PHILIP MORRIS - Legacy Tobacco Documents Library

Mr. Manfred Gesierich
Korber A.G.
80 Bergedorf 800460
Kampchaussee 14-18
WEST GERMANY
Dear Manfred:
PHILIP MORRIS
U.S. A.
P.O. BOX 28603, RICHMOND, VIRGINIA 23261 TELEPHONE (804) 271-2000
November 21, 1989
Subject: Protos 100 Data Collection Qualification
1. A delegation from Philip Morris U.S.A. will visit the Korber A.G.
facility in Bergedorf, West Germany during the week of December 4, 1989
to discuss the data collection system on Protos 100 and other related
subjects. Hotel accommodations need to be made for the evening of
December 3 through the morning of December 10, 1989 for the following
personnel:
Bogdan Alexander Joe Rush
Ron McGuffin Will Snow
2. The VAX software developed at Philip Morris for communication with MLP
requires the OSAK software package for VAX and the tape drive model TK-50
for loading the program. Please indicate the availability of these two
items at Korber A.G. as soon as possible.
/rbc
Sincerely,
G>t*oUiu QW*u*A>-—
B. N. Alexander
copy: D. Basinger, Hauni Richmond E. E. Richardson
J. L. Calloway 0. B. Rush
D. W. Hirsch R. E. Shaulis
M. G. Hubbard R. G. Snow
R. H. Hubbard W. C. Snow
R. V. McGuffin R. L. Trebilcott
D. E. Merrill K. S. Whittle
G. B. Reid
File: CD01-0062;PR154;C15
MARLBORO BENSON & HEDGES MERIT VIRGINIA SLIMS PARLIAMENT SARATOGA MULTIRLTER ALPINE

PHILIP MORRIS U.S.A.
INTER-OFFICE CORRESPONDENCE
RICHMOND, VIRGINIA
G. M. Iyon Oav>- Nov. 21, 1989
V. T. Wnitaker
I.E. SUPPORT FOR DOWNTIME STOP? ON FOCKE 700
Subject
This memo requests I.E. support to perform a downtime study on the Focke 700
module.
Highlights
Philip Morris will be evaluating the Focke 700 module at the Machinery
Development Facility. As part of the evaluation, we would like to make a (2)
week production run. We will run the module at 700ppm, one shift a day. We
request that the I.E. group perform a downtime study during this period. The
current schedule for the evaluation is attached.
cc: D. A. Davis
H. K. Junginger
R. T. Mitten
A. P. Shulick
File: EA38-0001; PR154; C15
C>

Schedule Heme i FOCKE 700 AND NONORAiL EVALUATION
Responsible : V. HHITAXER/H. JUNGINGER
As-of Dote : 16-Hov-89 Schedule File : C:\TL3\DATA\700TEST
Task Naae
TUNE t TEST 700
Start
Date
15-Jar*-90
EVALUATE SETUP & ADJUSTN 15-Jan-90
EVALUATE SAFETY
EVALUATE CONTROL LOGIC
EVALUATE PROOUCT QUALITY
TEST MAT'L. KANIPULATOR
TRAIN P.M. PERSONNEL
TEST RUNNING
TEST HONORAIL THROUGHPUT
TEST LIFT TABLE
EVALUATE 775 BOXER
DOWNTIME STUDY
QUALITY AUDIT
DETERMINE MANNING
EVALUATE ERGONOMICS
TEST PALLETS & CARTS
EVALUATE MAINTENANCE REQ
TEST BRAND CHANGE-OVER
EVALUATE BRAND SECURITY
INSTALL PM UNIV. CARRIER
TEST PM UNIVER. CARRIER
DISMANTLE t, CRATE 700
22-Jan-90
29-Jan-90
5-Feb-90
9-Feb-90
15-Jan-90
19-Feb-90
19-Feb-90
19-Feb-90
19-Feb-90
19-Feb-90
19-Feb-90
19-Feb-90
19-Feb-90
19-Feb-90
19-Feb-90
5-Mar-90
7-Mar-90
12-Mar-90
16-Mar-90
29-Mar-90
90
Duratn End Jan
(Days) Date 15 22 29
if*
10
5
14
9
5
35
28
10
10
10
10
10
10
10
10
10
3
3
4
9
10
15-FeO-yu nrn«mnmn»»n
26-Jan-90 ^^.
26-Jan-90 ^ ^ .
15-Feb-90
15-Feb-90
2-Mar-90 ' • • • • ^
2S-Kar-90
2-M8P-90
2-Mer-9Q
2-Kar-90
2-HBP-90
2-Mor-90
2-Mar-90
2-Mar-90
2-Mar-90
2-Mar-90
7-Mar-90
9-Map-90
15-MBP-90
28-Kar-90
11-Apr-90
Feb Har Apr
5 12 19 26 5 12 19 26 2 9 17
• •

PHILIP MORRIS U.S.A. 1*7
INTER-OFFICE CORRESPONDENCE \ /
RICHMOND. VIRGINIA
To: Mr. G. B. Reid Date: Nov. 16, 1989
From: V. T. Whitaker
Subject: . Shortened Test Schedule for Itacke 700
Subject
This memo outlines a shortened test schedule for the Focke 700 packer module
and monorail. This represents the minimum time that the Focke 700 should be
tested before it is ready for production. This does not include time to
train operators and fixers.
Highlights
The time for test running the 700 module has been shortened from the 26 weeks
on the original schedule down to 11 weeks. The attached schedule shows the
main tasks that need to be accomplished during these 11 weeks. The tasks are
as follows.
1. Evaluate Setup & Adjustments - Check ease of making sensor adjustments,
temperature adjustments, timing and machine adjustments.
2. Evaluate Safety - Check all machines and peripheral equipment for safety
hazards and that it complies with safety specifications.
3. Evaluate Control Logic - Test the operational sequence that controls the
speeds and starting and stopping of the various pieces of equipment.
4. Evaluate Product Quality - Check pack, carton, and case quality. Check
that the monorail does not damage bobbin materials.
5. Test Material Manipulator - Test ease of operation, safety/ and
practicality of a manipulator. The manipulator is a back-up system for
loading bobbins in the event of a monorail failure.
6. Train EM Personnel - Have the Training Center personnel, mechanical
supervisors, and electrical supervisors present during the test running
to become familiar with it.
7. Test Monorail Throughput - Ensure that the Monorail maintains the supply
of the direct materials.
8. Test Lift Table - Evaluate the effectiveness of the lift table as a means
to minimize the bending over required to unload pallets.
9. Evaluate. 775 Boxer - Conduct a mini qualification on the prototype 775
boxer since it was not tested at PM Holland.
10. Downtime Study - Conduct a 2 week I.E. downtime study.
11. Quality Audit - Conduct quality audits during the test run to check
quality consistency.
12. Determine Manning - Determine what personnel is needed to run the module
at full speed.
13. Evaluate Ergonomics - Assess the man-machine interfaces.
14. Test Pallets & Carts - Test the ease of off-loading carts compared to
off-loading pallets of direct materials.
15. Evaluate Maintenance Requirements - Keep a log of the maintenance that is
required during the test run.
\' L

Page 2
16. Test Brand Change-over - Assess the ease of removing naterials from the
module and loading new naterials.
17. Evaluate Brand Security - Test the effectiveness of the brand security
features that Focke has designed into the system.
18. Install Hi Universal Carrier - Replace the Focke bobbin carrier with the
PM designed Universal carrier and adjust the bobbin elevators to
accomodate it.
19. Test Hi Universal carrier - Test the ability of the HI Universal carrier
to handle all direct materials.
There are two schedules attached. The first shows the detailed tasks
involved in the Tune 6 Test phase and the Test Running phase. The second
schedule shows the entire project plan without the detailed tasks.
cc: W. C Hamilton/ A. P. Shulick ,
Junginger - ..d*?
Mitten Y^ M
H. K.
R. T.
File: E2k38-0001;Project Schedules;C15

Schedule Maee : FOCKE TOO AND MONORAIL EVALUATION
Responsible : V. UHITAKER/H. JUNG1HCER
As-of Date : 16-BW-89 Schedule File : C:\TL3\DATA\700TEST
Te»fc Haw
Start
Date
TIME t TEST 700 15-Jan-90 24
EVALUATE SETUP t ADJUST* 15-Jan-90 10
EVALUATE SAFETY 22-Jan-90 5
EVALUATE CONTROL LOCiC 29-Jen-90 H
EVALUATE PRODUCT QUALITY 5-Feb-90 9
TEST MAT'L. MANIPULATOR 9-Feb-90 5
TRAIN P.K. PERSONNEL 15-Jan-90 35
TEST EUNHIN6 19-Feb-90 28
TEST MONORAIL TKROOCHPOT 19-Feb-90 10
TEST LIFT TA8LE 19-Feb-90 10
EVALUATE 775 BOXER 19-Feb-90 10
DOWNTIME STUDY 19-Feb-90 10
QUALITT AUDIT 19-Feb-90 10
DETERMINE HAMMING 19-Feb-90 10
EVALUATE ERGONOMICS 19-Feb-90 10
TEST PALLETS t CARTS 19-Feb-90 10
EVALUATE KAINTEKAMCE REQ 19-Feb-90 10
TEST BRftiCO CHANGE-OVER 5-Kar-90 3
EVALUATE BRAND SECURITT 7-Mar-90 3
iNSTALL PM UNIV. CARRIER 12-Mar-90 *
TEST PM LKIVEE. CARRIER 16-Mar-90 9
DISMANTLE t CRATE 700 29-Mar-90 10
Duratn End
(Days) Date
15-Feb-90
26-Jen-90
26-Jen-90
15-Feb-90
15-F«b-90
15-Feb-90
2-Nar-90
28-Nar-90
2-Mar-90
2-Mar-»0
2-Nar-90
2-Ner-90
2-Mar-90
2-Kar-90
2-Har-90
2-Mer-90
2-Kar-90
7-Mer-90
9-Mer-90
15-Nar-90
28-ftor-90
li-Apr-90
90
Jan
15 22 29
Feb
S 12 19 26 Kar
12 19 26 Apr
2 9

Schedule Haoe : FOCJCE 700 PROJECT PLAN
Responsible : R. T. HITTEK
As-of Date : 16-Kov-S9 Schedule File : C:\TL3\DATAV700PLAM
PROJECT SCHEDULE FOR THE 700 IH THE MACHIKERT DEVELOPMENT
FACILITY
Start
Task Naae Date
SHIP FOCKE 700 COMPLEX TO USA 13-Oct
IKSTALL OSCAR t PROTOS #1 Z3-Oct
INSTALL FOCKE 700,740,750,790 27-Mev
VACATION/HOLIDAY 18-Dec
INSTALL FOCKE 317,775,485 3-Jan
INSTALL PROTOS #2 3-Jar.
TUNE t TEST COMPLEX 15-Jan
TRAIN P.M. PERSONNEL 15-Jan
TEST RUNNING 19-Feb
OISKAHTLE t CRATE COMPLEX 29-Mar
Duratn End
(Days) Date
20
15
15
9
8
8
24
35
28
10
9-Nov
10-Nov
15-Dec
2-Jan
12-Jen
12-Jan
15-Feb
2-Mar
28-Mar
11-Apr
T — Detail Task ••••• Suanary Teak H Milestone
••^ (Started) ssass (Started) >» Conflict
B ^L_ (Slack) •=— (Slack) ..•• Resource delay
.................. scale: 1 day per character --------------------
TIME LINE Gantt Chart Report, Strip 1
C
89
Nov
6 13 20 27 Dec
4 11 18
90
Jon
27 2 8 15 22 29
Feb
5 12 19 26
Mar
5 12 19 26
Apr
2 9 17

PHILIP MORRIS U.S.A.
INTER-OFFICE CORRESPONDENCE
RICHMOND, VIRGINIA
J. B. Vaden Date: Nov. 9,1989
V. T. Wiitaker
G.D Packer Improvements Since 1983
Subject
This nemo lists the Engineering projects that have been done since January
1983 to improve the operating efficiencies of the G.D packaging equipment in
the Manufacturing Center.
Highlights
1. Machine Tests Standardized
There have been 393 Machine Tests standardized and implemented on the G.D
packaging equipment since Jan. 1983. The breakdown is as follows.
180 G.D X-2 MT'S
108 G.D X-l MT'S
66 G.D 4350 MT's
30 G.D Boxer MT's
9 G.D Stamper MT's
2. G.D Rebuild Program
Since 1983 there has been many G.D.X-l and G.D.X-2 packing complexes rebuilt
at York Engineering and G.D Richmond. This rebuild increases the speed
rating from 300 ppra to 400 ppm.
3. Foil Embossing Improvement
Implemented steel on steel embossing as opposed to steel on rubber embossing
to increase the life of the embossing rollers and improve the quality of the
embossing.
4. PARK (Phase 2) Project
PM USA angineering is working with PM at Neuchatel on the PARK project. The
goal is to design ways to improve the efficiency of a Protos/G.D.X-2 module.
5. ITRAN Vision System
Itran vision systems have been installed on many of the G.D.X-l packers in
the M.C. for 100% quality inspection. This has been a useful tool to the
operators in that it shows them when machine adjustments move out of
acceptable tolerances and allows them to get it back within tolerance
quicker.
oc: W. C. Hamilton/A. P. Shulick
File:0000-0001:Presentations;C15

PHILIP MORRIS U. S. A.
INTER-OFFICE CORRESPONDENCE
Richmond, Virginia
To: E. J. Wooldridge Date: November 9, 1989
From: L. L. Pitt
Subject: LARK 5-PAK CARTON
There has been some concern over the top pack of cigarettes staying in the lid when
first opening the cartcn. This is caused by friction between the lid and the edges
of the pack and pressure from the hand gripping the lid. To alleviate this
condition, sample blanks were made with a taller innerframe in the front of the
carton that is approximately 1mm from the edge of the top pack. These samples were
run on the cartoner in McFadden warehouse during the production run. This
modification to the blank helped considerably, but did not completely eliminate the
problem. One of the reasons, as mentioned above, is the pressure of the hand and
fingers. If the lid is gripped at the two outside corners of the carton, the pack
will not raise with the lid. But if the thumb is placed in the front-center of the
lid (which seems to be the most natural way to open it) enough pressure is placed on
the pack itself, due to the cut out area of the innerframe, to lift the pack with
the lid. Another situation that will cause the pack to stay in the lid is the
attitude in which the carton is held while opening. If the back of the carton is
parallel with the floor, gravity plus any friction will cause the pack to tip over
into the lid. If the carton is help upright, this does not occur.
Another suggestion to eliminate this condition was to make the blank larger for a
more loose fit of pack-to-carton. This cannot be done due to the machine methods of
forming the carton. The five packs act as a mandrel around which the carton is
formed. The carton therefore, will always take the shape and size of the packs.
This has been tried in the past with no success.
A third suggestion was to glue the top pack to the innerframe using stick-no-stick
glue. This would not be advisable as the glue could not be controlled sufficiently
to keep from getting all over the pack and would possibly create a worse problem in
getting the pack out of the carton. Also, the adhesive would show up against the
white on the pack.
In conclusion, the taller innerframe is the best solution even though it is not
100%. However, the cost of changing the blank may be prohibitive if done now since
the existing five-up production die cannot be modified. The cost of a new die will
be about $5,000 and will take approximately six to eight weeks to make. The
existing die will eventually have to be re-knifed because of wear. The most
cost-effective means would be to make a new die at that time.
Engineering and Purchasing technical services will continue to search for a solution
if requested to do so. If you have any questions, please let me know.
—?V^_
L. L. Pitt
cc: W. C. Hamilton H. Vogt
P. D. Moore IDA/S. Dodge (CP01-0074;PR154;C15)
G. B. Reid
O fr

PHILIP MORRIS U. S. A. \1
INTER-OFFICE CORRESPONDENCE
Richmond, Virginia
To: Mr. C. V. Bucker Date: November 10, 1989
From: R. T. Mitten
Subject: Minutes of Focke Meeting of Oct. 26. 1989
The following are the minutes from the meeting held with Focke
representatives on October 26, 1989.
1. Glue Probes:
Bob Mitten asked Focke about glue probes he had received and he was told
that they are new probes which have been epoxy sealed. Focke is sending
Bob five new amplifier units to be used on the two 400ppm machines at
Stockton Street.
2. CRT Spares:
Bob informed Focke of the DC converter failure in the monochrome monitor
in the 08 BPOW and no spare available for it. Focke asked the part be
sent to Verden for replacement and a Focke part number will be assigned
for spare part ordering. Focke also indicated that it would be advisable
to replace the monochrome with a color CRT for standardization of
machines. Focke will quote on the CRT change.
3. DC Drives:
The problem of DC Drive repair was discussed. Focke indicated that they
would have Siemens, Germany contact Siemens, USA and arrange for repair of
Drives in the US. Focke will inform PM of the Siemens contacts in the US
and Germany. Focke also indicated they would have the Siemens training
department in the US informed by Siemens, Germany on the units they are
using so the proper training can be given.
4. Ends Detector Boards:
Focke provided PM with a complete list of all circuits boards and parts
numbers used in any of the ends detectors made by Focke. This information
will used to order the correct boards for spares.
cc: B. Diehr
T. Joyce
File: CP01-0000;PR164;C15

Mr. Jurgen Sussenguth
Focke & Oo.,Inc.
Siemensstrasse 10
Postfach 1369
D-2810 Verden (Aller)
West Germany
PHILIP MORRIS
U.S.A.
P.O. BOX 26603, RICHMOND, VIRGINIA 23261 TELEPHONE (804) 274-2000
Subject: Pneumatic Relay for E-Stop Circuit
Dear Jurgen,
November 10, 1989
In response to your letter dated Nov. 3, 1989, we find the reccnnended
pneumatic relay from Telemecanique of acceptable quality and approved for
use on future equipment. We also checked your drawing for inplementation
of the relay and would like to note that the reset button for the 510 and
485 should be removed from the circuit (see attached drawing) and used
only with machines having the pneumatic timing relay, KL9/P.
Since the reliability of this component is the critical factor to
disconnecting electrical power to the machines, a period of close
observation and evaluation will be necessary to determine that this is
the best design to meet our safety requirements. Our maintenance
department is aware that regularly scheduled tests of this circuit will
be required.
To eliminate this concern of reliability and the necessity for scheduled
testing of the circuit, Focke should give consideration to future
machines that may be designed with a mechanical type of braking mechanism
for stopping the machine under an emergency stop situation. Dynamic
braking should be used under normal stop conditions.
If you have any questions or further discussion on this subject, please
feel free to call me at extension 4323.
Attachment: Focke Dwg. 510.17.035
Yours Sincerely,
Eob Mitten
MARLBORO BENSON & HEDGES MERIT VIRGINIA SLIMS PARLIAMENT LIGHTS PLAYERS SARATOGA CAMBRIDGE ALPINE MULT1RLTER

Page 2 - Pnauratic Relay Far E-Stop Circiut - NcweEtoer 10,
oc: C. Ehrharctt - Pocks, Verdan
C. P. ELlett
H. M. Gonzales
B. B. Gray
W. c. Hamilton
J. E. Karris
J. W. Hctaack
M. G. Hubbard
D. Neuber - Focke, N, J.
G. B. Raid
A. P. Shulick
M. C. Sterchelle
Filet 0000-0001?PB154,C15

Mr. Claus Ehrhardt
Focke & Company
Siemensstrasse 10
Verden (Aller)
West Germany
RE: LARK STANDARDIZATION
Dear Claus:
PHILIP MORRIS
U.S.A.
P 0. BOX 26603. RICHMOND. VIRGINIA 23261 TELEPHONE (804) 274-2000
November 7, 1989
Pursuant to our November 6, 1989 telephone conversation, the information
needed from Focke and Ccmpany to expedite the standardization program is as
follows:
1. Marked-up Catalog Pages: One set required.
2. Parts List(s): Identifying all components required for installation.
3. Installation Instructions: One set is required. Installation
instructions are to be detailed enough to provide all appropriate
information for installing the modification.
This information is needed for the Alpha Numeric Display, Accusort Scanner
and Vacuum Transducer Kits.
If questions arise or additional information is required, please contact me
at once.
cc: C. Bucker
H. Gonzalez
B. Gray
W. Berghahn - Focke, USA
IDA File: EJ05-0006:PR169;C15
(F0CKE.DOC)
MARLBORO BENSON 4 HEDGES MERIT VIRGINIA SLIM8 PARLIAMENT LIGHTS PLAVERS SARATOGA CAMBRIDGE ALPINE MULTIFILTER
r» ?7

PHILIP WDRRIS U. S. A.
INTER-OFFICE CORRESPONDENCE
Richmond, Virginia
To: W. C. Hamilton Date: November 7, 1989
From: D. C. Wilder
Subject: 2QTH STREET ULTRASONIC WELDERS
As you requested, here is a breakdown of cost for renting or buying the 8
ultrasonic welders currently being used for production at 20th Street. The 8
rental units will be phased out starting January 1990 thru March 1990, and
replaced with 900 series welders.
RENTAL
Unit Rental Cost at $ 745.00/month
8 Units being rented at $ 5,960.00/month
Units rented from July-October 89 at $17,880.00
Projected turn-over of all units to 900
series by April 1, 1990 $20,860.00
TOTAL PROJECTED RENTAL COST $38,7*0.00
PURCHASE
Unit Cost at $ 7,450.00 each
8 Units $59,600.00
10% Discount ($5,960) $53,640.00
PURCHASE WITHIN NEXT 10 DAYS
July-October rental cost will be
credited toward purchase $17,880.00
Purchase cost $53,640.00
Credit $17,880.00
8 Units Cost Today $35,760.00
/nld
I. C. Wilde*
cc: R. C. Donoff S. Rinehart
H. H. Fishburne IDA/S. Dodge (PR154/C:15)

PHILIP MORRIS U. S. A.
INTER-OFFICE CORRESPONDENCE
Richmond, Virginia
To: Mr. R. S. Skead Date: November 14, 1989
From: R. T. Mitten
Subject: Marlboro Brand Standardization
The following information 1s in response to your requests during our
meeting on Marlboro brand standardization. As discussed, you asked for
approximate costs and deliveries for the purpose of your Initial
evaluation. Before any definite conclusions are made, I would suggest
that a more detailed Investigation of the machine requirements be
conducted and quotations from the OEM's be obtained.
The three areas In question were the teartape, innerframe, and foil.
TEARTAPE
1. Cost to change from a teartape width of 1.6mm to 2mm:
Modify 199 machines at $5000 e?,. - $995,000
2. Cost to standardize the position of the teartape pull-tab:
Modify 104 soft packers at $50,000 ea. - $5,200,000
INNERFRAME
FOR
1. Cost to modify machines running non-standard shaped Innerframe:
Modify 4 machines(6's HLP) at $2905 ea. - $11,620
- 5 weeks delivery for the I.F. cutter
Modify 1 machine(20's HLP) at $4860 ea. « $4,860
- 6 weeks delivery for the I.F. cutter
1. Cost to standardize machines to the "Brinker Embossing Pattern":
Modify 95 box packers at $5870 - $557,650
- 6 weeks delivery for the rollers, 2 years minimum for total
change-over
I hope this information along with the embossing samples and report that I
gave you will be of benefit. Once Operations Services completes their
study of the new foil embossing pattern, I will forward those results to
you as well. If you have any further questions, please feel free to call
me.
Attachment: Machines Running Marlboro Brands
cc: E. Gruca
W. C. Hamilton
A. P. Shulick
File: 0000-0001;PR154;C15

MACHINES RUNNING MARLBORO BRANDS
&£ - 15 G.O X-500 (by mid-1990)
- 15 Sasib Alpha
- 47 G.O X2
10 G.D XI
87 Total
Stockton
Louisville
Cabarrus
- 5
- 4
- 5
- 6
- 3
- 1
- 5
29
- 17
- 11
- 4
32
- 28
- 15
- 8
G.D XI
G.D X2
Focke
AHF
20's HLP
14's HLP
6's HLP
Total
G.D XI
G.D X2
6's HLP
Total
G.D XI
G.D X2
G,D MQO
51 Total
Soft Pack Machine Types Box Pack Machine Types
G D X500 G.D X2
G.D XI Focke
Sasib Alpha HLP
AMF

PHILIP MORRIS U.S.A.
INTER-OFFICE CORRESPONDENCE
RICHMOND, VIRGINIA
X. S. Whittle Datt: November 16, 1989
M. C. Sterchele y W

t 3
I
AUT ATI ORM
1. FftRT NUMEER A3/ - f f 6 ^ ^J
2. EQUIPMENT TYPE -? V P-
/£^
a MODULE FROM WHICH PART WAS REMOVED *^>° j kdOCO^-W)
4. CHECK IF FftRTS PROBLEM REPORT WAS RLLED OUT _i^
5. RETURN FORM TO JIM COLLINS
SUPERVISOR'S SIGNATURE.
GROUP LEADERS
jL^21^ APPROVAL
->

PHILIP MORRIS U. S. A.
INTER-OFFICE CORRESPONDENCE
Richmond, Virginia
To: W. P. Taylor Date: November 17, 1989
From: R. C. Donoff
Subject: OBJECTIVE STATUS FOR SUPER SLIMS PACKERS
The following are our objectives for improving the efficiency of the Super Slims
packers in Louisville.
Increased Machine Speed
Machine speed of 225 to 250 packs per minute is our target. The limiting factors
are the components in the innerframe folding area, behavior of materials (foil and
innerframe) at higher speeds and operation of the carton spacer inserter at higher
speeds. We plan to do the following:
1. Run the packer dry, with a strain gauge on the external folding plate lever and
closely monitor other components in the innerframe section. This will
determine the upper level of machine capability.
2. Run the packer with product to determine behavior of materials at the higher
speed.
3. Monitor quality at higher speed.
This test will commence when a packer is available. If time permits on packer #5 or
when packers #1, 2, 3, or 4 can be released from production.
Mentholated Foil Roller Scraper
A device to periodically scrape and remove the menthol crystal build up from the
foil accelerator roller has been fabricated and is being coated.
It will be installed in Louisville the week of November 27, if a packer can be
removed from production.
Accumulator Between The Packer and Wrapper
We will Investigate the effectiveness of an accumulator to limit the ups and downs
of the packer while clearing wrapper, inserter, and boxer jams.
3rd Wheel Pocket
Change material of pockets from nylon to aluminum to improve pocket stability and
eliminate warpage. Parts are in process for packer #5. They will be tested and
incorporated into the other four packers.

Mr. W. P. Taylor
Page - Two -
November 17, 1989
OBJECTIVE STATUS FOR SUPER SLIMS PACKERS
Innerframe Scoring Knives
A transverse knife was installed in Louisville and made an immediate improvement.
Innerframe scoring operated smoother, quieter, and the innerframe roll could be run
to the core. However, due to the increased load on the innerframe knife we
experienced a repeated cam follower failure. Redesign is underway to remove some of
the mass, change the knife over travel to a positive stroke and replace the ball
bearing cam follower with a standard cam follower. Parts will be ready for
installation the week of December 11.
Innerframe Slit Width
Left to right registration of the innerframe is critical for proper pack make up.
Narrower slit width innerframe lias been ordered for Louisville which will allow
leeway in registration and should improve consistency of pack makeup. This will be
tried in Louisville when received.
Power Unwind of Innerframe
Mass has been doubled on the innerframe roll. Design has started on power unwind
which will reduce load and take the snap out of the innerframe drive. Time is not
available to put this on packer #5.
4th Wheel
Keys and keyways have been added to parts which must be removed for clearing of
jams. This will make parts easier to set. Parts are in process for packer #5.
They will be tested and incorporated into packers #1, 2, 3, and 4.
4th to 5th Wheel Transfer
Check layout has been made to study parts relationship in this critical area. Areas
to be improved have been identified and parts are in process for packer #5. After
testing, parts will be incorporated into packers #1, 2, 3, and 4.
5th to 6th Transfer
The G.D detector at the 5th to 6th wheel is an "out of position" detector. Design
is underway to replace this with a jam detector.
yM

Mr. W. P. Taylor I
Page - Three -
November 17, 1989
OBJECTIVE STATUS FOR SUPER SLIMS PACKERS
6th to 7th Transfer
G.D is sending us a jam detector that will provide better protection for the 7th
wheel.
Control Out of the Wrapper
Reliance on gravity rejection in the two pack wrapper wheel has necessitated large
amounts of clearance in the wheel pockets. This is not a problem in a normal
transfer but when transferring into an inserter where the packs are being aligned
before separation for spacer insertion, skewing occurs.
Design of tighter pockets with positive rejection has been started; however, will
not be available before completion of packer #5.
Inserter Hopper
The weak point of the carton spacer inserter is the insertion of the two outer
spacers. The Longford inserter is scheduled to be installed on packer #5 and its
hopper is reputed to be able to handle bowed inserts in a positive manner. After
testing on packer #5 the hopper design will be incorporated into packers #1, 2, 3,
and 4.
Boxer Drive Disengagement
When the inserter is purged to clear jams, a carton blank is on the way to the
forming box. The boxer attempts to make up a carton with no packs present resulting
in a top folder jam. The boxer is being redesigned to disengage the carton feed
when a missing insert(s) is being detected. Design is complete and will be
installed on packer #5, tested and incorporated into packers #1, 2, 3, and 4.
Setting Book
Information on machine settings has been given to the Louisville Training Center.
They are compiling a book which should be available in January.
/co
cc: W. C. Hamilton R. N. Webb
G. B. Roid IDA/S. Dodge (CP01-0062;PR154;C15)
S. V. Ward
'0- J

RICHMOND MANUFACTURING CENTER
MODERNIZATION PROJECT
DRAWING TRANSMITTAL
Drawing Transmittal Purpose;
BAY 1
•—' Review and Comment to Originator by
CZf Distribution of Pinal Drawing
Drawing Originator: B. £>. &E-/V) Date: llflfa /8^
PM Mail Location QIC TIE Telephone Number: 4£>#6
^Transmittal only, Drawing not enclosed.
Contact drawing originator if drawing is required.
General Distribution Name (copies)
*A. L. Collins - OC/TTE
*W. C. Hamilton - OC/TIE
*T. Babbitt - MC/EW2
*R. L. Davidson - MC/EW2
J. A. Pruden - CC/T2E (1)
*B. C. Parkinson • MC/Primary
K. S. Whittle- MC/EW2 (1)
T. P. Foster - MC/EW2 (3)
R« G. Snow - KC/EW2 (1)
*R. D. Tobey - MC/QA
*P. W. Loaelin - MC/EW2
A. R. Pannell - MC/EW2 (1)
C. D. Hansen - MC/EW2 (1)
\J. S. Jones- OC/AIE (1)
*G. M. Lyon - 0C/A2W
J. M. Beal - QC/T2E (1)
*P. K. Moriarty - MC/EW2
This packane contains £
CORE: 3 t.ou»a^£ ,/ow»\
COfZ.^ 3 LOOi4

PHILIP MORRIS
U.S.A.
P.O. BOX 26603, RICHMOND. VIRGINIA 23261 TELEPHONE (804) 274-2000
Mr. Cort Rosebro
G.D Package Machinery, Inc.
501 Southlake Boulevard
Richmond, VA 23236
Dear Cort:
Subject: 2nd Wheel Housing Wear, 36X72
November 17, 1989
This is to confirm our discussion regarding the wear on 2nd wheel housing
0X7110, an example of which. I left with you on 11/15/89. Per Mr. Andy
DeVlitt of our Cabarrus plant, Uiis casting was recently removed from an X-1
on the "B" row at Cabarrus. This is not the first casting to be replaced,
and Mr. DeWitt and Mr. Al Karvelis of the Manufacturing Center have
indicated that other X-l's and X-2's are showing signs of wear in this
area. When the wear reaches a certain point, foil folding quality is
affected. Cabarrus has replaced 3 of the 0X7110 castings and 2 of a
similar older casting, 0X3892, in the past 12 months per our inventory
records. The measured diameter of the wear points was 109.847mm and
109,855mm on the outer and inner raceways respectively. The INA specified
minimum diameter for the bearings is 109.973mm, meaning the casting is worn
0.126mm undersize.
This bearing configuration has been supplied as a G.D standard in X-l's and
X-2's after batches 10942 for X-l's and 10957 for X-2's. It is being
retrofitted to all earlier X-2's as kit 36X72 in our rebuild program. When
this kit became available several years ago, Mr. Dan Sybert and I expressed
our doubts about the engineering soundness of running needle bearings on a
cast iron inner race of dubious surface finish quality. G.D assured us
there would be no problem.
Now that there appears to be a problem, we would like G.D to:
1. Recommend any action possible to prevent the problem from spreading.
2. Supply a repair procedure to salvage the worn castings and prevent
future wear once repaired.
MARLBORO BENSON»HEOGES MERIT VIRGINIA SLIMS PARLIAMENT LIGHTS aAYERS SARATOGA CAMBRIDGE ALPINE MULTIFILTER
I*
\V

Mr. Cort Rosebro
Page - Two -
November 17, 1989
2nd Wheel Housing Wear. 36 x 62
The factories must provide more information about lubrication procedures
and specific machinery serial numbers of the affected machines in order to
assess the magnitude of the problem and assist G.D in finding a solution to
the problem.
/co
Attachment: Catalog Pages 36X72.01
cc:
R. Allison
A. DeWitt
A. Karvelis
R. N. Webb
A. Shulick
B. Wray
IDA/S. Dodge (PR154;C15)

V
\J-

PHILIP MORRIS
U.3.A.
P.O. BOX 2M03, RICHMOND. VIRGINIA 23261 TELEPHONE (804) 274-200O
Mr. Paul Toland
Fleetwood Systems Inc.
Starline Division
P.O. BOX 590025
Orlando, FL 32859-0025
November 20, 1989
RE: CABLE SPEED CHANGES FOR BAY 1 CONVEYOR SYSTEMS
Per our conversation this morning, please find the new cable
speeds required to accommodate the electrical system and
cable slippage. Pulleys on the cable drive gearboxes and
associated drive shafts should be replaced to increase
speeds as shown:
CABLE DRIVE NUMBER PRESENT SPEED NEW SPEED REO'D
(maximum) (maximum)
CD1 240 fpm 265 fpm
CD2 260 fpm 300 fpm
CD3 287 fpm 315 fpm
CD4 298 fpm 325 fpm
CDS 311 fpm 335 fpm
I can be reached at (804) 274-5679 if questions arise.
Sincerely,
cc:T. Ashworth
J. Bowman- Starline
H. Gonzalez
M. Hubbard
P. Melton
T. Nguyen
M. Perry
D. Sharpe
K. Whittle
E. Wilkinson
File No. 1-2100 M/C Modernization
IDA File CP01-0010:PR154:C15
Michael Sterchele
MARLBORO BENSON * HEDGES MERIT VIRGINIA SUMS RARUAMENT LIGHTS PLAYERS SARATOGA CAMBRIDGE ALPINE MULTIFILTER
\ * d

PHILIP MORRIS U.S.A.
I N T E R - O F F I C E CORRESPONDENCE
RICHMOND, VIRGINIA
TO: .DISTRIBUTION DATE: NOVEMBER 21, 1989
FROM: .B. WETTSTEIN
SUBJECT: .EVALUATION OF "BALLUFF" SELF-MONITORING PROXIMITY
PROBES. 1 OF 2
IT HAS BEEN REQUESTED THAT ENGINEERING DEVELOP A SELF
MONITORING PROXIMITY DETECTORS FOR THE MISSING TEN PACK DETECTOR ON
THE G.D 4350 BOXER. I AM REQUESTING YOUR ASSISTANCE IN THE TESTING
OF A ELECTRICAL MODIFICATION, CONSISTING OF NEW PROXIMITY PROBES
WITH A SELF DIAGNOSTIC SYSTEM. THIS SYSTEM IS MADE BY BALLUFF INC.
AND IS BEING INSTALLED ON OUR NEW SASIB, AND G.D X500 PACKERS. WE
WOULD LIKE TO DETERMINE IF THE SYSTEM COULD BE USED ON ALL OUR G.D
4350 WRAPPER/BOXER.
PRESENTLY WE HAVE TEN STANDARD PROXIMITY PROBES INSTALLED
ON THE EXIT OF THE G.D 4350 TO TEST THE CARTONS FOR A MISSING PACK.
IF ANY OF THESE DETECTORS IS MALFUNCTIONING OR NOT INSPECTING, WE
COULD SEND OUT CARTONS WITH MISSING PACKS. THIS M.T. WOULD REPLACE
THE STANDARD PROXIMITY PROBES WITH THE NEW PROXIMITY PROBES THAT
INCORPORATE A SELF-DIAGNOSTIC SIGNAL. THE OUTPUT OF THESE PROBES
WILL BE SENT TO A TEST MONITOR UNIT, WHICH WILL DETECT IF THE
PROXIMITY PROBE, OR THE CONNECTING CIRCUIT IS SERVICEABLE.
IF A FAULTY UNIT IS DETECTED, THE CARTON BEING INSPECTED WILL BE
REJECTED, THE G.D 4350 WILL BE TURNED OFF AND WILL INDICATE
A BAD MISSING PACK INSPECTION CIRCUIT. THIS TEST SHOULD IMPROVE
OUR QUALITY AND REDUCED CUSTOMER COMPLAINTS BY ASSURING THAT
ALL CARTONS WERE FULL WHEN EXITING THE G.D 4350 BOXER.
I HAVE ONE SYSTEM IN TEST AS M.T.2730, SELF-DIAGNOSTIC
PROXIMITY PROBES ON PACK DETECTORS, G.D 4350. IT IS INSTALLED ON A
REBUILT G.D X-l, PACKER AT THE M/C, RICHMOND. IT HAS BEEN WORKING
SATISFACTORY FOR OVER A MONTH. WE ARE INTERESTED TO LEARN IF THIS
SYSTEM COULD BE INCORPORATED ON ALL THE TEN PACK DETECTOR CIRCUIT
USED ON THE G.D 4350, BOXER. IF YOU ARE INTERESTED I WOULD LIKE TO
EXPAND THIS TEST TO OTHER LOCATIONS. THIS SYSTEM WILL CONTINUALLY
CHECK OUR PROBES, CONNECTIONS, WIRING, AND INFORMING US IF A
DETECTOR IS NOT WORKING.

DATE: NOVEMBER 21, 1989
SUBJECT: .EVALUATION OF "BALLUFF" SELF-MONITORING PROXIMITY
PROBES. 2 OF 2
I WOULD LIKE THIS ON THE AGENDA FOR DECEMBER 1989
STANDARDIZATION MEETING. I WILL BE AVAILABLE TO PROVIDE THE
ENGINEERING SUPPORT AND PHILIP MORRIS DOCUMENTATION. THANK YOU FOR
YOUR SUPPORT, IF YOU HAVE ANY QUESTION FEEL FREE TO CALL ME AT 4417.
DISTRIBUTION LIST:
J. HARRIS
K. WIELAND/J. SAUNDERS
R. SAK
A. SHULICK
S. UHLER
J. WAYNE
D. ISING/D. LORENZ/R. DAUGHERTY
J. HOBACK
J. HUFFMAN
C. COPPER/C. PFEIFFER
E. DAY
D. WYATT
IDA/S. DODGE (EC02-0136) ; PR154;
CABARRUS
CABARRUS RESIDENT ENGINEERING
CABARRUS
O/C ENGINEERING
O/C STANDARDIZATION
LOUISVILLE
LOUISVILLE RESIDENT ENGINEERING
LOUISVILLE
STOCKTON STREET
S/S RESIDENT ENGINEERING
STOCKTON STREET
MC RIPPER ROOM #3
C15

'WW'-'--^"
To: G. B. Reid
U 1 . "^IW' 1 "
From: W. C. Hamilton
PHILIP MORRIS U. S. A.
INTER-OFFICE CORRESPONDENCE
Richmond, Virginia
Subject: CONTINUOUS MOTION WRAPPING MACHINE
Date: November 10, 1989
Unaware of Molins' particular designs for this device, the basic objective should be
the elimination of intermittent motion.
Since the first AMF and HLP, the pack forming and wrapping process has been
accomplished through intermittent motion. This has also been the limiting factor
for speed.
Although designs by Sasib, G.D, and Focke have greatly improved the quality and
speed of soft and box packing and wrapping the fact remains intermittent motion
(through genevas, Zed cams, etc.) is still an integral part of this machinery.
Continuous motion should permit greater speed, improved product handling, fewer
moving parts, and fewer machine adjustments.
/co
cc: IDA/S. Dodge (PR154;C15)
fi). £ dJa/ryidtlf^cif
W. C. Hamilton
'ft*

TVT
PHILIP MORRIS
U.9.A.
P.O. BOX 26603, RICHMOND, VIRQINIA 23261 TELEPHONE (604) 274-2C00
Mr. Claus Ehrhardt
Focke & Company
Siemensstrasse 10
D2810 Verden (Aller)
West Germany
Dear Claus,
November 9, 1989
Please find items to be discussed with Charlie Hamilton
during his visit next week.
cc:D. Neuber- Focke USA
C. Ducker
H. Gonzalez
C. Hamilton
J. Owen
File Mo. CP01-0012:PR.154:C15
Sincerely,
Michael Sterchele
V H
MARLOORO BENSON A HEDGES MERIT VIRQINIA SLIMS WflUAMENT LIGHTS PLAVERS SARATOQA CAMBRIDGE ALPINE MULTIFILTER f)

PHILIP MORRIS U.S.A.
INTER-OFFICE CORRESPONDENCE
RICHMOND. VIRGINIA
C. Hamilton oat* November 9, 1989
M. Sterchele -r-6
ITEMS TO INVESTIGATE
AT FOCKE-VERDEN
The following items should be reviewed with Focke during
your visit:
a)ACCUSORT SCANNER WILL NOT READ 5M CASES WITH
INTERLEAVE 2 OF 5 CODE:
Focke has been advised of problems occurring in Bay 5 with
new cases displaying the interleave 2 of 5, 4 digit
scanner code (see attached letter). Claus Ehrhardt has
indicated that the Bay 1 "B" line scanners can road these
codes without difficulties. Steve Craft in Bay 5 feels
Visolux (Aceusort of Germany) should be brought to P.M.
to resolve scanning problems.
It should be investigated that the Bay 1 "B" line scanners
do read the codes and set-up/training problems may be
occurring in Bay 5.
b) STATUS OF THE OPEN END FLAP DETECTOR SYSTEM PURCHASED FOR
BAY 2 FOCKE ELEVATOR:
A purchase order to Focke-USA was placed in late June 1989
for one system with no delivery date returned. This item
was raised during the Focke technical meeting last month
and Claus Ehrhardt stated he would get back to me. Nothing
has been heard. Please find out anything possible (See
attached P.O. requisition).
C)FILTEC REJECTOR NOT PROVIDING RELIABLE REMOVAL OF CARTONS
FROM INFEED CONVEYORS IN BAY 2:
The Focke-provided rejection systems are not operating
properly based on Ann McDaniels' latest study in Bay 2.
The air cylinders are unable to reject more than three
consecutive cartons at a time when cartons are present
with minimal spacing provided by Focke infeed/bypass
conveyors. The rejector's response is consistently
sluggish, frequently causing trailing cartons to skew
with resulting shutdowns of Focke equipment. Focke
should review tha design of these cylinders and recommend
solutions.
cc: H. Gonzalez
J. Owen

Mr. Claus Ehrhardt
Focke & Company
Siemensstrasse 10
Verden (Aller)
West Germany
PHILIP MORRIS
U.8.A.
• P.O. SOX 28803. RICHMONO. VIRGINIA 23241 TELEPHONE (804) 274-2000
November 2, 1989
RE: ACCUS0RT NON-READ OF HALF CASE SLEEVES
Dear Claus,
Recent changes from binary to interleave 2 of 5 codes
in Bay 5 have produced problems with the Accusort
Case Security System. The scanner head cannot properly
read 5M and 6M half case blanks staged for erection
in the case magazine.
tfto
Though scanner head support brackets have been modified
based on Focke recommendations, the scanning beam angle
is too severe to provide proper operation-. These units
must be turned off to remove successive false read signals.
Included in the additional Bay 1 N B N line test materials
are twelve (12) Cambridge half case blanks currently used
in Bay 5 with the interleave code. These cases should be
used to determine a solution to the existing problem. Your
urgency on this matter is requested.
Additional information will be returned with Hartmut Ley
next week.
If questions arise, please contact me at once.
BENSON S HEDGES MERPT VIRGINIA SUMS PARUAMENT LIGHTS PLAYERS SARATOGA CAMBM0GE ALPINE MUUTOITEH

cc: S. Craft
C. Bucker
H. Gonzalez
a. Gray
R. Hudson
w. Santera
D. Sharp*
B. Taylor
H. Lay- Pock* Verden
J. Sussanguth- Fecke Verden
w. Berghabn- Focke USA
IDA File CP01-0012:PR169:C13

Rev. 7
01/19/89
M/C MOPKBirailOW rKOJBCT
imaaamaxaH TO warns* FOHH
< * *
Authorisation is requested to purchase tha oquipsant and/or services daacribad for tha M/C
Modernisation Projact. Tha appropriate bid tabulation, bid analysis, and lattar of
recemendation, if naadad, ara attached.
Baseriptifn: _
Reason for Purchase hase
Funds Requested:-^ /gdO.^Zx. Job Order Ho. & ?*#> Aooroo. Mo/ ^4-og?
This Repeat jQ^L-Wos ___ Was Not Included in tha Above Job Order Scops for
LEVEL APPROVAL SIGNATURES SHOULD BE AFFIXED BELOW
2 V
$100,000
Over 5100,000
Level 1 - All Thru Snow
Level 2 - All Thru French
K. S. Whittle ^>^^^'-A Data » disks
P. N. Melton fci' Jn7/fe ^O/ffl Date; 6 //J^f
-R. G. Snou
KfJL^^^J Date: 6 As7o7.
R. E. Davis JData:.
R. M. Hassell . Data:.
-A. French Date:.
APPROVAL REQUIREMENTS
3-3

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C
L
Philip Morris USA
P.O. Box 26603
Riohaoud, VA 23261
Attn.: Mr. Charles Buoker
YoarreC: OurrtC:
Packing Machines.
Q00TATZ0H
Ho.: £434
D«t: June 2, 1989
With reference to Michael Sterchale's letter of April 24/891 ve are pleased
to offer the following for the Bay 1 project and as a retrofit for the
Bay 2 projeots
One set of sensors to reject cartons
with open end panels per oaohine DM 2,450.00
These sensors can still be added for the Bay 1 oaohinea and can be supplied
as retrofit kit for Bay 2.
Please let us know as soon as possible how to proceed.
RH/s
00: M«~38nttieldB»&
R. Furfero
Reidun Honsi
Fockc & Co. Inc. 20 Industrial Avenue Upper Saddle River. NJ. 07458 TeL: (201) 825-8440 Telex: 642 380

PHILIP MORRIS U.S.A.
INTEROFFICE CORRESPONDENCE
Richmond, Virginia
To: Engineering Staff t Date: * 11/21/89
From: Sherri Davis
Subject: RECORDS RETENTION PROGRAM - MEW CODES
We have now received all remaining sub-category codes. Attached is an
updated copy of pages 16-19 for your use.
If you have any questions, please let me know.
Attachments
(pages 16-19 Records Management Program Conversion Manual)
cc: File: AE01-0002;PR154;C15

ENGINEERING FILES = CATEGORIES. CODES, AND RETENTION PERIODS
CATEGORY CODE RETENTION
Sub-Category
ADMINISTRATIVE (Non-Project Related)
Associations & Memberships A123 CI
Building Administration Reports A125 CI
Calendars/Diaries/Notebooks (pocket/desk) A127 CI
Campaigns A128 CI
Copier Reports A133 CI
Correspondence, General A134 CI
Environmental Controls A136 CI
Equipment & Machinery Tracking A163 CI
Factory Computer Reports A139 CI
Government Relations A140 CI
Idea Club A590 CI
Labor Relations A143 CI
Material Destruction Authorization A146 CI
Organizational Announcements A149 CI
Production Planning A152 CI
Progress Reports A154 CI
Public Relations/Community Relations A156 CI
Quality Assurance Reports A157 CI
Shipping/Warehouse A158 CI
Special Events A159 CI
Sundry Orders A161 CI
Training, Conferences & Seminars A131 CI
Transportation A164 CI
Trip Reports A165 CI
Truck Logs A166 CI
York Information A169 CI
Action Cost Team Correspondence A121 C5
Consultant Services A132 C5
Cost Reduction (Active/Completed/Rejected)A591 C5
Estimates (Non-Budget Related) A13B C5
Jewel Awards (for ACT use only) A592 C5
Meetings A148 C5
Presentations & Speeches A151 C5
Project Status Reports A155 C5
Quality Circle/Employee Involvement A586 C5
RUP A593 C5
Time Tracking A587 CJ
Revisea 11/21/89
•MO

CATEGORY
Sub-Category
ADMINISTRATIVE (continued)
Art Inventory A122
Audio Visual Equipment A124
Buildings and Grounds Correspondence A126
Catalog Files A129
Engineering Standards A135
Loss Prevention/Indust. Hygiene/Safety A144
Material Evaluations A147
Organizational Charts A150
Process/Production Data A588
Programs (Software) A153
Qualification Reports (Machinery) A137
Reference Materials (General/Technical) A589
Specifications (General) A160
Telecommunications A162
Vehicle Maintenance and Use A167
Vendor Information A168
Cigarette Destruction A130
Installation Instructions A141
Instrument and Equipment Specifications A142
Machinery Standardization Information A145
FINANCIAL
Payrol1
Telephone Statements
Travel Expenses
Vouchers
CODE RETENTION
F116
F118
F119
F383
Appropriation (ROI* and Non-ROI) F384
(*suspended until after audit)
Asset Disposal/Request Notices F109
Budgets (Operating) F110
Capital Appropriation Report (Monthly) F385
Capital Forecasts (Five Year) Fill
Cost Information (Operating) F112
Expenses F113
Five Year Plan F114
Manpower Resource Reports and Resource
Charges F115
Profit Improvement F117
SUP
SUP
SUP
SUP
SUP
SUP
SUP
SUP
SUP
SUP
SUP
SUP
SUP
SUP
SUP
SUP
CI
CI
CI
CI
C5
C5
C5
C5
C5
C5
C5
C5
C5
C5
|t(0 t/0^

CATEGORY
Sub-Category
LEGAL/LITIGATION
Contracts and Agreements
Patents
Government Agencies & Legislation
OSHA - Federal and State
Policies & Procedures
PURCHASING/PROCUREMENT (Non-Project Related)
Awards Letters/Correspondence
Invoices
New Item Request
OEM Bids/Quotes
Purchase Orders/Receiving Tickets
Standing Orders & Rosters
PERSONNEL **
Compensation
Employee Records and Information
Employment/Staffi ng
Payroll Sheets/Vacation Schedules ***
Performance Appraisals
CODE RETENTION
L114
LU5
L116
L117
L118
PU147
PU148
PU1153
PU149
PU150
SUP
SUP
SUP
SUP
SUP
C5
C5
C5
C5
C5
PU151 SUP
PE142
PE143
PE144
PE146
PE145
** All permanent employee records are maintained in ERO
*** All employee copies of timesheets or vacation schedules are
considered "personal" materials and do not need to be coded. Official
Payroll records are maintained in Finance.
CI
CI
CI
CI
CI

CATEGORY
Sub-Category
PROJECT
CODE RETENTION
(Definition: A "Project" related file is any record that pertains to any
active, inactive, completed, rejected project for which a project number
has been assigned.)
To include, but not limited to:
Asset Transfer Form
Bid Packages/Specifications (PM/Outgoing)
Bids/Proposals (Incoming)
Bidders Lists/Contracts/Purchasing/
Procurement
Consultant Reports/Services
Contractor's Service (work order)
Tickets
Correspondence (generated & received)
Cost Information
Disposal Requests
Drawing Transmittals
Estimates
Invoices
Job Orders/Appropriations
Meetings
Permit Applications
Presentations
Product Evaluations
Project Manpower Plans
Project Request
Project Schedules
Project Status Reports
Purchasing/Procurement
RFC's
Receiving Tickets
Sketches/Charts
Technical Data
Union Subcontracting Notification Forms
Access Authorization
Calculations/Design Files
Development Project Reports **
Drawings
Engineering Notebooks (issued by IDA)
Historical Data
Legal/Litigation (background)
Parts Lists
Programs (software)
Property Surveys
Scope Documents
** With or without a Project Number
PR1141
PR152
PR166
PR169
PR1150
PR153
PR154
PR155
PR1142
PR158
PR160
PR161
PR162
PR164
PR168
PR1143
PR1144
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PHILIP MORRIS
U.S.A.
P.O. BOX 26603. RIChMOND, VIRGINIA 23261 TELEPHONE (804) 274-2000
Mr. Bob Bitner
Minnesota Automation, Inc.
First Street Southwest
P.O. Box 190
Crosby, MN 56441
REs 6.D 4350 Couponer
Dear Bob,
November 22, L989
I would like to thank you for your hospitality on our recent
visit to your facility. Please find enclosed a copy of the
Philip Morris Machine Specifications as we discussed.
After a review of the list of nonmetallic materials on the
couponer, I must ask you to investigate possible
replacements for all items containing Polyvinyl Chloride,
Teflon and Fiberglass which we have deemed unacceptable. We
will be glad to assist you should there be problems finding
suitable replacements.
Samples of the various coupons we would be using on the
couponer were not available at the time of this letter, but
will be forthcoming as soon as possible.
Again, thank you for making our trip to Crosby an enjoyable
one and please call if there are questions concerning the
enclosed material.
Enclosure
ccs H.W. Vogt
E.J. Wooldridge
IDA/S. Dodge (PR1545CPO10O51;C15)
Sincerely yours,
Mark R. Cruise
MARLBORO BENSON 4 HEDGES MERIT VIRGINIA SLIMS PARLIAMEN f LIGHTS PLAYERS SARATOGA CAMBRIDGE ALPINE MIJLTIFILTER
jM*

TO: W.A. Smith IV
PHILIP MORRIS U. S. A.
INTER- OFFICE CORRESPONDENCE
Richmond, Virginia
FROM: R.B. Allen 1 ^ ^ ^ ^
Date: May 19, 1989
SUBJECT: B/L PLANT MEZZANINE MCC ROOM - VENTILATION/HVAC
Eng. Project No. BB10-0004
The purpose of this memo is to resolve some of the
misconceptions surrounding the temperature regulation of the
subject room, to evaluate the options and to recommend a course of
action which should lead to a satisfactory completion of the
project.
BACKGROUND
In a memo dated 10/30/86 from D. Duncan to J. Youell
addressing this subject, D. Duncan described the (then) existing
system for ventilation of the subject room and recommended the
addition of a steam heating coil which would temper the outside
ventilation air during cold periods. An estimate for installing the
steam heating coil, associated piping and controls was $ 15,000.
In a memo dated 12/8/86 from J. Youell to D.L. Milby
requesting appropriation of funds to replace power distribution
equipment, J. Youell referred to those minor recommended changes in
the ventilation system as HVAC modifications. This was probably a
misstatement in as much as HVAC is a given acronym for
environmental conditioning equipment, That request stipulated
$15,000 in capital funds for "HVAC" which was recommended as
ventilation by D. Duncan in his memo of 10/30/86.
At that time there was no expectation of such extreme heat
build-up in the equipment room.
PRESENT
The present situation is that the steam heating coil and
associated equipment recommended by D. Duncan on 10/30/86 has been
installed at a cost of $ 11,343. Approximately $ 38,000 remains in
the budget including overruns, Any additional cost would require a
supplement to appropriated funds.
This requirement of 104 F (40 C) places considerable demand
upon the ventilation system. Referring to Frequency of Hourly
Temperature charts for Richmond, statistically the outside
temperature is 95 F or less for 99.5% of the time. This indicates a
9 degree differential between outside air and the maximum allowable
inside temperature (104 F).
There are several alternatives for conditioning the electrical
room, These alternatives are as follows:
1. Do nothing
2. Increase ventilation
3. Supplement existing equipment and controls
4. New air conditioning

*l.Do nothing
If we do nothing and let the temperature ride, the following
equation will prevail;
Q = 1.08 x CFM x temp. diff.
400,000 BTU/Hr. = 1.08 x 12,000 x temp. diff.
400,000 BTU/Hr,
temp. diff. = 1.08 x 12,000
temp. diff. = 30.9 F
This calculation indicates that with the existing, 400,000
BTU/Hr. load and 95 F outside temperature, the room
temperature would escalate to nearly 126 F. This condition
would be unacceptable to the switchboard manufacturer.
*2.Increase ventilation
If we increase the outside air ventilation to maintain room
conditions at or below those acceptable to the equipment
manufacturer, the following equation prevails:
Q = 1.08 x CFM x temp. diff.
400,000 BTU/Hr. = 1.08 x CFM x ( 104-95 )
CFM = 41,152
This system is estimated to cost in excess of $ 50,000 to
implement. It would also impose high air velocities in the
room and necessitate an exhaust system installation.
*3.Supplement existing equipment and controls
Should the existing equipment and controls be supplemented by
adding a new in-line fan, installing a DX cooling coil and
modifying the existing controls to heat and cool. The
following equations will prevail:
( assuming leaving air temp, at 60 F and room temp, at 104 F)
Q = 1.08 x CFM x temp. diff.
400,000 BTU/Hr.= 1.08 x CFM x (104-60)
4Q0,QQQ BTU/Ete..
CFM = 1.08 x 44 F
CFM = 8,417 (use 9,260)

COOLING BTU REQ'D TO MAINTAIN 60 F DISCHARGE:
Q = 4.5 x CFM x delta h
Q = 4.5 x 9,260 x (41.3-26.5) BTU/#
Q = 616,716 BTU/Hr. or 51.4 Tons
DISC, AIR RISE IF ONLY 5QQ.QQQ S,TU/Hr CQQLjNq PRQVIDEP,:
Q = 4.5 x CFM x delta h
500,000 BTU/Hr. = 4.5 x 9,260 x delta h
delta h = 500.000 BTU/Hr.
4.5 x 9,260
delta h = 12 BTU/it
41.3 BTU/# - 12 BTU/« =29.3 BTU/#
29.3 BTU/tt = 63.6 F (discgo. @ 95 db & 78 wb 500,000
BTU/Hr.)
ROOM TEMP. AT ELEVATED DISCHARGE
Q = 1.08 x CFM x temp. diff.
400,000 BTU/Hr. = 1.08 x 9,260 x temp. diff.
400.000 BTU/Hr.
temp. diff. = 1.08 x 9,260
temp. diff. = room rise = 40 F
Discge. temp. + room rise = room temp.
Room temp. = 6 3.6 F + 40 F
Room temp. = 103.6 F
This alternative is estimated to cost $ 31,000. It would be
supplied by 100% outside air and no return, ductwork would be
provided.
Should all new air conditioning be installed, the following
equations would prevail:

AIR VOLUME REQ'P
Q = 1.08 :< CFM x temp, diff. ( use 60 Disc. & 100 room )
400,000 BTU/Hr. = 1.08 x CFM x ( 100 - 60 )
400,000. BTU/Hr^.
CFM = 1.08 x 40 F
CFM = 9,259 CFM recirc. air. Outside Air = 1,000 CFM
Total CFM = 10,260
REFRIGERATION REQ'P
Q = [1.08 x CFM x temp. diff.]+[ 4.5 x O.A. CFM x delta h]
Q = [1.08 x 9,260 x 40 F] + [4.5 x 1,000 x (41.3-26.5)]
Q = [400,032] + [66,600] BTU/Hr.
Q = 466,632 BTU/Hr. OR 38.9 > 40 Tons
Maximum Room Temp. = 100 F
This alternative has been estimated to cost $ 50.000. It would
consist of a supply fan, DX cooling coil, existing heating
coil, DX condenser unit, outside air economizer unit, and
supply and return ductwork.
RECOMMENDATIONS
Alternate number three (supplement existing equipment and
controls ) is recommended because it is the only system explored
that will maintain the room conditions required by the switchboard
manufacturer and also meet the present budget restraints. In
addition, at a later date, the existing equipment could be reused
and new duct installed to achieve alternate number four.
The recommended system is composed of a new in-line fan with
capability of supplying 10,260 CFM of air at approximately 2"
static pressure but reduced to 9,260 for present application, a new
DX cooling coil, and 40 ton condenser unit with applicable
controls.
This system will ventillate and cool the switchboard room with
100 percent outside air. The ventlllation air will be relieved from
the room in the same manner as the present system, through cracks
and doors. Because of the extra heat in the 100 percent outside air
during warm days, much of the refrigeration capacity of the cooling
system will be consumed by outside air. At the design air capacity,
the room temperature should be 85 F at 45 F outside. As the outside
air conditions exceed 77 F @ 50% RH the room temperature should
begin to rise until it reaches 104 F at maximum outside design
conditions. The estimated cost of this system is $ 31,000.

APPROVAL/DISAPPROVAL
Please indicate approval/disapproval of this recommendation
sign in the appropriate space and return to the writer that this
project may proceed without delay.
[ ] APPROVED
[ ] APPROVED AS NOTED
[ ] DISAPPROVED
COMMENTS:
( signature)
Should there be any questions about this subject, please
contact the writer as soon as possible.
CC: D.T. Canfield
D.F. Hichak
D.B. Lowder
H.S. Nelson Jr.
R.N. Smith
J.D. Watkins/Project File: BB10-0004
Central Files: BB10-0004 * PftjSV &S
v-

TO: L.W. Lipscomb
PHILIP MORRIS 0. S. A. 1
INTER- OFFICE CORRESPONDENCE
Richmond, Virginia
FROM: R.B. Allen \
Date: March 16, 1989
SUBJECT: R&D Tower - Compressor Roof Flashing Approval by 0-C
Attached is an acceptance letter from Mr. A.J. Campbell of
OWENS/CORNING. This letter indicates the detail which was submitted
is acceptable for our intended use. That use being, flashing of two
concrete refrigeration equipment support pads. Mr. Campbell also
requires the name of the approved roofer doing the work, which we
should supply as soon as we decide, and the guaranty number for the
Tower, which is DB-30416.
Also attached,for clarification,is the request for approval
letter which was sent to Mr. Campbell.
Should there be any further questions or comments about the
subject matter, please contact the writer as soon as possible.
Attachments
tyMlt
CC: D.B. Lowder
J.D. Watkins/Project File: TM01-0001
Central Files:. TM01-0001 ypgj^.' OS

FlBERGilAS
W ^
OWENS-CORNING FiBERGLAS CORPORATION EXECUTIVE COVE CENTER. S602-B VIRGINIA BEACH BLVO., SUITE 201
March 10, 1989
Mr. R. B. Allen
Philip Morris U.S.A.
P.O. Box 26603
Richmond, Virginia 23261
RE: R&D Towers Roof
Dear Barry:
The detail in your March 6 letter to me is acceptable.
Please advise the name of the OCF Certified Roofing Contractor
who will do the work. In addition, please send me the Guaranty
number for this building. We file all guaranties by number, so
I need this to update the file with this information.
Sincerely,
OWENS-CORNTNG-FfBERGLAS CORPORATION
A. J. CampHell
Senior Sales Representative
Construction Products Group
Mid-Atlantic District
AJC/ed
VIRGINIA BEACH RESIDENT OFFICE
VIRGINIA BEACH, VIRGINIA 23462, PHONE: (604) 49O-S801
Ouotntiona In thla letter aro not Intended ot oilers. All ordart and contractt are taken tubjact to acceptance by thtt corporation at Toledo, Ohio

Sandy Campbell
Owens-Corning Fiberglass Corp.
5602-B Va. Beach Blvd.,
Suite 201
Va. Beach, VA 23462
Dear Sandy,
PHILIP MORRIS
U.S.A.
P.O. BOX 26603, RICHMONO, VIRGINIA 23261 TELEPHONE (804) 274-2000
March 6, 1989
This letter is to notify you of an anticipated change in the
R&D Tower roof at our R&D complex. As you may remember, the R&D
Tower was re-roofed in 1985 and carries an Owens-Corning special
"Philip Morris" 20-year warranty. The change consists of two
concrete equipment support pads.
The enclosed roofing detail, which will be used, is like
Detail #14 (window washer pad detail) which was used in the 1985
re-roofing, with one exception. The exception is a base sheet
envelope which will be used to isolate the pad detail from the roof
insulation system. As required, the use of an Owens-Corning Double
Eagle certified roofer has been specified.
Should there be any questions about this matter, please
contact me as soon as possible.
R.B. Allen ^ ^
Roofing Coordinator
MARLBORO BENSON i HEDGES MERIT VIRGINIA SUMS RARUAMENT LIGHTS PU/ERS SARATOGA CAMBRIDGE ALPINE MULT1F1LTER

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TO: N.P. Sinclair
PHILIP MORRIS 0. S. A.
INTER- OFFICE FICE C CORRESPONDENCE 0 R R R
^1/
Richmond, Virginia
FROM: R.B. Allen U\I \ jj
SUBJECT: R&D Roof Repair Work - Scope Of Work
Eng. Project No. TMO1-0001
Date: March 29, 1989
Attached is a scope of work for the anticipated roof repairs
at the R&D complex.
Should the scope not meet with your satisfaction or there be
any questions about this matter, please contact the writer as soon
as possible.
Attachment
CC: L.W. Lipscomb
D.B. Lowder
J.D. Watkins/Project File: TMOI-0001

SCOPE OF WORK
Provide labor, material and supervision to repair roof defects
as specified in appended report and/or as modified at time of
pre-bid site inspection. All materials shall be of a type compatible
with the existing material being repaired. All work and methods
must be acceptable in all National Roofing Contractors Association
manuals and/or Sheet Metal and Air Conditioning Contractors
National Association manuals which apply.
>
'1

w
TO: R.H. McMath
PHILIP MORRIS 0. S. A.
INTER- OFFICE CORRESPONDENCE
Richmond, Virginia
FROM: R.B. AlUn fifl^j^
Date: July 12, 1989
SUBJECT:Operations Center Roof Repair Proposal - Weldon Roofing
Engineering Project No. TMOi-0001
Enclosed is a roofing repair proposal for the Operations
Center from Weldon Roofing. Please note that the proposal price is
cost plus mark-up not to exceed a cap as follows:
* Reroof low cafeteria roof and Cost + NTE...$43,400
repair high roof.
* Reroof all Cafeteria roof areas Cost + NTE...$106,640
Mr. Todd of Weldon Roofing stated that he regretted what may
appear as excessive roofing costs but that accessibility and
availability may enter as a cost factor when reroofing a meeting
and dining facility. He also stated that the other 0/C repairs
could only be done COST + but had no estimate of the actual cost.
The recommended method for establishing a budget cost for the
other 0/C repairs is to use the cost of repairing the third floor
conference room corner as the estimate to repair the second floor
conference room corner. As for the other minor repairs required,
allow $2,000 for each separate repair area.
At this time, no cost has been established for metal atrium
leak repairs.
Should there be any further questions about this subject,
please contact the writer as soon as possible.
Attachment
cc: K.A. Gammon
R.C. Kistler
D.B. Lowder
J.D. Watkins/Project File:TM01-0001
Central Files: TM01-0001 J J^JS+J OS"

P.O. Box 471
Weldon, N.C. 27890
Phone: Day (919) 537-8168
Night (919) 536-4367
Sldtec KOPPERS Hi-Tuff \^^M
PROPOSAL
- FROM -
WELDON ROOFING
and
Sheet Metal, Inc.
Since 1936
COMMERCIAL AND INDUSTRIAL ROOFING
Manvll, e
TO Philip Morris U.S.A. DATE_§=2Q=82_
P.O. Box 26603
Richmond/ VA 23261 RE: Operations
\4
Fl£ER(jLA$ TROCAL gj
Attn: Barry Allen
BASE BID .$ 43/400.00
WE ARE QUOTING AS FOLLOWS:
To remove roof at skylights and replace including roof insulation and new
membrane approximately 35 squares/ not to exceed on a cost plus basis $43/400.00.
Item #1 — If balance of roof is to be removed/ add to base bid not to exceed
on a cost plus basis $63/240.00.
Item #2 — Combination bid for both areas $105/640.00.
Acceptance Will Constitute a Contract
ACCEPTED:
Yours truly,
Licensed In:
NC (5842)
VA (9777)
SC
WELDON ROOFING & SHEET METAL, INC.
Per J/r^- /in^UIJjli^^^
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