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Elements and Performance Criteria

1. Prepare to change advanced or complex die
   • Determine when changeover will be required, and plan requirements for die change
   • Prepare dies and all equipment related to the advanced or complex die change
   • Prepare the moulding machine for die removal according to enterprise procedures
2. Change dies
   • Remove die according to enterprise procedures, in a safe, systematic and time efficient manner
   • Clean and store die according to workplace procedures applying corrosion protection if required.
   • Prepare the moulding machine according to procedures
   • Attach replacement die to the machine according to procedures
3. Set advanced or complex die
   • Set machine conditions for new die
   • Restart machine in accordance with procedure
   • Dry cycle machine and die according to enterprise procedures
   • Check operation of die and power and control devices against die set up 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

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, manual handling 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.
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: technical specifications technical drawings 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.
Die	A die is a former used to give shape to the product and used under pressure. Dies are typically used in the extrusion, injection, blow moulding and general rubber sectors. Dies which are not subject to pressure are referred to as 'moulds' in this Training Package.
Advanced die	An advanced die is a two or three plate die which has one or more product forming components which: move in a direction other than the mould open axis are driven by the mould rather than external actuation. An advanced die will typically feature one or more of: 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 die	A complex die is either: a die which has one or more product forming components that: use an external power and control source to actuate product forming components move in a direction other than the mould open axis require sequencing with the mould operation a mould which retains molten material within the mould between cycles. A complex die will typically feature one or more of: hot runners insulated runners externally actuated sliding blocks, cores and unscrewing systems safety interlocks.
Tools and equipment	Tools and equipment include: dies/tools ancillary equipment, including one or more of: hot-runner temperature control hydraulic or pneumatic power supply for actuation of equipment, such as cores or sliding blocks mould temperature control hand/power tools used in this process. Additional tools and equipment will be selected as required from: hoists/lifting equipment not requiring any special permits or licences manual handling, aids such as hand carts and trolleys relevant personal protective equipment (PPE).
Hazards	Hazards must be identified and controlled. Identifying hazards requires consideration of: weight, shape, volume of materials to be handled hazardous products and materials rotational equipment or vibration sharp edges, protrusions or obstructions slippery surfaces, spills or leaks smoke, dust or other atmospheric hazards high temperatures electricity gas gases and liquids under pressure structural hazards equipment failures machinery, equipment and product mass other hazards that might arise.

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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 technical and product specifications, instruments/control panels and data

plan and prepare for die changeover

remove, clean and store die according to procedures

place, attach and adjust die to specifications

make hydraulic, pneumatic and electrical connections as required

set machine conditions for new die

monitor key variables, including:

alignment and fitting to patens

stability during production

fine adjustments of die movements to optimise production

die temperature control

die component stroke

clamping force

speeds

pressure

sequencing

interlocks

machine pressure, sequencing and interlocks

check the installation and operation of new die to identify conformance and/or non-conformance to specifications

make adjustments to settings and equipment operation to rectify variations in equipment operation or product quality

identify hazards and apply relevant hazard controls

distinguish between causes of problems, such as:

operational problems

instrument failure/malfunction

hydraulic failure/malfunction

pneumatic failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

wrong dies

wrongly set die

worn or damaged die

non-optimum process conditions

incorrect material type or poor quality

equipment design deficiencies

resolve non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records.

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Knowledge Evidence

Must provide evidence that demonstrates knowledge relevant to their job sufficient to fulfil their job role, including knowledge of:

types and features of advanced/complex dies, including

sliding blocks or cores actuated by skew pins or cams

baffled, spiral, tube, and heat pipe cooling systems

rising cores

internally actuated unscrewing systems

external power and control sources,

externally actuated sliding blocks, cores and unscrewing systems

safety interlocks

die setting procedures for advanced/complex dies

verification procedures for advanced/complex dies

impact of incorrect or faulty fitting

settings and adjustments of equipment, machine components and ancillary equipment in fine tuning dies

routine and non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

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