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Elements and Performance Criteria

1. Check work requirements.
   • Identify the type of product required.
   • Check for any special requirements.
   • Recognise mould parts required.
   • Interpret mould and part dimensions.
   • Check with supervisor/appropriate person if requirements are not in accordance with usual practice.
2. Assemble mould.
   • Select and check required mould parts.
   • Use correct mould set-up jig.
   • Assemble mould as per procedures.
   • Check position of mould in relation to rest of machine.
   • Check mould will open and close.
   • Apply release agent.
   • Check breather/vent system for safe functioning.
   • Pack breather/vent system with material to avoid spillages.
3. Dismantle mould.
   • Use correct mould dismantling jig.
   • Dismantle mould as per work instructions.
   • Strip mould of release agent.
   • Clean mould to remove contaminants in accordance with procedures.
   • Dry out mould.
   • Store mould parts in appropriate place.
4. Identify and replace worn parts.
   • Identify worn parts.
   • Check condition of other mould parts.
   • Replace worn mould parts.
   • Record details of worn parts.
5. Maintain mould part stocks.
   • Check stocks of spare parts.
   • Advise supervisor of stock required, parts used and date of completed mould.

Required Skills

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

Application of knowledge of the materials equipment and process sufficient to recognise out of specification products process problems and materials faults

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

Application of the knowledge of managing risks using the hierarchy of controls applied to the moulding process Application of approved hazard control safety procedures and the use of PPE in relation to handling materials equipment operation and cleanup

Knowledge of and skills in the operation of injection moulding equipment and main components sufficient for consistent production of quality products including

different mould part types

types of releasing agents

role of releasing agents

procedures

identifying factors which may affect product quality or production output and appropriate remedies

distinguishing between causes of problems such as use of incorrect mould parts incorrect positioning of mould parts worndamaged mould parts

Competence also includes the ability to

plan own work including predicting consequences and identifying improvements

identify when the operator is able to rectify faults when assistance is required and who is the appropriate source for assistance

identify and describe own role and role of others involved directly in the process

Language literacy and numeracy requirements

This unit requires the ability to read and interpret typical product specifications job sheets procedures material labels and safety information as provided to operators

Writing is required to the level of completing workplace forms

Basic numeracy is required eg to determine that two kg bags are needed to make up a requirement for kg

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 knowledge and skills defined in this unit These may include the ability to

recognise the importance of material properties and qualities apply approved procedures

take appropriate action to resolve faults or report faults to appropriate personnel

Consistent performance should be demonstrated For example look to see that

production standards are met consistently

upstream and downstream communication is timely

effective operating procedures and work instructions are read and interpreted correctly

problems are identified and appropriate action is taken ie the problem is fixed or reported

all safety procedures are followed

Assessment method and context

Assessment will occur using industrial mouldsequipment and will be undertaken in a worklike environment

Competence in this unit may be assessed

on a processing plant allowing for operation under all normal and a range of abnormal conditions

in a situation allowing for the generation of evidence of the ability to respond to 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 applies to all work environments and sectors within rotational moulding, polyurethane, composites and thermoforming where moulds are used. It includes the operation of all relevant additional equipment where that equipment is integral to the moulding process.

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. These may include:

assembling cast and prefabricated moulds (typically made from metal or composite materials)

using hand tools as required

interpreting production schedules/ work cards as appropriate.

Tools and equipment

This competency includes use of equipment and tools such as:

handling aid such as handcarts, hoists, jigs and gantries

pedestrian forklifts

hoists, jigs and gantries

powered equipment/aids such as sanders and sand blasting equipment

relevant personal protective equipment.

It does not cover the use of equipment requiring special licences.

Hazards

Typical hazards include:

noise, light, energy sources

humidity, air temperatures, radiant heat

stationary and moving machinery, parts or components

manual handling hazards.

Problems

'Respond to routine problems' means 'apply known solutions to a limited range of predictable problems'. Typical process and product problems may include:

matching moulds to production requirements

servicing of moulds

recognising parts requiring replacement

selecting correct parts for replacement

using incorrect mould parts

incorrect positioning of mould parts

worn/damaged mould parts.

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