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Elements and Performance Criteria

1. Prepare to change dies.
   • Determine when changeover will be required, and plan requirements for die change.
   • Obtain dies and or cores and all parts and tools to match the production order.
   • Follow procedure for machine close-down and for informing relevant personnel.
   • Take last-off samples as required for die reports.
   • Close down machine in accordance with procedures.
   • Prepare machine for changeover in accordance with procedures.
2. Change dies.
   • Plan removal process to ensure no damage to self, equipment or others.
   • Remove, clean and store die according to workplace procedures applying corrosion protection if required.
   • Attach replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification.
3. Set dies.
   • Set machine conditions for new die.
   • Restart machine as per procedure.
   • Dry cycle machine and die according to enterprise procedures.
   • Check operation of die against product quality specifications.
   • Check the first off sample for compliance with required standards.
   • Fine tune settings and other production variables as required.
   • Note any equipment variances between actual production and documented set up conditions.
   • Complete workplace documentation and report to appropriate personnel.
4. Anticipate die setting problems.
   • Identify potential problems which may occur during the die changing and setting process.
   • Determine possible causes of these problems.
   • Identify most likely causes and prioritise appropriate actions.
   • Rectify problems using appropriate solutions within area of responsibility.
   • Recommend improvements in systems or procedures.

Required Skills

This describes the essential skills and knowledge and their level required for this unit

Competence in this unit includes the ability for the practical completion of the job to apply andor explain the

organisation procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards

construction of simple dies and their components including fixed and removable cores inserts ejection systems vents

methods of connecting dies to machines such as bolting to platens slots etc

the function of each machine setting and the appropriate ranges of settings for a given die

equipment and process sufficient to recognise conditions which may lead to out of specification production

impact of incorrect or faulty fitting

correct selection and use of equipment and procedures

hazards of the removal and fitting process and appropriate hazard control procedures

relevant information and workplace records

safety precautions appropriate to the task

use PPE safely handle products and materials read relevant safety information and apply safety precautions appropriate to the task

It also requires skills in the safe precise and efficient removal of simple dies and their correct installation and the ability to plan their own work including predicting consequences and identifying improvements

Language literacy and numeracy requirements

This unit requires the ability to read and interpret typical production orders and die setup information

Writing is required to the level of completing workplace forms and production reports

Basic numeracy is required eg to monitor and set displays gauges and dials to correct values according to setup sheet

Evidence Required

The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria required skills and knowledge the Range Statement and the Assessment Guidelines for this Training Package

Overview of assessment

A holistic approach should be taken to the assessment

Assessors must be satisfied that the person can consistently perform the unit as a whole as defined by the Elements Performance Criteria and skills and knowledge

Critical aspects for assessment and evidence required to demonstrate competency in this unit

It is essential that competence is demonstrated in the ability to change and set a die in a manner which will put the moulding machine back into full production of in specification product in standard time In particular it is essential that the operator can

select install and check the performance of dies and cores

apply safety precautions appropriate to the task

recognise potential situations requiring action and then implement appropriate action

Consistent performance should be demonstrated For example look to see that

standards are met consistently

problems are appropriately resolved

Assessment method and context

Assessment will occur on equipment using simple dies and will be undertaken in a worklike environment

Competence in this unit may be assessed

by using an appropriate industrial moulding machine requiring demonstration of die change and die setting procedures

in a situation allowing the generation of evidence of the ability to perform die change and die setting procedures and to recognise and resolve problems

by using a suitable simulation andor a range of case studiesscenarios

through a combination of these techniques

In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practicalsimulation or similar assessment Assessors need to be aware of any cultural issues that may affect responses to questions

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy language and literacy capacity of the assessee and the work being performed

Specific resources for assessment

This section should be read in conjunction with the Range Statement for this unit of competency Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation A bank of case studiesscenarios and questions will also be required to the extent that they form part of the assessment method Questioning may take place either in the workplace or in an adjacent quiet facility such as an office or lunchroom No other special resources are required

Access must be provided to appropriate learning andor assessment support when required Where applicable physical resources should include equipment modified for people with disabilities

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Range Statement

The Range Statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts.

Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.

Context

This competency unit includes the setting and removal of simple dies. It does not include advanced and complex dies

This competency applies to all work environments and sectors within the plastics, rubber and cablemaking industry which use moulding dies. It includes the operation of all relevant ancillary equipment.

Die

A former used to give the required shape to the product and used under pressure. Dies are typically used in the extrusion, injection, blow moulding and general rubber sectors. Dies used which are not subject to pressure are referred to as 'moulds' in this Training Package.

Simple die

A two plate die including any ejection system operating in the mould open axis, but excluding moulds with molten material retained within the mould between cycles. Products are simple, straight drawn items. Typical features may include: force, cavity, back plates, support plates, cold runner, sprue, nozzle seat, locating ring-tab, sub, fan, diaphragm and direct gating, ejector pins and sleeves, ejector plate and stripper plate, simple drilling for mould cooling.

Advanced die

A two or three plate die with one or more product forming components which move in a direction other than the mould open axis, and which are driven by the mould rather than external actuation. Excludes moulds which retain molten material within the mould between cycles. Typical features may include: sliding blocks or cores actuated by skew pins or cams; baffled, spiral, tube, and heat pipe cooling systems; rising cores; and internally actuated unscrewing systems.

Complex die

Dies which use at least one external power and control source to actuate product forming components, which move in a direction other than the mould open axis, and require sequencing with the mould operation. Includes moulds which retain molten material within the mould between cycles. Typical features may include: hot runners; insulated runners; externally actuated sliding blocks, cores, and unscrewing systems; safety interlocks.

Requirements

Requirements for the die change may include checking the die dimensions such as mould height and required ejector stroke to ensure it is compatible with the selected machine

Setting

Setting of the machine conditions may include setting the mould height on the machine, the clamp force, the mould safety system, the ejector system, the mould opening and closing distances, speeds and forces and the injection unit.

These settings may be performed automatically, using an electronic storage device to load settings from a previous run of this product, or may be performed by manually setting controls individually.

Procedures

All operations are performed in accordance with procedures.

Procedures include all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.

Tools and equipment

This unit of competency includes use of equipment and tools such as:

hand carts and trolleys

hoists/lifting equipment not requiring any special permits or licences

basic hand tools

relevant personal protective equipment.

Hazards

Typical hazards include:

hazardous materials

manual handling hazards

hot surfaces.

Anticipate problems

Anticipate problems includes taking a proactive approach to a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures, and endeavouring to learn from the problem so that it does not recur.

Typical die setting problems may include:

lack of cleaning of die surface and cooling channels, leading to corrosion

inadequate fitting of the dies to the platens, causing poor alignment or movement during production

fine adjustments of die movements, to optimise production.

All operations are performed in accordance with procedures.

Variables

Key variables, and their causes, to be monitored include:

time/effort required to set a die

number of attempts to produce a first off within specification

the need to reset/adjust a die during then production run.

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