CM *I I CO CO 1 1 1 O' 1 p*-- 1 i in i i l 1 4 i CM i O' CO Ui 1 1 4 1 l 4 1 1 O4' 1 1 1 i -- 1 i i l ro i in i t O' 4 1 l4 2E 1 1 1 1 1 i *r i i i 1 in i ro i 1 1l1Ii i ii l i ii l o 1 |*-C |4 ICM 1 J*-- i in 1 1 in l in in 1 i in i i in i in 1 in 1 i UJ i CM 1 1 CM 1 CM i CM 1 i OO i -t 1 i i CM i CM 1 o- 1 in i y f i r- 1 1 On i i 1 CM i i mQ i ro i f*- t NO 1 in i UJ i LTt 1 1 O' i i CM l NO i O i* ni V i 04 1 1i i 1 1 O' i i t ro i 1 i i CM 1 NO 1 i ixiae: i 1 1 i i * i 1 i i 04 1 1 i i iin (O' InO |nO nn 1 LiiOUl 1 in t O' 1 ro l 11 1 I x: 3C 1 1 CM 4 i 00 4 1 1 CO 4 1 1 'O 4 1 1 O l 1 h-- f-- 1 in i "4* 1 1 CD 1 CM 1 i <T i oo t -o i 'O in GO 04 O' 1 1 O' 1 \4 1 1^ IOJ |4 i \ CO 00 \ 1 1 1 1i I i 1 in i in i in i t in \ r*n m in CO in ! i 1 CM i o1 4i i i in i CM i l I CM cm in cm ICO 1 05 ce 1 in i i i * in i ro CM i ro O' ro ro -4-* | in ro ro I* ro i CM in ro ro in t uj UJ On o\ 11iii ti 4 1 1 4 1 1 i i I i i qr 1 nO 1 i M3 i i i i in CM 1 * in 4*-- r i i i ro i ro l i i i i i i HO CM ro ro CM in CM In ro CM Q H Sh UIA 1 i 1 1 i 1 in i--IOC r 4 i 4 1 4 in in in i in in in in <D in CM 44 4 cm m4 O' i M3 t co 1 GO co in cm ro nO ro i O- i 1 ro ad co i i O' r*-* t r 1 1 GO <4P cox i i 1 ro i no oo i oj i in i ro in CM CSI in in s -O ro m oo in i to UJ CJ i UJ i I UJI 1 A t 1 rsi 2 UJ o i i i *^"1 a i i i l 1 1 Ou o I l 1 X UJ o 1 1 1 A Z O 1 1 1 M CJ u- \ rn I UJ l o i 35 1 Q 1 o w i UJ i ad l UJ t l 1 >-- CO 2E i ad i O f * .*11 l 2d Ui o <r j <r 1 !-- 1 UJ f QC l o o i :3 1 1 tAl o1> n C4M 004 'O ^On 0*4 ^44 444 444 UJ UJ CO UJ 4C <CU4 CO CO CO y*|U***fe :fc. l VAB.0001189768 ADMTNTSTBATIVB SERVICES - D. A. Barclay Safety There were no reportable safety instances this month. Quality All natural teams met in February. Processed Processed Invoices Working Fund Checks Written Cost Savings Through Bid Process Raw Material Purchase Orders Issued MRO/AFE Purchase ORders Issued Spare Parts Purchase Orders Issued Packaged Finished Goods Ending Inventory Month 1008 7 $2899 100 199 166 Y.T.D. 6131 69 $20396 535 1232 1170 Feb.. 1991 Compound "A" Grade PLENEX Compound Off-Grade (BC) Compound Off-Grade (H) Millscrap(*) Dry Blend "A" Grade Dry Blend Offgrade Resin Type I Resin Type "BC" Vacuum Dust Total Packaged Warehouse 4,054,762 64,682 734,449 73,172 132,457 312,968 44,605 636,800 37,600 6,418,636 * Includes PLENEX millscrap and cleanout. Bulk Finished Goods Ending Inventory Feb.. 1991 Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade Total 1,774,593 368,450 1,550,810 1,057,260 5,926,350 ____58Q.250 11,257,713 (Decrease) 4,091,582 74,019 736,079 82,772 69,916 309,147 42,805 574,450 37,500 6,344,493 55,769 9,337 1,630 9,600 <62,541> < 3,821> < 1,800> <62,350> < 100> < 918> <55,194> Mar.. 1991 1,422,788 177,500 2.185.510 873,660 7.809.510 1.189.150 13,658,118 (Decrease) < 351,805> < 190,950> 634,700 < 183,600> 1,883,160 608.900 2,400,405 tn to to i to oi i to g IIII MI It CO IIII HH II IHI to wo s J3 u*n cu i*j r -> 13C1( rC"** r **4 'm IB* tMIMMlMMMOTWiW VAB.0001189770 H|* 1 1 1 1 I 1 ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS MARCH 1991 -SHIPMENTS BY PRODUCTS- PUBLIC MONTH IPT/ITC EXCN/TOLL RESIN-BULK RESIN-PACKAGED 20,271,760 10,514,800 231,500 126,300 363,900 0 FLEXIBLE COMPOUND-BULK 737,410 FLEXIBLE COMPOUNO-PACKAGED 2,091,821 730,300 0 0 0 NEW BUSINESS 9,722 00 RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED 4,093,190 401,457 345,600 0 0 0 TOLLING - BULK TOLLING - PACKAGED 0 00 0 00 PLASTICIZER TOTAL 130,480 1 27,967,340 84,440 11,001,440 559,650 923,350 YTD PUBLIC IPT/ITC EXCH/TOLL 118,010,754 1,205,683 79,676,270 1,260,900 1,777 ,400 0 4,378,400 15,310,969 6,660,500 711,002 0 0 43,075 00 20,911,890 2,165,691 0 0 3,214,950 521,706 0 0 0 0 1,401 iW AtQ44Q| 33 779, ISO 714,510 3,281 ,760 162,803,012 92,739,838 6,494,720 SHIPMENTS 8Y MOOE BULK: -Nwcir RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER t t i 1 1 1 1 1 RAILCAR CUSTOMER PICKUP 28 0 6 0 COMMON CARRIER 35 5 4 5 TOTAL TOTAL MARCH *YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUNO PLASTICIZER TOTAL YTD PACKAGED MARCH* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER TOTAL MARCH *YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER TOTAL YTD 193 34 49 993 60 138 14 1,205 CUSTOMER PICKUP 2 21 0 0 23 252 0 22 29 303 COMMON CARRIER 9 54 15 0 78 216 20 65 25 326 TOFC AIR/WPS 00 00 00 00 00 AIR/UPS 2 5 0 0 7 22 69 0 0 129 388 0 0 6 78 0 0 0 100 157 536 0 0 30 61 3 0 94 276 1,461 80 225 68 1.834 TOTAL 13 80 15 0 108 121 578 87 1 787 CC: DAB,TLC,AEV,JRF VAB.0001189771 1000 03/90 06/90 07/90 06/90 11/90 01/91 03/91 04/90 00/90 00/90 IQ/90 12/90 02/91 PKG'D PRODUCTS INVENTORY pp WWWWMWNM* VAB.0001189772 ftc IAP<mWm - J. M. Edwards, Jr. A. Safety There were no safety incidents in the Laboratory during March. The monthly safety meeting topic was "Lead Handling in the Lab" taught by Jim Edwards. B. Customer CoRttCtt There were three customer contacts made in March. John Irvine, Rendell Newton, Mark Eramo end Jim Edwards visited KlocknerPentaplast, American Mirrex and FVC Container Corporation. We met with Odell Sargent and Louie Pritchett at Klockner on 3/26/91. We discussed product quality and specific improvements that are needed in contamination, fiber and gel count. Action steps were also discussed to locate sources of line streamers. We met with Lynne Webb, Dave Pullin, John Blum and Ronnie Foster at American Mirrex on 3/27/91. Vista's 5305 contamination count was compared to Oxy's equivalent. 5305 has approximately twice the contamination as Oxy's resin per the Syntron method. Mirrex is also concerned about fibers and line streamers. We met with John D'Avella from PVC Container and Frank Pallante, Bill Gibby and Phillip Friedman from Novatec Plastics on 3/27. They like Vista's 5265 for bottle manufacturing and compare it to Georgia Gulf and Pac West as a good alternative except for color. In 16 to 18 mil bottles, the throat at the top turns slightly grey using 5265. It takes three times the amount of blue toner to com pensate for the grey. R&D in Austin will identify the source of the greying. C. Customer O.C. Problem Reports and CNR's 03/06 American Customer complained of two separate incidents of high moisture and yellow discoloration with Vista 5305 and 5265 resin. The 5265 complaint was from material that had set in their silo a long t ime and had collected toisture at the bottom outlet. The 5305 complaint was from a compartment in railcar GACX 73381 traced to a dryer start up. John Olson wrote a letter to Mirrex addressing the wet 5305 issue. Continued Continued 3/07 Customer complained of higher than normal contamination in two compartments of 5305 railcar VIPX 45747. During the 3/27 visit, a statistical analysis was presented to Dave Pullin and Lynne Webb showing that although the numbers looked high, they were within specification and within our upper control limit. They agreed but said that our con tamination was twice as high as the competi tion's . 03/08 Customer complained of getting poor service at the loading dock in terms of scheduling a pick-up and expediency. Don Barclay's in vestigation showed several instances of miscommunication which caused the problems. Future pickups should run smoother as a result of the CNR. A truck of 5385 sent to Textileather for evaluation failed their contamination specification. After further conversation and testing, it was learned that they need very low contamination 5385 (10/50 max). The replacement truck and the truck that followed ran very well for them. 3/27 Customer complained of contamination in 38601 black compound causing excessive screen pak changes. Samples of the screen pak showed uncrushed crystals of calcium carbonate during a preliminary investiga tion. Samples were forwarded to R&D Analytical in Austin for confirmation. American Mlrrex. News Castle. DE The "A" compartment hatch was open on 5265 railcar UTCX 46442 as it arrived at the CSX terminal. The latch mechanism had vibrated loose during transit. This compartment was withheld from shipment to Mirrex. VAB.0001189774 I ^v. f-ABOBATopy - Continued D. Product Waivers Eagle 80273G WHT 110 Eagle 80273G WHT 110 Eagle 80273G WHT 110 Vinyl Building RP-20 WHT 121 Products Color 1 R/C Long Stab. & 40 Mesh 1 R/C High Eq. Torque 1 R/C Fusion Torque 1 R/C Western Ag. E. PVflM 80273G WHT 110 40 Mesh 2 R/C RVCM of The following is a summary of residual VCM results on in- process samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of March, 1991. Number of Samples Average RVCM, ppm Reactor Slurries ________Drier 5265 5305 26 0.271 49 0.208 The following is a summary of the residual VCM analysis of shipment samples for the month of March, 1991. Product Number of Samples 5265 5305 5385 5395 5415 Debox Dry Blend 48 66 49 28 46 16 24 0.114 0.112 0.379 0.022 0.066 0.280 0.150 Mi m I m WWPf VAB.0001189775 Continued Resin (based on dryer "regulars") 5265 mi 5385 51i Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle size, microns 1.19 0.49 -- 3,72 3.67 1.89 1.33 -- 1.21 -- -- -- 151 0.94 0.89 0.56 1.83 8.67 3.67 3.75 -- 2.67 -- -- -- 158 1.13 0.56 -- 2.07 -- 1.78 3.00 -- 3.02 -- -- 58.8 186 1.19 0.64 -- 1.89 -- 5.00 1.71 -- 2.21 3.65 -- 0 1.67 5415 1.12 0.70 ------ ---- - 3.00 ------ ------- - 2.67 3.75 1.25 6.41 4.26 1.96 0 191 Hardness Color Hard Particles Heat Stability Contamination Dispersion Dicing Cross Contamination Mischarge Total Adjustments M Lbs. (%) 7.0 90.0 -- 7.0 ------------------------- -- <0.21> <2.72> -- <0.21> -- -- -- __ZJ2 <0.21> 111.0 <3.35> fon--ry Rejections M Lbs. (%) .... 37.5 14.4 -- 4.5 10.1 14.5 3.2 _2jJ> 93.7 __ <1.13> <0.43> ----- <0.14> <0.31> <0.44> <0.10> <0 29> <2.83> Color 40 Mesh 19.5 3.5 <0.37> <0.07> I. Miscellaneous 1. All six natural teams met during the month. 2 "D" shift made their presentation to management. Their project was to re-arrange lab furniture and equipment to enhance testing efficiency and reduce steps (walking). 3 The software program 4. Precision studies were done on the new viscosity testing equipment. VAB.0001189776 SAMPLE SHIPMENTS MARCH 1991 A RESIN Ship Date 3/01/91 3/01/91 3/05/91 3/08/91 3/11/91 3/18/91 3/20/91 Product 5265 5385-1 5385-3 5415 5325 5305 5265 5385 5415 5265 5415 5385 * 5385 Amount Customer 3X1 lb. 3x1 lb. 3 X 1 lb. 3 X 1 lb. MULANOVICH REPRESENTACIONES (PERU) 4 X 50 lbs. Premier Polymers 50 lbs. Burton Rubber Company 50 lbs. 50 lbs. 50 lbs. Uniroyal Chemical 5 lbs. 5 lbs P* D. I. Inc. 25 lbs. 10 kg FABRICA ARGENTINA ALPARGATAS ALPARGATAS S.A.I.C. (Argentina) COMPOUND Ship Date 3/06/91 3/07/91 3/08/91 3/11/91 3/13/91 3/15/91 3/20/91 3/20/91 3/21/91 Product 35852 NAT 02 462-83A NAT 462-83A NAT 38931 WHT 810(00) 45541 NAT(OO) 419-50-A 58162 NAT 55041 CB 50 54331 CB 50 17462 GRY 545 58162 GRY 545 Amount 1500 lbs. 1400 lbs. 100 lbs. 50 lbs. 50 lbs. 5x5 lbs. 200 lbs. 300 lbs. 1300 lbs. 200 lbs. 200 lbs. Customer Savannah Wire & Cable Co Automotive Industries Americhem Inc. AFC Furon Company Associated Plastics Anchor Wire Corp. Tandy Wire & Cable National Door VAB.0001189777 COMPOUND (Cont.) Ship Date Product 3/22/91 18831 WTCL 3/25/91 452-116A WHT DRYBLEND Ship Date 3/08/91 3/13/91 3/19/91 Product 80273G WHT 110 80273G WHT 110 489-98 WHT 125 PLASTICIZER Ship Date 3/26/91 Product mm 108P MI SC. Ship Date 3/08/91 Product Vent Dust Sample Shipments/March 1991 Pacte 2 Amount 100 lbs. 1400 lbs. Customer QUIMBOL SA (Bolivia) Sunbeam - Northern Amount 1190 lbs. 1 lb. 35100 lbs Customer Available Plastics LAJA LTDA. (Uruguay) Vinyl Building Products Amount 2 gal. Customer Blane Polymers Amount 10 lbs. Customer Wexford International VAB.0001189778 ABERDEEN CHEMICAL PLANT CUMULATIVE RECORDABLE INJURES QC Ld A Oct Nov Doc Jan Fob Mar Apr May Jun Jul Aug Sep MONTH WORST (1985) --BEST (1990) 1991 MONTH Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep TOTALS ABERMH't OSBA RECORDABLE INJURIES FECAL YEAR 1985 1986 1987 1988 1989 1 3000 02 100 1 00 1 2 20 100 20000 0 1300 00 1 0 1 30023 1 0000 21 113 12110 0001 0 1990 1 1 0 1 0 0 1 0 0 0 1 0 1991 0 3 1 0 1 1 VAB.OOOl189779 ABERDEEN ENERGY CONSUMPTION B T U /L B an/rue VAB.0001189780 MONTHLY MONTH --------- 12 MONTH AVERAGE f *