Document zz0qMRB1zdYodr2YM3dgXyvVn

To: T. H. Huffman Interoffice Communication From: Date: Subject: D. C. Skokna June 15, 1989 ABERDEEN MONTHLY PROGRESS REPORT - MAY, 1989 There were two first aid and three OSHA recordable inj reported in May. The first aid injuries were to a Compound Operator who bruised her foot when she dropped a wooden pallet, and a Mechanic who bruised his knee when a part was dropped from a work table. The OSHA recordable injuries were a Mechanic who pulled a groin muscle when he stepped down from a reactor head to the platform and two Mechanics who were burned on the backs of their legs when splashed with chem wash. As of May 31, 1989, the plant's employees have worked 3,618 days or 4,763,491 manhours since the last lost time injury. Key Statistical Information Mav 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 Costs 37.0 85.8 96.1 1.0121 4.2 93.7 4.2 100.0 1.5 86.1 < 4.0> 9.8 102.2 305.8 90.9 96.3 1.0080 51.3 95.3 41.1 99.7 13.9 91.6 < 4.0> <137.8> 967.1 Fixed costs were essentially at budget. The primary causes of the favorable efficiency variance were better than budgeted VCM usage and product mix effects. QMP Fifty percent of the plant's natural teams met during the month. The first class of SPC expert training was completed in May with twelve successful graduates. VAB.0001190467 fl-r "V v, . . r-r., -I f?ni' t - > s J`-i J ,** r n. * y -r-11.-MI T. H. Huffman 06/15/89 Aberdeen Monthly Progress Report Pace 2 - May, 1989 OMP - continued An action plan was developed in to the recent Wire audit. The plan addresses items and uViara the audit showed we should improve. jpC D. C. Skokna Plant Superintendent rah VAB.0001190468 DISTRIBUTION Houston J. D. Burns R. T. Ferrell COVER LETTER X X ENTIRE REPORT T. H. Huffman X C. J. Matson X D. F. Harman X H. R. Flammer X R. R. Smith X K. J. Eggers X R. H. Gerlach X R. D. Gamblin X Ponca Cltv S. E. McGuire X R. L . Poe X H. J. Hall X Oklahoma Citv H. G. Garrison X LCVCM Plant LCCP Plant R. A. Conrad J. Friend X X LCLAB Plant J. W. Ware X Baltimore L R. Bauer X Hammond J. B. Maher X Blane Premiere Aberdeen C. R. Miller P. L. Foote RWS/DCS (File Copy), PJK, JEN, MRK, DAM, RBN SCH X X A ri'^trLtt ir-i 'PfP= V1 'JF'j.'jJi.ie'i VAB.0001190469 -- I O-l-iis.|-: fl-iiSl-IJSVitli.: JJ.i r^:. : U . . f. bl . H Jj '"|-f:-- :? SAFETY - B. L. Trego, J. V. Uptain Mav Fiscal Y-T.D. 1989 Fiscal Y.T.D. 1988 First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 0 0 2 0 0 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 0 1 4 0 0 0 5 Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 0 0 2 2 1 0 0 5 4 0 3 2 0 0 _l 10 Non-Occupational Injuries Lost Workday Cases Days Lost 0 0 Safety Record Last lost time injury - 7/5/79 Days since - 3618 Employee hours since - 4,763,491 During the month of May, there were two first aid cases and three OSHA recordable cases. The first aid cases occurred when a Compound Operator bruised her foot as she dropped a wooden pallet, and a Mechanic received a bruise on his knee when a part was dropped from a work table. The medical treat lent injuries a Mechanic who pulled a groin muscle while stepping down from a reactor head to the platform, and two Mechanics who received caustic bums to the backs of their legs when splashed with chem wash. VAB.0001190470 SAFETY - Continued A On May 31, 1989, the employees of the Aberdeen Plant completed 3618 days with no lost time injury. Topics for the plant safety meetings during the month included Review of Recent Injuries, Material Safety Data Sheets, Hazardous Materials Handling, and Review of Safe Work Sampling Results. Routine dosimetry results for the month were Chemical VCM Lead Total Particulates <- PEL Number 77 100.0 13 100.0 1 100.0 > PEL Number 0 0.0 0 0.0 0 0.0 Monthlv Iniurv Suramarv Iniurv Class DeDartment FA Compound FA Maintenance MT Maintenance MT Maintenance MT Maintenance Description Contusion of left foot. Contusion of right knee. Strain of left side of groin. Caustic burns of both legs below knees. Caustic burns of both legs and right hip. 'r !:rntTfi.,pnr..`jt " 'T - **f' - 5"^ : ?i--nf ................. VAB.0001190471 :--e* M!' #*! :mins- '-ri 1 : h: IV v.-p:n -V ii-y r-. ; . ,{ ' d : 't .Li i- j -**+-'1. I:x* S' |-! c-i i QUALITY DEVELOPMENT General The first class of SPC expert training was completed in May. Twelve employees committed their time and effort toward improving their knowledge of SPC techniques. The second class of SPC expert training is scheduled to begin in mid-July. A corrective action plan was developed in response to the recent Prestolite Wire audit. The plan addresses items and areas where the audit showed we were deficient. The plan is in final review and will be sent to Prestolite in mid-June. A meeting was held with those who had been trained as team facilitators (eleven total) to determine what resources were needed in order to provide consistent facilitation to teams. An action plan is being developed. M. R. Kane attended the annual American Society of Quality Control Congress. Six natural teams made progress toward developing mission statements this month. Vinvl Department The Vinyl Superintendent's Natural Team met once during the month. The meeting agenda included a review of each of the active employee activities during the month, progress on customer visit, exchange plans, brainstorming ideas for a mission statement, and continued work on key performance area identification and updated capability calculation. There are three active employee teams in the department. Each team met at least once during May, 1989. Process Engineering Department The Chief Process Engineer's Natural Team met in May to discuss status and timing of projects. Both Senior Process Engineers' Natural Teams met in May to work on projects. Several process engineers participated in a team facilitator follow-up meeting to discuss the progress on facilitation of plant natural and project teams. Shoo Utilization Team The Shop Utilization Team met in May to review the two plans the separate groups came up with. The team is requesting preliminary cost estimates for each plan so they can decide which plan is more attractive with respect to space availability and costs. The team will schedule another meeting as soon as the estimates are available. VAB.0001190472 QUALITY - Continued Plant Manager The Plant Manager's Natural Tea met once this month. The purpose of this was to review the progress on the major feedback items from the first series of QMP Managers Meetings. A r fa: li .. iiirr.- ij...............................................!$*[**. I "** TMTT n.| tfia I IP* ttlirj iMtj-Xf tfitt <&=* T'- VAB.0001190473 ,T. . .....................-ithS'-'l* Kit'- .1 1 A- - . il-T-1" I r--- - y -fr -h -* ' ."Hr COST VARIANCES - D. C. Skokna Variable Costs Product PVC Flexible Compound Rigid Compound Plasticizer Mav. 1989 Variance. $M Efficiency Pyice Total $ 56.1 (10.0) 49.8 6.3 $102.2 $ 726.4 152.0 195.1 30.6 $1104.1 $ 782.5 142.0 244.9 36.9 $1206.3 PVC - VCM use was below budget and the variance attributed to product mix was favorable. Flexible Compound - The variance was essentially at budget. Ripid Compound - The month's favorable variance is primarily due to product mix. Plasticizer - The variance was essentially at budget. Price Variances VCM Resin to Compound Alfol* 610 610P to Flexible Compound Pthallic Anhydride Other Price Variances Total Fixed Cost Variances - Payrolland Benefits - MM&C - Miscellaneous - TI&D - Clearances Total $749.4 299.2 40.6 16.7 (22.7) 20.9 $1104.1 $M ($63.9) 59.7 27.3 ( 11.6) ( 1.7) $ 9.8 VAB.0001190474 COST VARIANCES - Continued Payroll and Benefits - was above budget due to the holiday and benefits being above budget. M. M. & C. - was below budget due to low contractor activity. Miscellaneous: - Outside Professional services - T&E - Moving/Home Assistance $16.OM ($12.8M) $20.4M A -t>r 1 -.1- h!?i ft;^gha5milWilil>pmUMHrT1 i^.-H wu-pi^am-d-bait 1 - i- - r VAB.0001190475 't j.'Mia tj{. .1 JiJ'-iI tUnL . . M-lriL^L ______________ AND MECHANICAL DEPARTMENTS - P. J. Kober, D. A. Miller J. E. Nickerson Mechanical Safet There were three medical treatment cases and two first aid cases in the Operations/Mechanical Departments this month. The first aid injuries involved a Mechanic who received a bruise on his knee when a part was dropped from a work table, and a Compound Operator who bruised her foot handling a wooden skid. One medical treatment case occurred when a mechanic stepped off a reactor head down into the platform (about a two foot step) and strained a groin muscle. The other two medical treatment cases involved a Mechanic and an Instrument Tech who were sprayed with chem wash rinse water solution and received minor first and second degree chemical and thermal burns to the legs. The investigation of this accident is in progress and will be complete in June. The monthly safety meeting covered safe handling of hazardous chemicals. The meetings included a film covering general topics and discussion on specific hazardous chemical concerns for the various departments and areas in the plant. VINYL - P. J. Kober, C. J. McDonald General Production was limited due to inventory control measures and VCM availability. When possible, downtime was used for maintenance 2. A new 5415 dryer cleaning program was instituted in response to a customer problem. 5415 dryers are now cleaned every three days. The resin raw materials in the 744 account were valued at $374.9M. Mav YTD - Production, MM Lbs. - Daily Rate, M Lbs./C.D. - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor(#4-#8), % - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime 37.0 1194 875 28.2 85.8 59.7 97.8 96.1 305.8 1258 7217 29.7 90.9 74.6 96.3 96.3 Reactor Downtime Hours Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks, new module rinse/charge water conflicts, waiting on QC data before charging, no place to dump, and inclement weather). 198.3 Maintenance downtime (hydroblast D744 and D745 reactor shells and condensers, repair D400 agitator seal, repair D741 and D742 agitator gearboxes, repair new unit reactor evacuation steam jets, replace D743 condenser gasket, change screens in old unit dump screener, D744 agitator motor repairs, and miscellaneous instrument and valve repairs). 279.0 Other downtime (reactors were idled to reduce finished product inventories and because of VCM availability). 581.1 A r -:l r - If- IiVI-M irifft * i H rpl1 -- . J"-t ll! -i it in n.: .s.e.r- -Trf-F-f-"i hhk i:*k !. * -s- VAB.0001190477 T 'i;: : .--1" ' . : 'll- :.-i -I >!. 11..! + 1-1-J.n-h t VINYL - continued Reactor Downtime - continued Dryer Downtime Reactor limited production Operational downtime (centrifuge plugs, clean dryers, activator transfer problems, checking dust collector socks, pulsing socks, check screener rings, and flameouts. Maintenance downtime (change #8 dust collector socks, #6 tumbler switch, #6 feed valve, and various activator and centrifuge repairs). $ Of Total Downtime 84.1 9.5 6.4 Kev Maintenance Work - J. B. Autrey, J. B. Hegwood Reactor Area Reactor 400 was shut down for a seal change during the month. This seal was changed due to an excessive oil leak which was caused by a throttle bushing that had worn out. This seal had been in service for twenty-six months. Number 7 Bird centrifuge was shut down dt developed during normal operation. While down, the seals, thrust bearings and bush The old reactor unit chem wash pump was shut down for a complete overhaul during the month. The bearings, shaft, seals and the pump fluid end were replaced. Reactor 300 was shut down for repairs to its gearbox during the month. The gearbox input shaft seal had failed because of a problem with the fluid coupling. The seal was replaced and a spare fluid coupling was installed. The old fluid coupling will be rebuilt and used as a spare. Reactor 744 was shut down for hydroblasting during the month. The reactor shell was hydrobias ted and the condenser drilled. Number 6 Bird centrifuge was shut down because of a bushing failure. The bushings were replaced and the centrifuge was put back in service. VAB.0001190478 I I .1 VINYL - continued Kev Maintenance Work - continued Reactor 742 was shut down and the gearbox was removed because of an oil leak that had developed in the case. The leak was repaired and the gearbox was reinstalled. Reactor 741 was shut down and the gearbox was removed because of two seal failures. The oil seal and the input shaft seal had failed. The seals were replaced and the gearbox was reinstalled. Reactor 743 was shut down because of a gasket failure on the bottom of the reactor condenser. The condenser was lifted and the gasket was changed from a Monel jacketed gasket to a Flexitallic spiral wound gasket. The Flexitallic spiral wound gasket has proven to be very reliable. Training on the new maintenance hydraulic torque wrench was completed during the month. This torque wrench is being used as part of the reactor bolted joint program to help improve reactor bolted joint integrity. Reactor 744 agitator breaker was replaced during the month. The breaker would not reset after being shut off. There was no apparent reason for this failure. There were six major valves changed out in the reactor area during the month. A ............-n inr ic' i i v| w? -*i- - I1 ivi:!hu........flf-wmfcttttr:';' i MKi'ikj+irlsn i p+. -m- VAB.0001190479 ! - <i. if?"-I -:P. . . i: > l- H- -J--M. r - r*il-H-t> COMPOUND - J. E. Nickerson, J. B. Autrey General The three compound lines, dry blend, and plasticizer experienced scheduled downtime in May due to the demolition of the old compound cooling water tower. During this outage, the new condenser for plasticizer reactor R-2 was installed. Contamination was encountered on several products using altu inum trihydrate (Aluchem AC-712K). The lab confirmed that the contamination was due to this raw material, Approximately 250M pounds of flexible compound were off-graded due to this contamination. Operating Comoound Production Days Month Avz./Dav Fiscal Y.T.D Line I Line III Line V Total 27.5 19 5 1830 2057 265 4152 67 108 53 16423 27282 7616 51321 Downtime Uns-X - Product Changes - Dicer Problems & Maintenance - Transfer Problems & Limitations - Miscellaneous Maintenance - Quality Problems & Control Line III - FCM Gearbox Maintenance - Product Changes - Dicer Problems & Maintenance - Hydro therm Maintenance - Quality Problems & Control - Miscellaneous Maintenance Line V - Product Changes Hours 93 25 16 12 11 36 34 12 12 7 6 14 4- VAB.0001190480 M i- = COMPOUND - continued Operating Davs Month Production (M Lbs.) Avg./Dav Fiscal Y.T.D. Rigid Compound 23 4245 185 41129 Downtime Hours - Product Changes - Welex Problems & Maintenance - Screener Problems & Maintenance - Quality Problems & Control - Transfer Problems & Limitations - Miscellaneous Maintenance 42 29 28 12 12 9 Operating Davs Month Production (M Lbs.) Avg./Dav Fiscal Y.T.D. Plasticizer 27 1475 55 13850 A Kev Maintenance Work - J. B. Autrey, J. B. Hegwood The Line III FCM was shut down due to a gear failure during the month. The gearbox and the adjoining rotors were replaced with a spare. The gears were removed from the old rotor shafts and were sent to Houston for analysis. The cause of the failure has not yet been determined. The Line III mill was shut down for repairs to its rotary joints, which supply steam into the mill, on two different occasions during the month. The rotary joints were changed out and the mill was put back in The number one dry blend Welex was shut down during the month due to a seal failure during which time the seal and the bearings were replaced. The Compound and Plasticizer units were shut down for four days so that the north compound cooling tower could be demolished. The tower had been condemned and was scheduled for demolition. Also during this time, several maintenance items were taken care of in each unit. The south dry blend "Gump" screener was shut down and the moved for repairs. A spare gearbox was installed and the screener was put back in service The old gearbox will be rebuilt and kept for a spare II- : I K 1.- 1. :v:. I I 1 i : n i <i Ip -i . - J i. $]- |. fj|:-1_ H-'ir ri * . -I --I' - *i<l ' I - ''.I ........................ it 'FfcfllWirrt*!' i ' i"1 r'Trlit'T'iiTssr = :icw n:n:/? n i 'i VAB.0001190481 --'V i r, i ... | Utilities - J. B. Autrey, J. B. Hegwood The plant was switched from number one boiler to number two boiler for three days so that several steam leaks could be repaired on number two boiler. The number three water well was shut down during the month because of debris that was surfacing in the water system. The well and casing were cleaned and the pump was returned to service. VAB.0001190482 ENGINEERING - R. E. Polk, S. C. Hillman, V. L. Thornhill PROJECTS IN DEVELOPMENT - GENERAL Vinvl Control System Modernization Taylor Instruments has been selected to supply the control system for the project. Information is being gathered to prepare project economics and the final cost estimate. Plant Water System Revisions Visits were made to municipal sites using each of the water treating systems under evaluation. Work on class nAn design is underway. The initial draft will be issued early in July. IPSM Classes at Aberdeen Several process engineers attended IPSM training held at the Best Western in Aberdeen. Business Area Information Meeting Lucted an informational i eeting on 5/25/89 about the Business Area for the plant engineers. The meeting focused on Business Area job functions and opportunities. A u-1:. M n hump i . r. >-T' I .... -.nv^jr ..* VAB.0001190483 H 11 : J EjI$t: IS` >T' " Ah v1.p---rf F!r-!' !i :V wn.wv ' rrva. .; n H+l * ................ * pto ha * 3 a S3 a s a 3 53 a& 3 a 3 3 S3 . aa|s s5 aa aa nets ss w as^322 #-- S3 53 ~ ~a EB a SS8 a S 3 88S B*5 a CS3 ssl 2i S 9 a 5 B a * 5s s oa co a 3 3 a a 2 aasia* * * * 33222 a M MS aSli!e aa a A CK3 a as o o a g 2S s & as S> 5g pij !uHM-Mi-mitanwwmomaHui-aiii-oiib-io><-a<a SBB a ss 33 3 MNE8 IRNG R.g. POL ,E S.C. IHLLHA ,R V.l. THORN IHLL VAB.0001190484 ' It ilfr=r.i' rrii 1: 1 3 era * r-- '! I :i5 - h1: : :!" :v: 1 |: - TiL : v 'In -+fl--hL i >:H > i ; 4I-+P1-*`I'1*-- Nifs 1 vs ! .-jfc-1-s-r.-r:! f-jrnr.'y:<-r-dr-H!*^*1jjf VAB.0001190485 4 -1kMShU Hiw^|tep*Misqv^--i ' l-h--r-- *- 1- i r .1< - .1- T !+; .'Jlr .; =sr.:. !. tv.n u Ii^lruv:.| :|.. < J I*. k>, <-::*- -i ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were within NPDES limits for the month of May. Second quarter sampling of the pond #6 Outfall for priority pollutants indicated no VCM detected and 38 ppb di-n-octyl phthalate. Superfund Results from samples taken by EPA in February have still not been received. Vendors have been contacted about resampling the three groundwater monitoring wells at the plant. Two quotes have been received. Work is expected to be done in July. Air A letter discussing our centrate water recycle project and the resulting VCM emissions from the cooling towers was sent to the State. Verbal approval from the State was received. Written approval was requested and should be received in June. Waste/Offgrade Manaeeme May waste shipments included One bulk load of separator oil to Stauffer Chemical One bulk load of lead bags to Chemical Waste Management. Stauffer Chemical notified the plant that effective July 1 all separator oil shipments will have a fee of $2.52/100-pounds. Previously, we only paid for shipping. I evaluated alternatives to Stauffer and found Systech in Demopolis, Alabama. I am working to get separator oil approved at Systech. May offgrade shipments included: One load of reactor culls in super-sacs to Sun Polymers. Core samples were taken off pond #2 and submitted to Mississippi State University's labs for priority pollutant analysis. A list of all plant wastes was compiled for plant management. VAB.0001190486 ....... ENERGY CONSERVATION - D. A. Moore Mav. 1989 I. Energy Conservation Data A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU -4.05% -5.23% 2603.00% 122.12 This corresponds to an adjusted CMA of and an unadjusted CMA of 50.73% 39.00% Fiscal Y-T.D- -4.03% -4.87% 2542.94 1047.53 51.26% 39.78% II. Plant Energy Conservation Program A. Maintenance There were fifty-seven energy related items completed in May, 1989. Fifty-two of these items were steam leak repairs. The remaining five were steam trap repairs. Ill. Boiler Operation Boiler Combustion Efficiency % May. 89 Fiscal Y.T.D. No. 1 No. 2 No. 3 82.97%<n 83.34% 83.14% 83.59% 83.46% 83.16% (1) Boiler #1 operated two days during the month. 'r' ^ . ait*, -- ! I? \ . . Jt= sf*1! i-'i: l; " lif*- f ild*" 1 1 .ill . %'lvg ii-Lfrj lfc>, If- S' V.-rrY-m/'l* VAB.0001190487 1lK-s,i,:! ^ !<* ; .-j.-!-.j .-d.. vi - rtiTr-TSTi-'it-ri .:e vq. HOMAN RESOURCE REPORT MAY, 1989 Personnel - J. E. Beall Empl nvment Brian Aftergut, Rehire, Co-Op Engineer Matthew Smith, New Hire, Summer Engineer None Retirements None Thomas E. Bales, Yard "A" Operator, Deceased To/From Leave of Absence None VAB.0001190488 A ABERDEEN. MISSISSIPPI Salaried Employees Hourly Employees Total Employees MAY, 1989 MONTHLY PERSONNEL REPORT 78* Minority Employees #, % 111 Salaried 7 9% 253 Hourly 67 38% Total 74 29% New Employees 0 Hourly Min. Hired 0 Terminations 0 % Min. Hired 0 Hourly Min. Term. % Min. Term. Q. 0 DEPARTMENTS PAR #EMPLOYEES MIN. EMP. %MIN. NEW HIRES YTD TERM. YTD. TURNOVER YTD. Warehouse 16 Gen. Plant -11 Maintenance 41 Laboratory 24 Compound 40 Vinyl 33 Plasticizer 5 15 17 39 24 42 33 5 7 42 a 0 0 0 0 n 6 0. 7 0 0 0 10 oo o 5a o. afl 27 00 00 10 a (2 o 0 0 a 2 Q. 0 0 0n Number of Applicants: Month 0 Year To Date 21 APPLICANT BREAKDOWN: # Minority 0 % Minority 0 # Female 0 % Female 0 Hires (Hourly): Month 0 Year To Date 7 Terminations (Hourly): Month 1 Year To Date 1 Overall Turnover . 6% Projected Annual Turnover 1.4% * Includes 1 Co-op Engineer and 1 Summer Engineer. VAB.0001190489 -- ,*T.' V" ! y - 1 " IMFf:'*- - m -r euttrtht - 1 i^W***V*\*$WVW+*"im*W'*r~***'*'TM'- ^ C----!r - -sT - . It-.:.-- .. I -S I i - r '..t* '!> I tW-' : f-f dl * t/'->'!* s1 H > vO <r m o o on CM m o m CM -* lO t pH o GO <T CO CM to o CM oa Cl GO cn CM mO ON U* 41 (A o H CM 4 rH o o o rH m CM i-M <r * oo * o m r** ON * O 43L* H m* o o ON \0 mO m GO >T mo ON o r''- <r m 41 to o H a) u c a* c o o o O'! cn oo CM <r oO o w oo O O m x* u < cn pH CO H CM QQ U 3 O 4 41 QQ CO V CM O CM nO m vO m ao cn CM ao sO * w c *o 3Q e 41 o to *H u 4*1 41 to a MQ CL C o c> to *o >* to 41 4* '0 M Ac o> ji 00 eu 3 0 u o 3 Li <0 c a oo u Li at nB C mH L to x0Gt CM O * CM m ON o NO VO a CM * CM o CM * CM * CM -M * u CM M0 ao GO CM 3 CM G*HO cn 00 41 l> co o * c oC a Li 3 t>o O r CO $ Li *3 CO bJ H3 2 00 LaJ 0) c CO Li o 00 a CM u 3 O tt Li O hJ * Li X HOfi Ul pH <"M *43J Mo 41 t i i oOooo i o a o * oa o a o a i io lo i io io i i CO O 41 3 00 41 3 U4> Li e oo i QO o CM CM GO i <r CM vO O i i CM i i cn HO 00 2u CO ci Li o t i i CM i \ i i i \ 4) c E 41 u 3X Uo O X 0 H 4) . > O 4o1 aX 41 pH M lO r^. Om o o o in om o O om m CM o m Om 00 c 4J 3 13 V co 3 > pH oH u0 GO CM ON CM CM o 00 <T d cn cn d o CM <n m nC m m vH ON OrH cn cn ON CM CM CM V U X V *aH 41 41 e 4> o u a> *4 o Va m H^ u 41 O 3a 00 ^ CO aw Li 3 41 O CO X o m O o m |V oo mo m CM oo oo mm CM CM aa aa a a rH O CM ON fS ON vO CM CM CM GO o m (S CM m cn X <r NO m cn r-* o o r-H xO 00 r-* CM cn W 4> > o *3 E l 41 a Li V > 41 O Li 4 J0J > o o 3 4> CD Wu CO c U4 hO EU 2 <0 00 >- < <*4 u ad jj ofi < {Jj O CM =o CL o t-M HCO 3 H O U1 <% 2 % 3 o <Q L c O0 uo 1 c o u -- n w o t .*, VAB.0001190490 A There were no safety instances this month. Concluded review of dock area portable safety barriers will be used to alert employees during truck loadings. Cost Savings Savings due to competitive bidding were $9775 for the month, and $82,784 for FY1989. Savings due to prompt payment discounts were $2347 for the $15,494 for FY1989. onth, and Warehouse - Finished Goods Inventory Concerns with overcrowding in the finished in May with a 1,108M inventory reduction. However, slow moving and offgrade inventories are still excessive. May inventories were as follows: Total Slow Moving Offgrade Flexible Compound 4,780,727 970,624 474,637 Rigid Compound 601,189 230,406 99,377 Resin 852.764 N/A 211.764 Total 6,234,680 1,201,030 785,778 Training Jack Little attended "IPSM" May 17-18, 1989, at the Aberdeen Best Western. Meetings Jack Little was in Boston May 22-23, 1989, to review computer software in conjunction with "Oasis". (Marcam and Software 2000). i ............. : !< i1 . : 7h . - a, VAB.0001190491 W -S :^ --h F=-!,+J-4-i - :i-=.i-1 ;.`T .. . t ,J"'C V iKf'-J-il:: n ; r 4- rr>^p! ij Tt i * i < T1W ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS NAY 1909 -SHIPHENTS BY PRODUCTS- PUBLIC MONTH IPT/ITC EXCHANGE RESIN-BULK RESIN-PACKAGED 20,359,880 10,873,609 417,500 47,450 YTD PUBLIC IPT/ITC EXCHAN6E 140,490,150 92,761,929 4,012,100 366,450 . k"4A4i.j,- FLEXIBLE COMPOUND-BULK 1,688,130 FLEXIBLE CQNP0UND-PACKA6ED 3,177,835 1,033,250 32,193 12,218,560 10,076,390 30,878,209 841,146 RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED 3,815,250 420,867 0 985,871 30,705,450 4,518,648 3,867,950 995,171 PLASTICIZER 169,600 0 555,150 1,483,520 864,850 2,563,900 TOTAL 30,049,062 12,972,373 555,150 224,306,637 109,773,886 2,563,900 -SHIPHENTS BY MODE- BULK: IMAYI RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER TOTAL MAY RAILCAR 141 15 19 3 178 VISTA CUSTOMER COMMON PICKUP CARRIER 41 90 4 2 00 12 1 0 0 04 55 91 8 TOTAL 276 17 32 7 332 IYTDI RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 1,049 119 182 19 352 671 17 25 0 3 54 27 4 15 0 20 2,089 147 267 54 TOTAL YTD PACKA6E0: IMAYI RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 1,369 VISTA 4 36 19 446 698 CUSTOMER PICKUP COMMON CARRIER 40 29 26 1 15 44 TQFC CONTAINER 1 AIR/UPS 11 3 2,557 TOTAL 27 94 36 0 TOTAL MAY 59 34 49 0 1 14 157 IYTDI RESIN FLEXIBLE COMPOUND ru*u**ii/i uAunnurnunuiunmu PLASTICIZER TOTAL YTD 35 37 77 297 237 336 371 / 00 7 0 03 398 281 509 0 22 171 2 8 880 i i 167 3 3 30 1190492 LABORATORY - H. G. Coleman A. Safety - There were no incidents in the Lab this month. The monthly safety meeting, conducted by Richard Williams, was an excellent program taped from the Disney Channel on home including fire s emergencies, safety inspections and safeguarding your home. B. Customer Relations Customer Contacts There were no customer contacts this month by Laboratory personnel C. Product Waivers Customer Product Reason No. Avg. particle size (158 y) 1 HT D. RVCM Summary RVCM of In-Process Samples The following is a summary of residual VCM results on process samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of May, 1989. Number of Samples Average RVCM, ppm RVCM of Shipment Samples Reactor Slurries 872 162 Drier 5265 5305 23 0.705 57 0.494 The following is a summary of the residual VCM analysis of shipment samples for the month of May, 1989. Product 5265 5305 5385 5395 5415 5465 Dry Blend Debox Pond Number of Sanmles 60 87 42 8 61 0 24 20 6 Averaee RVCM. oom 0.192 0.189 0.185 0.059 0.031 -- * 0.053 0.225 0.326 * .r .'.r!.-!> -Liifr-,'-Lj -j-h h VAB.0001190493 |< Jlj K : *rhi rrTlITf -IJ li | ^-1--F''r FL^TlM-tv -rr+iM mti r i 01 .M-rfrfii; . LABORATORY - Continued Resin Process Capabilities (based on dryer "regulars") 5265 5305 5385 5395 Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Drytime Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) 0.48 0.70 -- 7.33 1.11 4.67 1.43 -- 0.79 -- ---------- ---- -------------- -- 0.62 0.88 0.46 4.33 7.33 1.67 3.00 ---- 1.64 - ----------------- 2.36 0.63 -- 12.33 -- 2.33 2.75 ----- -2.47 1.00 -- -- 12.3 0.95 1.67 -- 13.33 -- 6.00 0.56 -- 0.30 1.33 3.71 -- 0.0 5415 0.58 0.96 -- 6.33 -- 2.83 3.89 0.56 2.79 2.67 4.25 2.48 1.0 Average particle size, microns 138 149 164 152 170 F. Compound Quality Summary Adjustments M Lbs. XU Rejections M Lbs. XU Color/Clarity Hard Particles Contamination Dicing -- -- -- Total -- -- -- ----- 25.3 82.7 52.9 5.3 166.2 (0.60) (1.97) (1.26) (0.13) (3.96) G. Drv Blend Quality Summary Rejections M Lbs. (%) 40 Mesh Retention 3_JL Total 3.9 (0,09) (0.09) H. Compound SPC Test Results nX 3 38401 - Hardness - Specific Gravity - Hard Particles 41 41 48 83.80 1.373 21.10 1.04 0.014 3.93 35031 - Hardness - Specific Gravity - Hard Particles 44 44 46 49.80 1.378 5.48 0.85 -- 3.53 Mill Temperature, F Oven Temperature, C 44 324.9 All Readings 1.04 204C. VAB.0001190494 LABORATORY - Continued I. 5415 Control Resin Test Results n Moisture Dry time Particle Size - 60 mesh - 80 mesh - 100 mesh - 120 mesh - 140 mesh - 200 mesh Pan Bulk Density Color - L A B Flow Time, sec. Hard Particles, 7 min. Inherent Viscosity 61 30 62 62 62 62 62 62 58 30 62 61 59 31 62 30 0.172 4.89 1.54 32.64 33.56 18.08 7.58 5.16 1.40 0.500 100.36 -0.01 1.84 7.70 6.18 1.0127 3a 0.33 0.33 0.52 2.81 1.11 1.57 0.97 1.17 0.50 0.006 0.45 0.22 0.38 0.46 3.00 0.078 J. Miscellaneous 1. Anne Chepolis (TSR) was given some training in the Lab about methods and procedures on May 26. 2. H. G. Coleman attended IPSM on May 17-18. A tape drive was installed in the compound/dry blend Q.C. computer for backup data storage. 4. The Lab ordered a new Brabender torque rheometer to replace our old Haake unit. A . -h-.. . . ^ ... . . , J r *' irf'l tl'HrW.ti'J iA*": | J| ,l.r I-U-p.- h h. ^p! L' piHvi fftj-n >: iMSlf.jir Ijf VAB.0001190495 ; i : m ..fc r .. i |- id I:. | - ' :--'rta- . 7r'i:s -i' ir:v:p-"h:. r. .j RESIN Ship Date SAMPLE SHIPMENTS MAY 1989 Product Amount Customer 5/01/89 5/03/89 5/03/89 5/03/89 5/05/89 5/12/89 5/18/89 5/18/89 5/19/89 5/23/89 5/25/89 COMPOUND Ship Date 5265 5385 5305 5305 5305 5265 5305 5415 5385 5415 5415 5385 5395 Product 50 lbs. 50 lbs. 100 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 100 lbs. 150 lbs. 250 lbs. 50 lbs. 250 lbs. 250 lbs. Huls American, Inc. AL-KASWA ASSOCIATES DUPONT OF CANADA Hoechst Celanese Klockner-Pentaplast Morton Thiokol C. ITOH AND CO. CARGILE SONATRACH CABEL CORP. OF INDIA LTD. Applied Plastics Amount Customer 5/01/89 5/05/89 5/07/89 5/18/89 5/24/89 5/31/89 5/31/89 DRY BLEND Ship Date MSP Pellets 38525 BLK 38841 NAT 419-33D BLK 376FR NAT 18961 NAT 38931 WHT MSP-90 MSP-90 Product 5 lbs. 1500 lbs 300 lbs. 300 lbs. 300 lbs. 50 lbs. 5 lbs. 50 lbs. 100 lbs. Ron Walker Times Fiber Northern Electric Florida Central Extrusion Tie Down Engineering Tackett Plastics Inc. Flex-Rite Amount Customer 5/16/89 5/24/89 80273G WHT 110 25 lbs. 378-143 BLUE 170 Purge 30 lbs. Finance Int'l Trade & Service Ltd. Silverline Building Products VAB.0001190496 A ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) 40 30 20 IS TO 0 J'87 FMAMJJASOND J'BB FMAMJJASOND J*89 F M A M TOTAL INJURIES O OSHA RECORDABLE NUMBER OF INJURIES ' ,Ji .........| I "r.t llr'".:S !-'M 'S. - ^ . i-- -u' r T - VAB.0001190497 A*J* I^ 43 n; i-rf-*-A. ' i W'l'Mtf | 1 '* J tf-W |- If* [jJM F'. 7 - ?!' li-i . la:.-' * jj .p . i.^.. . . : s . I i : i !! |iarT . r '! *1 * r ' ' ABERDEEN ENERGY CONSUMPTION BTU/LB an/ms MONTH ....-- 12 MONTH AVERAGE- 4 j Ol 00 o: <cl oo oo on <CL oo oo roo aa<.: VAB.0001190498 .V..K i I