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Elements and Performance Criteria

1. Determine trial requirements
   • Gather all relevant information available
   • Interpret job sheets or equivalent instructions correctly
   • Confirm machine/equipment suitability
   • Confirm die state
   • Confirm readiness of raw materials
2. Set die and machine
   • Follow safe working practices
   • Fit and set up die
   • Set up process conditions
   • Set machine to meet specifications and operational requirements
   • Dry cycle machine and die according to procedures
3. Perform die trial
   • Carry out trial process following enterprise procedures
   • Identify and record variations from specifications
   • Monitor control panel and interpret test results for fluctuations, variations and trends
   • Determine process limitations with respect to product and production specifications
   • Adjust controls to ensure parameters are maintained to job specifications
4. Rectify equipment and quality problems
   • Identify range of faults that will affect product and production specifications
   • Determine changes required to tooling and equipment to meet product and production specifications
   • Maintain appropriate records related to machinery and equipment to enterprise standards
   • Identify problems
   • Worn or damaged tooling is identified and changed as required
   • Rectify problems that are within area of responsibility
   • Report problems that are outside area of responsibility to appropriate personnel
5. Complete trial
   • Shut down equipment as required
   • Record trial results
   • Return machine to service
   • Instruct machine operator

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Regulatory framework	The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used. Applicable legislation, regulations, standards and codes of practice include: health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials Australian/international standards relevant to the materials being used and products being made any relevant licence and certification requirements. All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.
Equipment	Equipment includes the setting and trial of one or more of: injection moulding machines blow moulding machines similar machines
Operational requirements	Operational requirements include one or more of: die/tool set up and adjustment machine speed cycle time temperatures, including heating and cooling rates product quality measures any other specified requirement.
Procedures	All operations must be performed in accordance with relevant procedures. Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of: emergency procedures work instructions standard operating procedures (SOPs) safe work method statements (SWMS) formulas/recipes batch sheets temporary instructions any similar instructions provided for the smooth running of the plant.
Simple dies	Simple dies include one or more of: two plates, including ejection systems operating in the mould open axis cavity back plates support plates cold runner sprue nozzle seat locating ring-tab sub, fan, diaphragm and direct gating ejector pins and sleeves ejector and stripper plates.
Advanced dies	Advanced dies include one or more of: 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 sliding blocks or cores actuated by skew pins or cams baffled, spiral, tube, and heat pipe cooling systems rising cores internally actuated unscrewing systems.
Complex dies	Complex dies include one or more of: 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 moulds which retain molten material within the mould between cycles hot runners insulated runners externally actuated sliding blocks, cores and unscrewing systems safety interlocks.
Hazards	Hazards must be identified and controlled. Identifying hazards requires consideration of: material spills or leaks hazardous products and materials manual handling hazards stationary and moving machinery machinery hazards protrusions or obstructions slippery surfaces smoke, dust, fumes, vapours or other atmospheric hazards humidity, air temperatures and radiant heat noise, light and energy sources other hazards that might arise.
Causes of faults include one or more of:	Causes of faults include one or more of: materials heat equipment adjustment equipment set-up.
Problems/solutions	Problems/solutions include one or more of: selecting the right tools for a new job using new and untried die or tool adapting the process to the new product and die/tool observing the process to obtain useful trial data comparing the product to the desired specification determining the cause of non-compliances.

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Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret procedures, job specifications, material labels and safety data sheets (SDS)

determine production requirements

discuss work progress with other workers

conduct pre-start checks

start up and shut down equipment following appropriate procedures

inspect product conformance to requirements

identify and rectify routine faults

identify routine product problems and notify appropriate persons

distinguish between causes of problems, including:

operational problems

materials properties

process variables

procedural errors

store equipment, materials and product appropriately

adhere to safety requirements.

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Knowledge Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate knowledge of:

the impact of incorrect or faulty materials

types of products made with different processes

changes to raw materials during the process

production work flow sequences and materials demands

selection practices for equipment, materials, processes and procedures

materials and process hazards

appropriate hazard control procedures

the importance of material properties and qualities

the importance of process conditions

approved procedures

appropriate action to resolve faults or report faults

start-up and shutdown procedures

safety requirements.

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