Google Links

Follow the links below to find material targeted to the unit's elements, performance criteria, required skills and knowledge

Elements and Performance Criteria

1. Prepare for trial to procedures.
   • Gather all relevant information available at the enterprise.
   • Confirm machine/equipment suitability.
   • Confirm die/tool state.
   • Confirm raw materials readiness.
2. Set die/tool and machine.
   • Fit and set up die/tool.
   • Set up process conditions.
   • Set control panel to cycle time, temperatures and heating/cooling rates as required.
   • Dry cycle machine and die according to procedures.
3. Trial die/tool, interpret data and adjust operation to procedures.
   • Carry out trial procedures in a systematic manner to meet trial objectives.
   • Identify and record variations from normal.
   • 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.
   • Check that process operation has improved.
   • Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications.
   • Shut down equipment as required.
   • Record trial results.
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.
   • Make sure appropriate records related to machinery and equipment are maintained to enterprise standards.
   • Identify and rectify problems that are within area of responsibility.
   • Report problems that are outside area of responsibility to appropriate personnel.

Required Skills

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

Knowledge and understanding of the materials equipment and process sufficient to recognise and rectify potential problems Knowledge of organization standard procedures and work instructions and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and in a manner relevant to the job

Understanding of the polymerprocess interactions

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

Knowledge as a basis for solving processing and material problems including

product specifications and limitations

production equipment capability

types and grades of materials and their limitations

die or tool conditions and operational limitations

use of ancillary equipment

Language literacy and numeracy requirements

This unit requires high levels of numeracy and literacy with the ability to interpret technical specifications and reports Advanced numeracy allowing the calculation and interpretation of statistics product formulae and process conditions is also required

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

understand procedures and know the importance of critical material properties and quantities

recognise potential situations requiring action and then in implementing appropriate action

Consistent performance should be demonstrated For example look to see that

new or untried diestools are tested thoroughly

product quality and output standards are met consistently

problems are anticipated from process observations

problems are efficiently resolved

the process runs consistently and smoothly

Assessment method and context

It is preferred that assessment takes place on industrial equipment 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 recognise anticipate and 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 of variables 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

---

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 use of injection moulding, blow moulding and similar equipment. This competency applies to all plastic and rubber processes which involve a die or tool. It applies to situations such as injection or blow moulding dies. It does not apply to situations such as rotational moulding or composites (see PMBPROD431A ).

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.

Die

A former used to give the required shape to the product and which is 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.

Tools and equipment

This competency includes use of equipment and tools such as:

hand tools as required

relevant personal protective equipment.

Hazards

Typical hazards include:

noise, light, energy sources

humidity, air temperatures, radiant heat

stationary and moving machinery, parts and components.

Problems

'Anticipate and solve problems' means resolve 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.

Typical process and product problems may include:

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.

Distinguish between causes of faults such as:

materials/heat

equipment adjustment/set-up

Variables

Key variables to be monitored include:

die/tool set up and adjustment

machine speed, cycle rate

temperature

product quality measures.

---