JUNE 2011 / Q2 Ascend News Message from The president of ISC Git et am sandi officium iderro inctionseque et optatur re, simet quatior eperumque quae simpos vellandi to volore ea et velenihic ium eosse eum raecus essitaspid minctur? Pici quat omnis debis ulparuptat maionem expelibus es incto et et quo dundunt dunt, nis dolor sunt voloria poreprem inum doloreiur sunder- chilis solupta tiaerum exce rum est alic testrum quaesec abori bus modit earum rae moloreh endebis peristi onse- qui dolum volor aut eatur, audi aut et laut alitio. Puditas et qui autemoles cus, offici adist lacite voluptaspid que vel idigenda nia int et in exerovit pe volorem estione cerferf eritassit et que derernatur, odist, nobissendem acestia musapiendam, tota dolorias sunt, nobisincto quaecte esendebit fugit enit, occuptatur, que optatem vent harchic testianda quis maximil luptat facipici nita- tem atemqui conest dolum volupti beritatibus magnate nonemquam, con nonsedis et arum volupti atureror- rum nes non rerum solo temoditibus pro maximet endi acepudae cum reperch iliquas enem aut doloreris doloris sincia ne nis sit minciae cernaturesto dis maxim recabo. Ed que min cum quaera dolor aut eatem que susdae sum lacest re laccupt atempero eaquam reptaque doleste do- lupta turepre mincta conse pellorestis aut laudis peruptat magnihil etur alici dit omnimporum alignatur maximus estrum quas ma poris maiorro quaerestiam esseque duci utatur? Qui ducieni moluptati re volupta tiassum quistio nsenimusapis dolum et vel es volor aut minitatque min rem voleni alit ea natem qui officit facesequo veresten- dus suntorp orercit que nobis sum, into cus aborendis ilicaborum sit aut autem elesti dolorum fugiaturias doluptatium que volorerit reicimusa eium solupta spicide eos nobitio molorio. Eque porepellant, occulpa consequis minctec atiamus ditatibus pe nulpa il ist ut et illut velesequassi omniaturest as ad quidentiis ium et ipsam quae. Lorecabore alitiis reiunt, sus consequae sum que nis quam apictat emporemque dellaccum delictur si doluptatem ut at. Ulles sinullo reptasi dolendios pero magnimus di corae vent pelendi stiur, ut et volutemo dolupta quam eturept atquas mollam quiati officid maio. Nem ipsunt endes- tisquo dolo volo voluptas ut expe volendi dolupta sam nienimust velique quo dessequae nonsequibust om- molum ent ommoles il ea porrupta ipsaest reiur, cus magnimos doloresequis nimus, consequas eatur? Naturio officim aximus. Conet prem eati siti in rerissu scimpor sitaten imendani remporaerum voluptae volesed quiaesti ressini magnam, quatur, aperci qui corporion est, consenis voluptae dip- sant, tes dolorporrum is mo tem alitiam net ea consequa- tium expla voluptatio. Ita voloresequae dolor serro tet im que poriat occustisim sit, tem que event, que nusto to explatiant qui reheniae rero occusam quatust exerferum quam et facitaectet lam fugitassequi rendent aute nientia spelestrum il es ex et facepra essundam, serspic teces.
Transcript
JUNE 2011 / Q2
Ascend News
Message from The president of ISC
Git et am sandi officium iderro inctionseque et optatur re, simet quatior eperumque quae simpos vellandi to volore ea et velenihic ium eosse eum raecus essitaspid minctur? Pici quat omnis debis ulparuptat maionem expelibus es incto et et quo dundunt dunt,
nis dolor sunt voloria poreprem inum doloreiur sunder-chilis solupta tiaerum exce rum est alic testrum quaesec abori bus modit earum rae moloreh endebis peristi onse-qui dolum volor aut eatur, audi aut et laut alitio. Puditas et qui autemoles cus, offici adist lacite voluptaspid que vel idigenda nia int et in exerovit pe volorem estione cerferf eritassit et que derernatur, odist, nobissendem acestia musapiendam, tota dolorias sunt, nobisincto quaecte esendebit fugit enit, occuptatur, que optatem vent harchic testianda quis maximil luptat facipici nita-tem atemqui conest dolum volupti beritatibus magnate nonemquam, con nonsedis et arum volupti atureror-rum nes non rerum solo temoditibus pro maximet endi acepudae cum reperch iliquas enem aut doloreris doloris sincia ne nis sit minciae cernaturesto dis maxim recabo. Ed que min cum quaera dolor aut eatem que susdae sum lacest re laccupt atempero eaquam reptaque doleste do-lupta turepre mincta conse pellorestis aut laudis peruptat magnihil etur alici dit omnimporum alignatur maximus
estrum quas ma poris maiorro quaerestiam esseque duci utatur? Qui ducieni moluptati re volupta tiassum quistio nsenimusapis dolum et vel es volor aut minitatque min rem voleni alit ea natem qui officit facesequo veresten-dus suntorp orercit que nobis sum, into cus aborendis ilicaborum sit aut autem elesti dolorum fugiaturias doluptatium que volorerit reicimusa eium solupta spicide eos nobitio molorio. Eque porepellant, occulpa consequis minctec atiamus ditatibus pe nulpa il ist ut et illut velesequassi omniaturest as ad quidentiis ium et ipsam quae. Lorecabore alitiis reiunt, sus consequae sum que nis quam apictat emporemque dellaccum delictur si doluptatem ut at.Ulles sinullo reptasi dolendios pero magnimus di corae vent pelendi stiur, ut et volutemo dolupta quam eturept atquas mollam quiati officid maio. Nem ipsunt endes-tisquo dolo volo voluptas ut expe volendi dolupta sam nienimust velique quo dessequae nonsequibust om-molum ent ommoles il ea porrupta ipsaest reiur, cus magnimos doloresequis nimus, consequas eatur? Naturio officim aximus.Conet prem eati siti in rerissu scimpor sitaten imendani remporaerum voluptae volesed quiaesti ressini magnam, quatur, aperci qui corporion est, consenis voluptae dip-sant, tes dolorporrum is mo tem alitiam net ea consequa-tium expla voluptatio. Ita voloresequae dolor serro tet im que poriat occustisim sit, tem que event, que nusto to explatiant qui reheniae rero occusam quatust exerferum quam et facitaectet lam fugitassequi rendent aute nientia spelestrum il es ex et facepra essundam, serspic teces.
ascend caresf o u n d a t i o n
The Ascend Cares Foundation was set up to aid the employees and
resident contractors which comprise the Ascend Family, to care for
each other in times of hardship. Our initial solicitation for donations
was in support of the members of the Ascend Family affected by
the tornadoes that struck the Decatur area in late April. Your
generous donations have helped a number of Ascend Families in
Decatur meet their immediate needs following devastating losses.
| While there are many local, state, and national agencies that
provide disaster relief, the intent of the Ascend Cares Foundation
is to provide immediate and personal relief to the Ascend Family,
from fellow workers. In addition to the relief provided to our
colleagues in Decatur, the Ascend Cares Foundation Committee,
along with Decatur leadership, is evaluating some specific needs
of the communities in which our colleagues live. | We would like
to remind our colleagues in Decatur that we are still accepting
applications for relief. The Application for Assistance form is
attached. | We would also like to remind everyone that we
continue to accept donations to Ascend Cares. For your
convenience, the payroll deduction form is attached,
or you may make a one-time donation to Ascend Cares
by sending your check as follows –
Ascend Cares Foundation
Ascend Performance Materials
600 Travis Street
Houston TX 77002
If you have questions regarding the Ascend Cares Foundation, or if
you need more information regarding relief funds or contributions,
accomplished, period.” | Faulkner said employees have strong bonds with friends, with their families and in their ties to the community of Decatur. “They’re very active within the community and several are members of our city councils. Many are actively involved with area charitable organizations including United Way, and several are volunteer firemen and volunteer emergency medical technicians,” he said. | Perhaps it helps to grow up in the City of Decatur, today the busiest port on the Tennessee River and known as “The River City.” | But the city, too, had to earn its present-day success. It endured several encounters during the Civil War. When all but four buildings were burned during the 1864 “Battle of Decatur,” it was referred to as A Tough Nut To Crack. | Even the city’s name came at a steep price – the death of naval officer and national military hero Stephen Decatur, Jr., killed by another naval officer, Commodore James Barron, in a duel on March 22, 1820. | Today, 55,778 call this north Alabama city home, making Decatur the state’s eighth largest, sandwiched between Dothan (seventh) and Auburn (ninth).
Site Focus: What is it about Decatur?Employees, despite earlier setbacks, rally to achieve excellence.
Editor’s Note This is the first in a series of articles profiling our plants. Look for upcoming issues of Ascend News. Yours could be next!
Since mid-2009, business volume at Ascend’s plant in Decatur, Ala., has been booming. How come? | Sound management – encouraging employees to overcome barriers and providing tools to do so – has certainly been a factor. While necessary, effective leadership frames the picture. But the picture’s focus is clearly the character of the employees who work there. | Decatur’s 235 employees, 110 contractors and the entire Decatur community for that matter are a close-knit bunch. They develop strong bonds of friendship, camaraderie and have a resolute belief that they will always triumph over adver-sity. Plant Manager Al Faulkner is proud of his employees’ commitment to work through the difficult times. Downsizing, business losses and layoffs marked the decade just past. “They are now able to experience the improvements that their years of hard work have led to,” Faulkner said. | They just don’t give up, he added. “Their commitment to safety, improvements in productivity and quality is as solid as a piece of granite,” he said. “When these folks set out to accomplish something, that something gets
Decatur Takes The Gloves Off, Saves $22,000Increasing efficiency by cutting unnecessary expenses go hand-in-hand with always seeking out ways to make things better, which is the essence of Ascend To Excellence. | Such opportunities are all around us, some right in hand. We just have to look. When a team of Ascend employees at the Decatur, Ala., facility looked, they uncovered annual savings of almost $22,000. | Did the team discover a high-tech solution that cut costs? No, they simply looked at their work with fresh eyes and, in a moment of creative insight, realized that by reviewing the types of gloves used for certain jobs and implementing a glove management system, they could improveselection criteria and use, increase hand safety and save a lot of
money. | The Decatur glove team comprised Lisa Naccarato, ES&H Department; Maintenance lead Jamie Dozier; Darrell Eddleman, Laboratory; Davis Canady, of off-site contractor Mundy, Inc.; Ray Halbrooks, Area Operations; Joe Forton, Continuous Improvement Lead and Storeroom personnel Loyal Parker and Matt Kenum. | The team began by assessing current glove usage and inventories. They ran reports on glove use at Decatur and other Ascend sites. This enabled them to focus on the most predominately used gloves. By standardizing the types of gloves used for various applications and soliciting prices from several glove manufacturers,
the team found gloves that were just as effective at less cost.
• The Decatur Plant employs 235 and has 110 contractors.• The plant serves internal customers at Greenwood and Pensacola. • Decatur produces H.M.D. (hexamethyldiamine) for external customers.• The plant manufactures three products: A.D.N. (adiponitrile, a key intermediate chemical in the production of Nylon 6,6), H.M.D. and coke, a form of carbon.• The facility is located on a 750-acre site along a peninsula bordered by the Tennessee River.• The property was purchased in 1952.• Chemstrand, headquartered at the site in 1952, would become Monsanto, then Solutia and now Ascend Performance Materials.• The Decatur Plant is one of four production-scale A.D.N. facilities in the world. (Two are in Texas, and one is in France.)
Decatur Plant Facts
Gearing up for
It’s that time of the year! Please be on the lookout
for Broadcast Announcement in the near future.
2
Celebrating 50 YearsAscend employee Betty Qualls began job in 1961 when plant was Chemstrand By Eric Fleischauer • Decatur Daily • April 17, 2011 Betty Qualls has worked for Ascend, which was formerly Chemstrand, Monsanto and Solutia, for 50 years. Barges, trains and trucks travel at her whim, heedless of the changing corporate sign outside the window of Betty Qualls. | The 83-year-old, who coordinates transportation at Ascend Performance Materials, has worked at the company and its predecessors for 50 years. | “I always felt this was where I belonged,” said Qualls, who started working at the Decatur plant in 1961. “I enjoyed my work. You’ve got to enjoy your work to stay with it for 50 years.” | Ascend—like Solutia and Monsanto before it—produces two intermediate chemicals, adiponitrile and hexamethylene diamine. The plant is on the Tennessee River near the intersection of Beltline Road and Alabama 20 ships the chemicals out as liquids. Other Ascend plants convert the intermediaries into nylon salts, which customers use in plastics and carpet fibers. An expanding market is nylon 6,6, often used for under-the-hood automotive parts because of its heat-resistant properties. | The goal of logistics—or “traffic,” as it was called when Qualls entered the department 35 years ago—is a steady routine of shipments to and from the plant. The reality of logistics is maneuvering from one crisis to the next, making sure the Decatur plant has the raw materials it needs and that downstream plants have the Decatur intermediaries they need. | Qualls’ supervisor, Kim Roberts, is a 13-year employee. “She’s seen many different business situations and many different management styles,” Roberts said. “She’s very good at managing crisis situations when we’re trying to secure our raw materials or get our finished goods shipped out.” | Qualls often gets calls after hours and over the weekend, Roberts said. “She always responds with a positive attitude, regardless of the hour,” Roberts said. | On the wall of Qualls’ office is a sign that explains Qualls’ significance to Ascend and its predecessors. “Betty’s Transportation Company,” the framed poster says with a simplicity that belies the juggling involved in the job. | Her lengthy tenure means Ascend is hard-pressed to present a new challenge. It also means Ascend benefits from Qualls’ relationships. | “As a result of her long tenure, she has a lot of great relationships with our carriers, whether truck, rail or barge companies,” said Plant Manager Al Faulkner. “As a result, they are very responsive to us. Betty has worked very hard with them for a lot of years.” | Qualls was born in 1927 in Arkansas. Her father was a federal marshal. She and her husband, Charles, moved to Decatur for his radiology job. | “We had a choice of three places, and this was the closest one to home,” Qualls recalls. “That’s why we chose it. I didn’t want to get any farther from home than Alabama. He had an offer in New Mexico and someplace else, and I said, ‘No, that’s too far away.’ ” | Qualls did not get a job in Decatur until her son went to school. | “I had grown so close to my boy—I had twin girls, too, but there was eight years difference in them. I never left
Betty in her office. photo by Brennen Smith at Decatur Daily
him with a baby sitter. I felt like it was time for us to break that tie. So when he was ready for school I came to work. On the Friday I came out here to get my physical, I cried all weekend. I didn’t want to leave. Charles kept saying, ‘You don’t have to go back to work.’ But I did, for (my son) and for me.” | Qualls was a reluctant convert to the computer age. “When I came out to work here, we’d never even heard of computers,” Qualls said. “We had calculators and adding machines and typewriters and telephones. The secretaries had desks all out in the hall here, and they took dictation from their boss and typed letters for them. The bosses did not know how to type. That was the biggest change, when high-tech and computers started coming in. Now nobody types a memo or letter for her boss. They do their own anymore.” | Qualls has no immediate plans for retirement, and she notes that her two surviving children are not pushing her to retire. “They want me to work,” she said. “They think it keeps me in better health if I work.” | She points out her window, past a dogwood tree that Solutia planted in her honor, to a plot of ground between Ascend and a neighboring plant. That, she explains with macabre humor, is supposed to be her burial plot. She scolded a contractor for infringing on the space when he expanded the parking lot. | Ascend is honoring Qualls on Thursday with a luncheon. Guests will include retirees and plant owners. “They’re making too big a deal of it,” Qualls said. “It’s not like I’m a celebrity.” | Within the confines of the plant, however, the woman everyone knows as “Miss Betty” is very much a celebrity. “The people here are so much family to me that I don’t want to leave them,” Qualls said. “They all work together. It’s a great place.”
3
Decatur Tornados and Comeback
EMPLOYEE IMPACTInjuries or fatalities: 0 employeesLoss of property, injured, or deceased relative: 23 employees (Ascend and Contractor) Significant damage or complete loss of their home:10 employees
PLANT DAMAGE• Minimal damage to exterior of cooling towers• Roof Leaks in several buildings• Very fortunate…significant damage to two plants three miles west of Ascend facility
On April 27, 2011 one of the largest tornado outbreaks in
American history occurred across the southeastern United
States. One EF5 tornado swept through several counties
in Alabama, terrorizing families and destroying everything
it is path. About 50 minutes and 55 miles later it was gone,
however, the aftermath remains.
Although the tornado passed within 2 miles of the plant,
the Ascend Performance Materials Decatur site had minimal
damage. While the plant was left completely without power,
only minor damage to the exterior of the cooling towers and
several roof leaks were reported. Site management consid-
ered ourselves fortunate. More importantly, good fortune
continued as we confirmed that there were no employee
injuries or fatalities. However, thoughts quickly turned to
the Ascend employees and contractors that were impacted
by their own loss of property, or an injured or deceased
relative. Immediately after the storm, the site leadership
team were not only on the ground working through their
restart strategy but also reaching out to impacted employees.
With rain in the immediate forecast, teams set out to provide
tarps to employees who sustained roof damage during the
storm. The storm provided the right opportunity to establish
the Ascend Cares Foundation as a way of allowing employees
to help each other. Funds were solicited and through the
generous donations of Ascend employees, resident contractors,
and suppliers. Several families impacted by the storm have
received relief funds and the impact on improving a difficult situation
has been tremendous. | Lack of electrical power was the site’s biggest
issue in preparation for restart. Emergency power was restored 1 week
after the storm. Restart power returned 2 weeks after the storm and was
under close oversight from TVA. This significantly complicates the restart
effort and of course, no restart can begin without resumption of power. |
At this time, the plant is completing a project pulled forward to maximize
production for the remainder of 2011. After the project work is completed
in early July the plant will return to full operational rates. The Decatur
site appreciates the thoughts, prayers and the outpouring of support
to the site and to our employees through Ascend Cares.
EF5 passed within 2 miles of the plant
4
scheduled for Q3. For Q3, improved AN volume, in addition to
continued strong demand for our other chemicals and the pro-
jected end of our Force Majeure on HMD during August, should
result in us meeting or exceeding our plan for the quarter. Of
course it will be critical that we run our plants with exceptional
reliability in order to take advantage of the opportunities in the
marketplace.
Business OverviewPlastics
Polymers & Fibers
ChemicalsMerchant market demand for Adipic Acid and HMD continues to
be strong, though there is some weakness in the Asian Adipic Acid
market as we typically see during the Summer due to a lull in Poly-
urethane demand. The majority of our Adipic Acid sales are under
long term contracts in North America and Adipic Acid volume
for Q2 was at AOP. Our Force Majeure on HMD resulted in a large
volume shortfall vs. AOP in Q2. Acrylonitrile demand and margins
weakened during Q2 due to poor demand for the two major AN
derivatives (Acrylic Fiber and ABS) and high raw materials costs,
resulting in a shortfall to AOP. The regional spike in propylene
cost in North America vs. Asia and Europe also made it harder to
compete globally during April and May. However, Propylene cost in
North America has decreased considerably from May to July which
will be positive for our Q3. While the AN market was weak we took
the opportunity to move up maintenance work that was originally
ISC ELT Scorecard | Q1
Major AchivementsCADN set 2 new MPRs in 4Q10. Decatur HMD set two new
MAR records in 4Q (369 and 372 MAR). Increased RADN
storage capacity by 5 Mlbs in November and utilized the tanks
in December to store RADN to prevent cutting rates (converted
Acrilan abandoned tanks). Set new production records for
MHBA and DPO as well as a new MPR for AN7. We achieved
a production record in Adipic Acid 1,008 BAR. Also received
approval of our 990 permit Adipic Acid Permit. Set BCF
(49.24 MAR) and IF (28.36 MAR) monthly production
records in October.
Major OpportunitiesSulfuric Acid spill on 10/30 resulted in 4.0 Mlbs lost ADN
production in November. Spill resulted from operator error
and failure to understand automatic fill program for sulfuric
acid tank. Lost of power at CHB (Nov 30th) due to Center Point
error caused site shutdown and significant impact to volumes
(18Mlbs AN, 2.8Mlbs HCN) and financial performance $7.5M.
Nitric Acid Unit failure caused significant mechanical failure
of the #2 plug. Lost 5 days of production of Nitric Acid, which
also impacted Adipic Acid production. Delay of Industrial
Fibers Phase 1 start-up and subsequent SSP upset resulted
Do you believe in ZERO? Do you believe you will be injured in the second half of the year?
Of course not! Then you believe in ZERO! No one expects to be injured at home or work, but
the real question is, “What are you doing to make that a reality for yourself?” | As we begin
the 3rd quarter, there is no better time to answer that question of personal accountability.
With the onset of summer, comes the heat, increased work activity at home, overhauls and
turnarounds at work, the distractions of vacations, kids at home, and longer days. With no
change in behavior, the probability of your risk of injury increases. So what will you do to be
ZERO? | Safety is our most important focus area at Ascend – we want everyone to return to
their families safely at the end of the workday. We continue to improve safety processes so
they are practical and easy to follow, and to provide safety professionals to address the tough
questions and issues in the workplace. We will continue to look for opportunities to make Ascend
a safer place to work. | Enjoy the summer and focus on being safe at work, at home, and at play.
We will provide as safe a work environment as possible and the rest is up to you. Believe in ZERO!
Pensacola FRC committee works to beat the heat
I Belive in ZERO!
It is a challenge to stay cool during the summer no matter where you are or what you are doing. Last fall the Pensacola site adopted a FRC policy for its Intermediates and shared services employees. While the FRC provides excellent protection against arc flash and flash fire hazards, it presents additional challenges to staying cool during hot summer months. | A committee of field employees from across the site took on the challenge of safeguarding Pensacola employees from the heat and came up with several ideas to help employees stay cool:• Smarter work practices such as scheduling more strenuous jobs in the mornings or evenings, and taking frequent breaks during the hottest part of the day• Changing up to eight work shirts to lighter weight, more breathable FRC shirts. The shirt will provide sufficient protection from a flash fire hazard however additional protection must be worn when there are concerns about arc flash hazards• Use of cooling devices such as cool bandanas, cooling vests, and hard hat inserts for particularly hot jobs• Education via Toolbox Safety Talks, Heat Index Alerts, posters and safety meeting discussions about heat stress hazards, the importance of drinking plenty of water, heat stress symptoms and treatment • Providing cooling areas with air conditioning or misting areas and/or tents for shade• Greater availability of drinking water and ice
While none of these ideas are the panacea for eliminating heat stress, used together they can help employees stay cooler and safer during the hot summer months.
Be pro-active to help your body tolerate the heat:LIMIT HIGH FAT “HEAVY MEAL” INTAKE High fat and “heavy meal” consumption results in an increase in bovdy metabolism which increases internal body temperature.LIMIT SODIUM (SALT) INTAKE Salt intake creates dehydration
which causes the body to work harder to circulate fluids which increases internal body temperature.INCREASE FLUID INTAKE A well-lubricated machine runs more efficiently. 3:1 RATIO Consume 3 waters to every 1 electrolyte replacement beverage.LIMIT CAFFEINE INTAKE Caffeine is a stimulant and a diuretic, thus it increases body metabolism two-fold, resulting in increased internal body temperatureLIMIT ALCOHOL INTAKE Alcohol is a diuretic. Fluid lost when consuming alcohol is greater than the amount of fluid consumed, thus placing the body in a dehydrated stateKNOW YOUR PRESCRIPTION MEDICATIONS Medications such as Lasix, HCTZ, and other “fluid” medications prescribed for heart or blood pressure conditions keep the body in a constant state of mild dehydration. Antibiotics can make us more sensitive to the solar effects of the sun, and to heatLISTEN TO YOUR BODYThirsty = I am too dry, water me Dizzy = I need to sit downNausea = I need to cool downSweating ceases & skin becomes hot & red = I am in TROUBLE!INFECTIONS Viral and/or Bacterial infections, up to one week after last symptoms, place additional strain on our bodies to regulate internal body temperaturesPERSONAL HISTORY OF A HEAT-RELATED ILLNESS If you have experienced a heat-related illness, you are more likely to have a recurrent heat-related event for up to a year later, with less heat exposure than the initial exposureTAKE FREQUENT BREAKSWEAR LIGHT COLORED/LOOSE-FITTING COTTON CLOTHING COOL THE CORE Apply cool packs to the neck, under both arms and to the groin area to decrease internal body temperature. Drink cold water if nausea has passed, and no vomiting is present. Avoid rapid cooling as this will cause the body to shiver, thus increasing internal body temperature. continued >
through sweating• Usually occurs after periods of strenuous
physical labor and heavy sweating
Loss of large amounts of fluid and excessive loss of salt
through sweating
Breakdown of the body’s heat
regulatory system
SYMTHOMS
• Psychological distress (feel
uncomfortable)• Loss of
coordination• Loss of alertness
• Dizziness/feeling of faintness
Non-contagious skin rash marked by red
pimples and intense itching
Painful, intermittent muscle
spasms or cramps
Weakness or fatigue, nausea, headache,
moist skin, pale/flushed complexion,
profuse sweating, and normal or
slightly elevated body temperature
Hot, dry, and usually red
spotted skin, body temperatures of 105° F or higher and rising, absence
of perspiration, mental confusion,
deliriousness, convulsions, and/or
unconsciousness
TREATEMENTMoving
the individual to a cooler environment
• Clean the affected area thoroughly with
water and allow it to dry
completely• Calamine and other soothing lotions help
relieve discomfort after leaving work
(don’t use Calamine while
still working in heat)
• Have victim drink water or electrolyte
replacement/sport drinks
• Persons with heart problems or on
a low-sodium diet should not use
electrolyte/sports drinks without
consulting a physician first
• Gently massage or use firm pressure on the muscle that
is cramping
• Have victim rest in a cool
environment and drink water or
electrolyte replacement/sport drinks
• Persons with heart problems
or on a low-sodium diet should not use sports/electrolyte
drinks without first consulting
a physician• Severe cases of heat exhaustion
require medical care
• Summon medical aid immediately• Move victim to
a cool environment and bathe his/her
body with cool water until body temperature is
reduced to 102° F. • Vigorous fanning will help increase
cooling effect• Don’t leave victim
unattended
!!
Medical emergency that requires immediate medical attention Heat stroke is always life threatening. Brain damage and death can result if the victim is not cooled quickly!
7
Driving Safely in the Rain
It’s coming! The LMS is coming!
So, what is an LMS? Why should I care?
Rain is blamed for thousands of accidents annually. When the road
is wet, the film of water on the asphalt can cause tires to lose
traction. Less obvious is the fact that rain reduces driver perception
— it’s harder to see through the rain — and decreases visibility
through its action on headlights, windshields and the road itself. |
Exercise extreme caution after a long dry spell. During a dry period,
engine oil and grease build up on the road. When mixed with water
from a new rainfall, the road becomes extremely slick. Continued
rainfall will eventually wash away the oil, but the first few hours can
be the most dangerous. | Allow for more travel time. Plan to drive
at a slower than normal pace when the roads are wet. Keep in mind
that traffic is likely to be moving slower as well. There is also the
possibility that your preplanned route may be flooded or jammed.
| Brake earlier and with less force than normal. Not only does this
increase the stopping distance between you and the car in front
of you, it also lets the driver behind you know you are slowing
down. Turn signals should always be used so other drivers know
your intentions; take turns and curves with less speed than you
would in dry conditions. | Most roads are crowned in the middle,
allowing the water will run off to the sides. If possible, stay toward
the middle of the road to avoid deep standing puddles. | Do not
use cruise control. If you hydroplane, there is the chance your car
could actually accelerate. Cruise control also allows drivers to be less
vigilant and to take their foot away from the pedals at a time when
reaction time is critical. | If you see a large puddle ahead,
drive around it or choose a different route. A pothole may be
hiding under the water, just waiting in ambush to damage a wheel
or knock your suspension out of alignment. | Do not attempt to
cross running water. All-wheel drive is not going to be much help
if your vehicle is being pushed sideways. Do not end up like those
folks on the nightly news who had to abandon their cars to Mother
Nature. | After you cross a puddle, tap on your brake pedal lightly to
dry off some of the water on your rotors. | Turn on your headlights,
even when there is a light sprinkle. It helps you see the road, and as
more importantly, it helps other motorists see you. Do not use your
high beams in the rain or fog — high beams further obscure your
view as the light is reflected on the water in the air. | Defog your
windows. Rain will quickly cause your windshield to fog up. Turn
on both front and rear defrosters and make sure the air conditioning
is on. The climate control system in most cars will automatically
engage the A/C when the windshields defrost function is selected. |
If you start to hydroplane, do not brake suddenly or turn the wheel.
Release the gas pedal slowly and steer straight until the car regains
traction. If you have anti-lock brakes and you need to break, keep
your foot on the brake. If you have older brakes, then tap the brake.
ESSH
A2E An LMS is a Learning Management System. It is a system
that will allow you to enroll in on-line learning programs,
and register for classroom learning events. When
rolled out, this system will identify a development for
each person. That means you will already be enrolled
in your compliance courses! Phase I of the system will
contain the ESSH courses you require to maintain your
qualification. In later phases, we will build an Ascend
course catalog, and add capabilities for you to sign up
for both on-line and classroom learning courses. |
The LMS will create a tracking environment for all
your courses. Everyone will be able to see a list of
their completed courses. Managers will be able to
ensure that their employees are current in their ESSH
qualifications! | This tool will help us standardize
our learning across Ascend while also providing
area specific courses. Stay tuned for more LMS news
as we get closer to launching this new system!
8
Employee Engagement Key Component of Pensacola Safety Effort
Decatur Reduces River Water Pump CostsDecatur recently completed a successful A2E project led by the
Boiler House “A” shift team. | The team identified an opportunity
to optimize the number of river water pumps in service. The Boiler
House operators were managing the river water pumps by a “seat
of the pants” method without enough data to understand whether
river water needs were being met, or whether too much river water
was being utilized. They relied on pressures, experiences, and
“gut” instincts. It was a poorly informed and unstructured way of
managing the pump operation. | The team, led by David Lowery,
identified the opportunity, discussed it with internal customers,
and developed an understanding of the needs, and a better
understanding of the critical equipment that used river water.
The team also consulted with engineering resources, as well
Supervisors and team leads. | The team used the following A2E
tools in their efforts: Team Charter, Brainstorming, 5- whys, Data
Collection, and Mapping. They sought customer participation to
help in the effort, and the team developed a monitoring table of
river water users across the plant. Now, they assist and advise
the manufacturing units in monitoring critical operating
parameters,and preventing pump startup too soon as ambient
river water conditions and manufacturing needs change. The initial
result of this A2E project was a $58K saving in the past month.
The team initially believed this effort was sustainable in the Spring
and Fall seasons, but after further review the team believes that
a net reduction of one pump from continuous operation is
possible for most, if not all year. This total reduction would
produce an annual savings of $337 K. | The key to success for
this team was obtaining and using customer information that
was previously unavailable. By obtaining the information, and
centrally cataloging it, the operators now manage area needs
while minimizing overall pumping costs. Technology was used to
provide pertinent information to operators who now decide how
many river water pumps to run based on data rather than “gut”
instinct! Congratulations to the A2E River Water Pump Team!
There are three key employee safety teams in place at the Pensacola site:
• Site Safety Steering Committee (SSSC)
• Nylon Plant Safety Team
• Area I Safety Steering Team
All three of these teams, composed almost entirely of hourly employees are focused
on improving safety at the site. The SSSC which includes members from each area
of the site targets activities that foster employee involvement such as hazard recognition
and resolution, focused safety audits, Voluntary Protection Program certification, and
poster contests. Members are also working on updating area safety orientation training
videos. | The Nylon Plant Safety Team includes maintenance and operations employees
who are committed to improving their area’s safety. Their activities include those that
address area employee concerns such as working safely in the heat, guarding equipment,
and work practices aimed at reducing risks associated with breaks in processes. |
The Area I Safety Steering Team’s mission is to empower each other to create a safer
and more productive working environment. This team has spent time ensuring that
its members are aligned in its mission and goals. One key accomplishment was to
set up a Cool Zone to provide some heat relief to workers involved in shutdown
activities at the Halcon Unit. This Zone included a tent with chairs, tables, fans,
and drinks. Feedback from the maintenance group was very positive. While each
team has different membership and a unique approach, they all have one common
goal – to create an injury free workplace. Working together, there is no doubt
they will accomplish this goal at the Pensacola site.
ESSH
A2E
Cool Zone
Ascend News Editorial Advisory Board wants your thoughts!Have ideas to share? Want to become a member of Editorial Advisory Board?We would love to hear from you! If you are interested in contributing, please contact us at [email protected].
9
10
SDI SSP Capacity IncreaseThe Greenwood Site recently expanded their Industrial Fiber (IF)
production on their Toray-licensed Solid Stating Process (SSP).
Originally supplied at a 30 tonnes per day capacity, the process
now has been demonstrated at >50 tonnes per day using innovative
technology and engineering modifications with minimal capital.
To achieve the capacity, a Project Team, with members from
Greenwood and Pensacola, developed an EVOP plan. Although
initial results were favorable, high temperature (exotherm) upset
events began plaguing operations, limiting production below
target. Toray could not provide technical assistance for these types
of process modifications. The Project Team developed parallel
paths utilizing experimentation and industry consultants to
develop the fundamental process understanding necessary to
prevent the exotherm events. With diligence, discoveries were
made, allowing process optimization to prevent the upsets.
To date, no new exotherm events have been experienced and
the plant has achieved >50 tonnes per day capacity. The use of
good planning, outside resources, technology development, and
team work has achieved a 67% capacity increase with minimal
cost. Great job by the Greenwood site and the SSP team!
DIAGRAM
GOES HERE!
11
People (anniversary, promotions, new hires)
People (anniversary, promotions, new hires)
12
People (anniversary, promotions, new hires)
13
IT Corner
Thank you for your contribution–
It’s hard to believe that nearly four months
have passed since we went live on our
own SAP system! Our SAP support team
is committed to making sure that all
production issues reported via the ticketing
system are resolved in a timely manner,
all requests for moderate system changes
are prioritized through a Change Control
Board, and all major system enhancements
are projects that are resourced appropriately to deliver significant
improvements to our various operations across Ascend. | Our
Change Control Board (CCB) consists of Finance, ISC, and HR leaders
that meet weekly to review and prioritize all pending requests
ensuring we are focused on the requests that drive the most
business value. If you’re interested in knowing who sits on the CCB
or knowing what changes your coworkers are requesting and when
they’re scheduled to go into effect, please visit our SAP SharePoint
site at [insert site link here]. | In the spirit of continuous improvement,
key SAP enhancement projects underway will deliver greater
visibility to our spend in the areas of Procurement and Logistics,
better on time delivery and credible promise dates to customers,
along with increased revenue opportunity through programs such
as duty drawback -- all coming in 2011. | In parallel with adding
new functionality in SAP, we’re streamlining/cleansing our system
by removing what is not applicable to Ascend. This will make our
SAP system more efficient and easier to use. But there is life
beyond SAP! Here are some other activities in underway… |
The IT Enterprise Applications team is gathering requirements
from business leaders to ensure our portfolio of systems is the right
tool set for Ascend, and is configured appropriately to improve
the way we operate internally, and with our customers and suppliers.
| We are also revamping our IT Service Desk. Our key goals are to
continually improve incident resolution time, establish service
level agreements with ongoing report-outs of success rates against
those commitments, and implement a centralized call center to
service all of our plants and offices, globally. | Beneath it all lies
the infrastructure on which these systems run. Our infrastructure
and network teams are building a plan to apply modern technology
solutions, which will enable us to reduce our overall hardware
footprint while replacing aging hardware in the most cost effective
and least disruptive manner. | Look for more IT news in upcoming
issues of the Ascend Newsletter.
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