Document zoV4wQOo7OexJMzLEgBabX5Zm

1983 Executive Tour Aberdeen Chemical Plant Aberdeen, MS 1983 ANNUAL REVTFW ABERDEEN CHEMICAL PLANT MARCH 15. 1983 TOPIC I, SAFETY II, ENERGY CONSERVATION III. EMPLOYEE EXPOSURE ABATEMENT IV. CASH FLOW PROGRAMS V. MAINTENANCE IMPROVEMENT PROGRAM VI. EMPLOYEE TRAINING VII. PRODUCT QUALITY PROGRAM VIII. COMPOUND/DRY BLEND/PLASTICIZER STUDY PRESENTED BY AL SATHER PAUL KOBER PETE MARKEY JOE HIGGINBOTHAM RICK SNOWDEN PETE MARKEY RANDELL JACKSON DICK FROHREICH DTH 000099819 DTH 0000998 INJURY FREQUENCY X1Q0 ABERDEEN CHEMICAL PLANT I)TH 000099821 SAFETY 1982 HIGHLIGHTS X. INJURY TRENDS H. 3 YEARS - NO LOST TIME 1. PROGRAM IMPROVEMENTS A. TEAM INVESTIGATIONS B. SAFETY MEETING RESTRUCTURING C. FOURTH QUARTER SAFETY REVIEW D. EMPLOYEE INVOLVEMENT 1. EMPLOYEE SAFETY ACTION REQUEST (ESARS) 2. PROJECT SAFETY AUDITS W. CONTRACTOR PROGRAM A. GENERAL SERVICES CONTRACT B. CONTRACTOR SAFETY ORIENTATION C. SAFETY MEETINGS DTH 000099822 -SAFETY 1983 PLANS l. TRAINING - SAFETY MEETING H. EMPLOYEE ENVOLEMENT/ DEPARTMENTAL EMPHASIS A. ESARS / SAFETY AUDITS B. DEPARTMENTAL PROGRAM HIGHLIGHT m. CONTRACTOR PROGRAM A. CONTRACTOR ORIENTATION/ACCESS CONTROL B. PLANT SAFETY EL FIRE PROTECTION A. IMPROVEMENT PROJECT B. P.M. PROGRAM DTH 000099823 DTH 000099824 ENERGY PERFORMANCE HISTORY - TEN YEAR PERFORMANCE - 1982 PERFORMANCE - 1981 vs 1982 DTH 000099825 DTH 000099826 1982 BUDGET vs 1982 PERFORMANCE ABERDEEN CHEMICAL PLANT 1982 BUDGETED ENERGY PERFORMANCE (PRODUCTION BASIS=454.2 MM LBS.) PRODUCT MIX EFFECT PRODUCTION LEVEL EFFECT V-ll CENTRATE PROJECT DELAY V-10 CENTRATE HEAT RECOVERY FLUID BED ECONOMIZER INCREMENTAL MMM BTU/YR. % %ADJ. CMA 42.1 17.4 24.4 13.4 3.8 (3.8) (0.9) (1.2) (0.7) (0.2) 0.2 ENERGY CONSERVATION ADMINISTRATIVE PROGRAMS 1. STEAM LEAK REPAIR PROGRAM, STEAM TRAP SURVEY PROGRAM, INSULATION PROGRAM 2. REDUCED AIR COMPRESSOR USAGE 3. REDUCED COOLING TOWER PUMP USAGE (5.7) 02.3) (19.7) 1982 ACTUAL ENERGY PERFORMANCE (ACTUAL PRODUCTION = 406.4 MM LBS.) 0.3 0.6 1.0 41.2 DTH 000099827 1981 - 1983 DTH 000099828 A 1983 PLANS REDUCED OPERATION PLAN BOILER OPERATION AIR CONSERVATION DRYER IMPROVEMENT CAPITAL PROJECTS DTH 000099829 ENERGY CONSERVATION FORECAST - 1983 1982 ENERGY REDUCTION vs 1972 (CM A ADJUSTED BASIS) INCREMENTAL MMM BTU/YR. % 1983 CHANGES vs 1982 PERFORMANCE V-ll CENTRATE HEAT RECOVERY (7 MONTHS) BOILER BLOWDOWN HEAT REC. (4 MONTHS) V-10 CENTRATE HEAT RECOVERY(6MONTHS) FLUID BED ECONOMIZER (6 MONTHS) COLD WATER RINSE (3 MONTHS) 33.4 2.7 4.2 3.6 6.0 1.8 0.2 0.2 0.2 0.3 % ADJ. CMA 41.2 ENERGY CONSERVATION ADMINISTRATIVE PROGRAMS 8.0 1.STEAM LEAK REPAIR PROGRAM, STEAM TRAP SURVEY PROGRAM, INSULATION PROGRAM 0.4 1983 BUDGETED ENERGY REDUCTION 44.3 DTH 000099830 DTH 000099831 ABERDEEN PLANT EMPLOYEE CHEMICAL EXPOSURE REDUCTION PROGRAMS I.1982 & 1983 Y.T.D. Exposure Statistics A. VCM B. Lead C. Particulates D. Other Sampling II. VCM Exposure Problem Area & Programs A. Employee & Supervisory Awareness B. Employee Training C. Detection Problems D. Equipment Related Problems III. Capital Project Work A. Recovery System Revisions B. Experimental RVCM Backflush Filter C. Exposure Reduction Project D. Emission Recovery System Upgrade E. 1984 Capital Projects Under Study IV. Overview A. Where We Are B. 1983 Goals DTH 000099832 1982 & 1983 Y.T.D. PERSONNEL DOSIMETRY DATA VC M % PERSONNEL DOSIMETERS ABOVE PEL 1st 6-MONTHSr1982 2nd 6 -MONTHS, 1982 11.4 8.4 JANUARY, FEBRUARY 1983 8.2 % OVEREXPOSED W/OUT RESPIRATORY PROTECTION 6.3 4.6 1.0 l EAD 1st 6-MONTH5,1982 2nd6-MONTHS, 1982 JANUARY, FEBRUARY 1983 5.3 4.0 3.4 PARTICULATES 1st 6-MONTHS, 1982 2ND6-MONTHS, 19 82 JANUARY, FEBRUARY 1983 5.1 4.0 0 0 0 0 0 0 0 DTH 000099833 CKM O a LLI __l a. < co 1982 VC M OVEREXPOSURE LEVEL OF VCM EXPOSURE (PPM) Sil3i3WISOa 13NNOSd3d 30 % DTH 000099834 VCM EXPOSURE REDUCTION TASK FORCE SAFETY OPERATION MAINTENANCE ENGINEERING DTH 000099835 VCM EXPOSURE REDUCTION EMPLOYEE & SUPERVISOY AWARENESS EMPLOYEE TRAINING DETECTION PROBLEMS EQUIPMENT RELATED PROBLEMS DTH 000099836 VCM EXPOSURE REDUCTION EMPLOYEE & SUPERVISORY AWARENESS IMPROVING LEAK RESPONSE GETTING LEAKS REPAIRED ON A TOP PRIORITY BASIS UPGRADING VCM EXPOSURE PRIORITY WITH RESPECT TO OTHER PRIORITIES DEMONSTRATING MANAGEMENT COMMITMENT DTH 000099837 VCM EXPOSURE REDUCTION EMPLOYEE TRAINING 12 HOUR JOB STUDIES, ONE ON ONE. JSA's & PROCEDURE IMPROVEMENTS. MECHANICAL SEAL TRAINING. PORTABLE VCM DETECTOR TRAINING -- OPERATORS. ----- I&E PERSONNEL. FIXED POINT MONITOR TRAINING --I&E PERSONNEL. DTH 000099838 VCM EXPOSURE REDUCTION DETECTION IMPROVEMENTS INVESTIGATING ALTERNATE PORTABLE MONITOR RESOLUTION OF FIXED POINT MONITOR COMPUTER PROBLEMS -- COMPUTER PROBLEMS. --BEACON ALERT PROLEMS IMPROVEMENTS TO FIXED POINT MONITOR --VCM TANK FARM TUBING. ROUTINE LEAK SURVEYS --WEEKLY SURVEYS --6-MONTH COMPREHENSIVE SURVEY. -- LEAK RESPONSE. SPECIAL DOSIMETRY STUDIES --PERSONNEL UNLOADING VCM CARS. -- SPECIFIC JOBS (l.E. FILTER PACK CHANGES, CONDENSER CLEANINGS) DTH 000099839 VCM EXPOSURE REDUCTION EQUIPMENT RELATED PROBLEMS VALVE & PIPING RELATED PROBLEMS --VALVE CHANGE OUT ACTIVITY. -- IMPROVE IN-HOUSE VALVE REBUILDING TECHNIQUES. "IMPROVE VALVE TO FACILITATE ON-LINE LEAK REPAIR. -- USE OF "LEAK REPAIR" CONTRACTOR. -- IMPROVED SHOP TEST PRIOR TO FIELD INSTALLATION. -- IMPROVE REACTOR HYDRO TEST. -- PLAN TO DEVELOP ON-LINE PIPING MANIFOLD TEST PROGRAM. -- DEFINE MEANS OF POSITIVE VALVE POSITION INDICATION. MECHANICAL SEALS SYSTEM IMPROVEMENTS OPERATOR TRAINING DTH 000099840 1982 ABERDEEN PLANT VINYL AREA VALVE CHANGE OUT AC TIVITY i 100-L -o4 o o 00 O "t o CN X 3Q NI A1IAI1DV IPO 3GNVHD 3A1VA ONITlOa H1NOW-C DTH 000099841 VC M EXPOSURE REDUCTION CAPITAL WORK recovery system revisions EXPERIMENTAL RVCM BACKWASH FILTER VCM EXPOSURE REDUCTION PROJECT EMISSION RECOVERY SYSTEM UPGRADE $402,000 CAPITAL, AFE 9771 CONSTRUCTION IN PROG. EST. COMPLETION 4thQRT.1983 TEST PACKAGE, Ml SC. UNDER $15,000 ENGINEERING COMPLETED EST. COMPLETION 3rdQTR.1983 $96,000 1983 CAPITAL BUDGET AFE 3RD QTR. 1983 $325,000 CAPITAL EST. COMPLETION DEC. 1983 POTENTIAL 1984 EXPOSURE REDUCTION PROJECTS VCM TANK FARM UNLOADING COMPRESSOR REPLACEMENT ADDITIONAL FIXED POINT MONITOR DTH 000099842 1983 GOALS Q i-- >co CO CN & < O om co co CN o CN CO O' O' o z z a h- LU OC O Oa CQ << < > LU a, < u + CO 00 LU O' LU " QC u_ D LU uo Z om U a. cq LU I-- LU^ o QC Q_ >QC OH- < O' LU I) LU CO ^ ^> LcUn QO UJ CQ LU CO Q LU QC - O 2 LU Q OC LL. S3 !3o X -Z LC q/ CO 00 co < "J z Lu O o "2 >- CQ o V < < Q_ 0 CO ea uz 3 < z < U_ u X ou CO < 3Z O^ Sis DTH 000099843 DTH 0 0 0 0 9 9 8 4 4 2co CO o LU oQ GQ o Q. uz> u D Q LU <LU OL < UJ LU Q C 2 O' ID CO 2 O 2<> LU 2O X <Q_ Q a. u oLU 3 LU Q LU O % LU u> DTH 000099845 CASH FLOW IMPROVEMENT 1982 Results A. Fixed Costs 1. Payroll and Benefits 2. Maintenance Materials and Contracts 3. Other B. Variable Costs Efficiencies 1. Product Mix 2. Utilities 3. Raw Materials and Offgrade C. Inventories 1. 739 2. 744 D. Capital Expenditures 1983 Projections A. Fixed Costs B. Variable Costs Efficiencies C. Inventories D. Capital Expenditures DTH 000099846 1982 CASH FLOW IMPROVEMENT RESULTS ABERDEEN CHEMICAL PLANT CATEGORY FIXED COSTS VAR. VARIABLE COST EFFICIENCIES VAR. IMPROVEMENT TARGET $712 (1582) INVENTORIES COMBINED DEVIATION FROM 12/82 TARGET 0 CAPITAL EXPENDITURES VARIANCE FROM P.O. 3237 TOTAL CASH FLOW IMPROVEMENT $2367 $M 1982 ACTUAL $856 (760) (4) 5639 $5731 VARIANCE FROM TARGE $144 822 (4) 2402 $3364 DTH 000099847 1982 CASH FLOW IMPROVEMENT RESULTS ABERDEEN CHEMICAL PLANT FIXED COSTS VAR. ($ Ml COMPONET TARGET PAYROLL & BENEFITS MAINTENANCE MATERIALS & CONTRACTS $407 289 OTHERS 16 ACTUAL $809 218 (171) TOTAL FIXED COSTS $712 $856 VARIANCE $402 (71) (187) $144 DTH 000099848 1982 CASH FLOW IMPROVEMENT RESULTS ABERDEEN CHEMICAL PLANT VARIABLE COSTS EFFICIENCY VAR.(SMI COMPONENT PRODUCT MIX UTILITIES RAW MATERIAL & OFFGRADE TARGET $(1645) 0 63 ACTUAL $(870) (64) 174 VARIANCE $775 (64) m TOTAL VARIABLE COSTS EFFICIENCI ES $0582) $(760) $822 TYPE PIPE FITTINGS RP-1 00 DRY BLEND PRODUCT MIX BUDGET MM# ____& 40.0 80 5.0 10 5.0 50.0 10 100% REFORECAST .MM.___ %. 25.5 49.0 20.0 38.5 6.5 5 2.0 12.5 100.0% ACTUAL -MM*. % 23.6 56.5 16.0 38.3 2.2 41.8 5.2 o oo DTH 000099849 1982 CASH FLOW IMPROVEMENT RESULTS ABERDEEN CHEMICAL PLANT INVEN TORI ES ($M) COMPONENT 0739(MAINTENANCE & OPERATING SUPPLIES) 0744 (RAW MATERIALS & PROCESSING SUPPLIES) TARGET $1410 1374 ACTUAL $1708 1080 TOTAL INVENTORIES $2784 $2788 VARIANCE $(298) 294 000099850 dth 1982 CASH FLOW IMPROVEMENT RESULTS ABERDEEN CHEMICAL PLANT TARGET $ 7099 CAPITAL EXPEN PIT UR ES($M) ACTUAL $4697 VARIANCE $2402 CAUSES OF INCREASED SAVINGS: ADDITIONAL DEFERRALS NOT APPROVED OR BEHIND SCHEDULE MATERIAL DELAY UNDER/OVER RUNS (NET) ESTIMATING ERRORS $ 875 362 247 676 2.4 2, $ 2402 DTH 000099853- 1983 CASH FLOW IMPROVEMENT PROJECTIONS FIXED COSTS PAYROLL & BENEFITS MAINTENANCE MATERIALS & CONTRACTS $M $200 0 VARIABLE COSTS UTILITIES RAW MATERIAL & OFFGRADES INVENTORIES-COST SAVINGS ON PURCHASES FROM FROM FROM 1982 ANALYSES 1982COMPETITIVE 1983COMPETITIVE QUOTES QUOTES CAPITAL EXPENDITURES 100 350 80 100 150 2205 DTH 000099852 DTH 000099853 MAINTENANCE IMPROVEMENT DTH 000099854 WHERE WE ARE WHERE WE NEED TO BE HOW WILL WE GET THERE WHERE WE ARE DTH 000099856 INCREASING COMPLEXITY OF EQUIPMENT LITTLE FORMAL TRAINING OPERATORS MECHANICS E.& I. TECHNICIANS DTH 000099857 SUPERVISORY SKILLS BEST ROTATING EQUIPMENT MECHANIC BEST GENERAL MECHANIC BEST ELECTRIC! AN DTH 000099858 WHERE WE NEED TO BE DTH 000099859 OPERATORS MECHANICS MECHANICAL TRAINING INTRUMENTATION TRAINING FORMAL IN-HOUSE TRAINING SUPPLEMENTAL OUTSIDE TRAINING E&l TECHNICIANS FORMAL IN-HOUSE TRAINING < SUPPLEMENTAL OUTSIDE TRAINING SUPERVISORS RESOURCE MANAGEMENT PLANNING DTH 000099860 HOW WE WILL GET THERE DTH 000099861 ELECTRICAL & INSTRUMENTATION THREE PRONGED ATTACK IMPROVE GENERAL SKILL LEVEL OF TECHNICIANS IMPROVE SKILLS IN PARTICULAR HIGH RISK AREA IMPROVE INSTRUMENTATION SKILLS OF SUPERVISOR DTH 000099862 GENERAL SKILL LEVEL TPC IN-HOUSE COURSE - 200 HOURS TAUGHT BY SUPERVISOR AND E& I ENGINEER RECOMMENDED BY MED AND DUPONT INSTRUMENT TRAILER (TAILORED FOR ABERDEEN) HIGH RISK MODICON SCHOOL ANALYZER SCHOOL SUPERVISORY SKILLS INSTRUMENTATION FOR ENGINEERS T PC COURSE PERSONAL INSTRUCTION JIM BROWN - MED RANDY POLK- PLANT ELEC. ENG. DTH 000099863 SUPERVISORY SKILLS CRAFT DELAY STUDY- MED SUPERVISORY STUDY- MED WORK PLANNING AND RESOURCE UTILIZATION - MED (TAILORED FOR ABERDEEN) DTH 000099864 WORK PLANNING DEFINING STEPS TO MAKE A SUCCESSFUL PLAN MAKING A PLAN MONITORING THE PLAN ONE-ON-ONE INSTRUCTION WITH PRACTICAL FEED BACK DTH 000099865 MANAGES PRODUCTIVITY, NOT PRODUCTION MAXIMIZES UTILIZATION OF MECHANICS ENHANCES EFFECTIVE USE OF THE BACKLOG USED SUCCESSFULLY WITH BROWN & ROOT AT CHOCOLATE BAYOU DTH 000099866 PREVENTIVE MAINTENANCE AUTOMOTIVE FIRE PUMPS dth 000099867 MAINTENANCE AS A CONTINUING INVESTMENT DTH 000099868 DTH 000099869 ABERDEEN PERSONNEL TRAINING & DEVELOPMENT PROGRAM I. Plant Hourly Employee Profile A. Department Breakdown B. Years of Service C. Education Levels D. Area Culture and Work Ethic II. New Employee Screening, Selection and Training Program A. Pre-employment Testing B. Interview Process C. Orientation D. Probationary Period III. Training Problems, Programs, & Philosophy A. Training Problems and Approach B. Safety C. Orientation D. Maintenance E. Laboratory F. Plant Wide IV. Overview A. Comprehensive Program Definition DTH 000099870 ABERDEEN HOURLY PERSONNEL PROFILE X)1H 0 0 0 0 9 9 8 7 1 NEW EMPLOYEE APTITUDE TESTING BENNETT MECHANICAL COMPREHENSION RBH TEST OF LEARNING ABILITY RBH SHOP ARITHMETIC DTH 000099872 NEW EMPLOYEE ATTITUDE TESTING INTERVIEW PERSONNEL DIRECTOR INTERVIEW DEPARTMENT HEAD INTERVIEW 2nd LEVEL SUPERVISOR DTH 000099873 ABERDEEN PVC PLANT NEW EMPLOYEE SAFETY ORIENTATION TRAINING CHECKLIST (1) ABERDEEN SAFETY ORIENTATION SHOW (2) HEALTH SHOWS: VCM LEAD TOSCA (3) SAFETY RULE BOOKS: CONOCO ABERDEEN (b) DuPONT SAFETY ORIENTATION (#500) (5) LIFTING: NSC BOOKLET DISCUSSION (6) FORKLIFT TRAINING: SHOW FIELD (7) ELECTRICAL LOCKOUT: ALLIED CHEMICAL FILM REVIEW OF ABERDEEN LOCKOUT PROCEDURE (8) RESPIRATOR TRAINING: SCOTT AIR PACK FRESH AIR DUST (9) EQUIPMENT ENTRY: CHARTER OIL FILM REVIEW OF ABERDEEN ENTRY PROCEDURE (10) PICTURES TAKEN (11) SAFETY EQUIPMENT ISSUED (12) ALL QUIZ SHEETS CORRECTED AND ATTACHED (13) INTRODUCTION TO PLANT MEDICAL TRAINEES (1) (7) (2) (8) (3) (9) (A) (10) (5) (10 (6) (12) DATE: DTH 000099874 APPRAISAL CHECK LIST Attribute Exceptional (Excel lent. Approaches Best Possible) Good (Above Stand ard) Averaqe (Meets job re quirements; Standard) Fair (Below stand ard; Improve ment Needed) Unsatisfactor> (Deficiency may justif terminatio SAFETY Knowledge, attitude & practice of safety rules Automatically works safety into job. Pro * motes safe practices. Works safely. Sets good Example. Reasonably Safe Worker Occasional Careless worke lapses in Accident re observing safe peater. rules and practices. i WORK ATTITUDE General at titude toward job, company, & supervisor. Displays ex traordinary enthusiasm and cooper ation. Shows con siderable interest 4 cooperation. Shows Inter est 4 cooper ation normally expected. Occasionally appears in different. Works half heartedly. No Interest In performing job Limited cooper ation. j-- INITIATIVE Ingenuity, self-reliance resourceful ness, In doing the job. QUANTITY Volume and rate of work handled. Com pare with others on same job. OUALITY Accuracy & thoroughness of work. Con sider supervision required. JOB KNOWLEDGE General knowledge of job. ABILITY TO LEARN Ability to learn & re tain new ideas,ability to do unre lated tasks. ATTITUDE TOWARD OTHERS Willingness to work as team member. Self-starter: Resourceful, Seeks addi looks for tional tasks; shortcuts to suggests im improve his provements. work. r Demonstrates unusual speed, volume & capacity for work. Fast, efficien t; output exceeds job require ments . Unusual ac curacy; ex pert work manship. . High quality work; thorough 4 neat. Does regular work without direction; occasionally suggests changes. | Output satis fies job requirements. Follower: Sometimes needs proding. Usually waits to be told; needs constant supervision. rr Output be low normal job requirement. Very slow work er; wastes time; output inadequate. r1 Work satis fies quality requirements of job. Quality be low standard; occasional errors. r Frequent erors made; excessive re work,wasteful . r Exceptionally well in formed. Can Well informed on all phases of job. Knowledge satisfies re- quirements handle com of job. plex jobs. r Lacks requir ed knowledge in parts of job. r Knowledge inadequate. Doesn't know job. rr Excellent; Understands new Understands 4 Instructions Learns very Understands & information retains must often be slowly. Dif applies in structions quickly 4 accurately. instructions adequately. repeated. Learning be ficult to adjust to quickly & ac low standard. changes. curately. r r rr r Unusual abil- Always cooper Normally Sometimes Uncooperative; i ty to. work ative and cooperative. difficult causes dis- with & favor friendly. to work with. sention, upset ably influenc e morale of others. others. j Attendance Includes all aspects such as promptness In returning from breaks. Perfect at Rarely absent; Good attend tendance. always prompt ance. Seldom Never late; in returning requests PB; on the job from breaks. normally early. r r prompt returning from breaks Attendance Poor attendanc record re excessive PB; quires im always late*re provement; turning from Must be re breaks. minded to (-- end breaksJ 1 THE EMPLOYEE MUST BE RATED IN EACH AREA. dTH 000099876 ABERDEEN TRAINING ON GOING TRAINING A LINE FUNCTION DEVELOPMENT OF COMPREHENSIVE TRAINING PROGRAM PRIORITES METHODS TIMING FUNDING DTH 000099877 ABERDEENS BIGGEST TRAINING PROBLEMS VINYL STANDARDIZATION OF METHODS LACK OF FULLY DOCUMENTED PROCEDURES & POLICIES COMPOUND, DRYBLENP, PLASTICIZER STANDARDIZATION OF METHODS LACK OF FULLY DOCUMENTED PROCEDURES & POLICIES MAINTENANCE I & E SKILLS LAGGING BEHIND TECHNOLOGY SUPERVISION, PLANNING & SCHEDULING SKILLS LABORATORY STANDARDIZATION OF TECHNIQUES UNDERSTANDING IMPACT OF QUALITY TEST ON PRODUCT OTHER CROSS TRAIN LNG DTH 000099878 ABERDEEN PERSONNEL TRAINING SAFETY SAFETY SECONDS PROGRAM SERIES ------ ATTITUDE ------ PLANNING ------ HOUSEKEEPING FIRE FIGHTING SCHOOL ------ TEXAS A&M, LAMAR SUPERVISORY 1st AID TRAINING ------ MEDICAL DIVISION DTH 000099879 ABERDEEN PERSONNEL TRAINING OPERATIONS VARIABILITY TEST RUNS ------- VINYL -------COMPOUND OPERATING MANUAL IMPROVEMENTS SPECIAL TRAINING ------ INSTRUMENTATION ------ MECHANICAL SEALS ------- YARD TRAINING TRAINING METHODS UNDER CONSIDERATION ------ CONSULTANT, MTS ------- API PILOT SERIES BY HOWELL TRAINING EQUIPMENT OPERATION ------- PROCEDURAL SIGNS DTH 000099880 ABERDEEN PERSONNEL TRAINING MAINTENANCE IMPROVE I & E SKILLS IMPROVE MECHANICAL KNOWLEDGE IMPROVE SUPERVISORY SKILLS ------ PLANNING ------ SCHEDULING DTH 000099881 ABERDEEN PERSONNEL TRAINING LABORATORY WORK TOWARD STANDARDIZATION OF TECHNIQUES ------ SUPERVISORY MONITORING ------ VALIDATION STUDIES ------ ROUND- ROBIN TESTING, PONCA , OKC DEFINING HOW THEIR WORK FITS INTO "BIG PICTURE" & FINISHED PRODUCT ------ PRESENTATION TO LAB EMPLOYEES DTH 000099882 ABERDEEN PERSONNEL TRAINING PLANT WIDE SUPERVISOR IDENTIFICATION PROGAM LOOKING FOR IMPROVEMENT METHODS DTH 000099883 DTH 000099884 90 S \ \ COMPLAINT HISTORY \ \ ABERDEEN CHEMICAL PLANT 80' ' 1978 through 1982 \ \ \ \ \' \ \ 70- \ v \ \ \ \ \ 60" 50- 40- 30- 20- 10 PLANT JUSTIFIED COMPLAINTS --------- TOTAL COMPLAINTS O-------- -O I 1978 T" 1979 1980 DTH 000099885 T 1981 1982 SPECIFICATION WAIVER HISTORY WAIVER PER M M LBS SHIPPED RESIN QUALITY/.SERVICE IMPROVEMENT PROJECTS AND NEEDS 1. PARTICLE SIZE 2. CONTAMINATION 3. INDUCTIVE RESISTANCE (ELECTRICAL) 4. OFF- GRADE REDUCTION 5. INVENTORY LEVELS-SPECIALTY RESIN DTH 000099887 COMPOUND/ DRY BLEND QUALITY IMPROVEMENT PROJECTS AND NEEDS FLEXIBLE COMPOUND 1. METAL CONTAMINATION 2. PRODUCT CROSS CONTAMINATION 3. COMPOUND HARD PARTICLE PROBLEM RIGID DRY BLEND QUALITY CONTROL TESTING OF RP PRODUCTS DTH 000099888 PRODUCT QUALITY MEASUREMENT TOOLS 1. COMPETITIVE RESIN SURVEY 2. CUSTOME R COMPLAINTS 3. PRODUCT QUALITY ACCOUNTING a) A- GRADE - PRIME b) WAIVED c) B- GRADE-(OFF SPEC) d) H - GRADE - (OFF SPEC PACKAGED) e) SIFTER OVERFLOW 4. RESAMPLING/ CLEAN- OUT MONITORING PROGRAM 5 . REPROCESSED MATERIAL- COMPOUND B.C. DTH 000099889 DTH 000099890 COMPOUND, PLASTICIZER, DRYBLEND STUDY OBJECTIVES 1- TO DETERMINE THE MANUFACTURING COST OF EACH PRODUCT PRODUCED IN THE COMPOUND, PLASTICIZER & DRYBLEND OPERATION. 2- TO DETERMINE HOW TO BEST SPEND CAPITAL MONEY IN THESE AREAS DTH 000099891 1982 ACTUAL FULL ALLOCATION PLANT FIXED COST X DEPRECIATION __________________ $ M____________________ RESIN 6,92 5 COMPOUND 2,402 PLASTICIZER 516 DRYBLEND 1,078 TOTAL 10,921 DTH 000099892 1982 ACTUAL FIXED COST ALLOCATION COMPOUND/PLASTICIZER BUSINESS PLANT FIXED COSTS X PLANT FIXED COSTS ___________ $ M FULL ALLOCATION 2,918 1,751 INCREMENTAL ALLOCATION 2,7 8 3 893 DTH 000099893 COMPOUND: 00<t 16851CB50 LINE 3 AVERAGE PRODUCTION RATE: 4573 LBS/HR RAW MATERIALS 665 5385 RESIN 631 DOP 815 SOYA EPOXY 397 BAR-CAD-ZINC 327 STEARIC ACID 954 4310-R1 BLUE CENTS/UNIT 17.510 51.210 47.144 95.428 51.426 242.143 UNIT/LB 0.77990 0.17145 0.03126 0.02350 0.00229 0.00020 CENTS/LB 13.656 8.780 1.474 2.243 0.118 0.048 SUBTOTAL PROCESSING GAINCLOSS) H GRADE MILL SCRAP SUBTOTAL ELECTRICITY NATURAL GAS TOTAL VARIABLE COST PLANT FIXED COST EX-PLANT FIXED COST TOTAL FIXED COST TOTAL COST EX PACKAGING PACKAGING COSTS BAGS BOXES BULK TOTAL COST 6.500 6.500 3.886 0.397 1.00860 26.318 (0.00350) (0.0 ) (0.0 ) (0.00510) ( 0.033) 1.00000 26.285 0.19522 0.11482 0.759 0.046 27.089 7.136 4.309 11.445 38.535 1.695 2.601 0.0 0.03680 0.0 0.96320 0.062 0.0 0.0 38.597 DTH 000099894 NO. 3 4 0 -1 0 D IETZG EN GRAPH PAPER D IE T Z G E N C O R P O R A T IO N