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Elements and Performance Criteria

1. Confirm die requirements.
   • Communicate with customer and other key stakeholders and agree on; product technical specification, product aesthetic requirements, timelines, cost, usage and other requirements.
   • Identify tool design/product design/process issues which may be in conflict and resolve.
   • Develop design brief, including relevant drawings, to meet needs.
   • Obtain 'sign off' on total design brief from all relevant persons.
2. Develop concept design specification of new die.
   • Select appropriate material(s) of construction or range of materials and grades.
   • Select appropriate finish requirements for die/tool.
   • Design die/tool using appropriate mathematical techniques.
   • Validate die design specifications against die requirements and design brief.
3. Liaise with toolmaker on die manufacture.
   • Discuss design brief and concept design with tool maker(s).
   • Verify understanding of die/tool requirements and ability to meet requirements.
   • Negotiate contract to make die according to company policy and procedures.
   • Continue to liaise with toolmaker.
4. Trial new die and determine modification(s)(if any) required.
   • Design trialing procedure to deliver required information.
   • Ensure OHS and environmental requirements are stringently observed.
   • Coordinate the trialing of the new die/tool.
   • Interpret die/tool trial results and guide die trial process.
   • Tune process to optimise use of new die/tool.
5. Bring new die into standard production.
   • Monitor initial production and adjust die, process and conditions to make the process a smooth operation.
   • Ensure process specifications reflect the optimised operation developed.
   • Ensure standard operating procedures are correct for the new product.
   • Ensure equipment and other hardware records are updated to reflect additions/changes.
   • Ensure project records are complete and all required reports have been completed and submitted.
   • Archive records according to company procedure.

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 design an efficient and effective die and to test that die in the process and validate its fitness for purpose

Knowledge of organization policies and procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and in a manner relevant to the job

Knowledge as a basis for solving processing and material problems including

die materials

die finishs

the impact of the melt viscosity on die size and design

runnersprue design needed

dies size and shape required to product required product

Fourier analysis

mould flow analysis

shear stressstrain rates viscosity

die design data

production trial data

Language literacy and numeracy requirements

This unit requires high levels of numeracy and literacy with the ability to write and 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

The critical aspects for this unit of competency is the ability to apply a thorough understanding of polymer materials their additives and the rheological heat and other effects of processing to the design of a new dietool The influence of dietool design on the operability of the process and the properties of the product also need to be understood The interpretation of die trial data and the modification of die andor process to improve the outcome are also critical

Assessment method and context

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

Competence in this unit may be assessed

using appropriate industrial diestools and polymers

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 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 is for the design of a new die or tool. It assumes an understanding of the operation of all relevant equipment and processes but does not necessarily require them to be used personally.

This competency applies to all work environments and sectors within the plastics, rubber and cablemaking industry. The competency assumes a working knowledge of all main processes, polymer materials and materials of construction of dies/tools so that an informed choice can be made between them

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:

injection moulding

extrusion

blow moulding

extrusion blow moulding

injection blow moulding.

This competency includes the ability to mathematically design dies and analyse die trials. It also requires an understanding of the operation of the process equipment

Problems

Typical process and product problems may include:

clarifying the design brief

communication breakdowns between product designer, die designer, toolmaker and production and maintenance needs.

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