Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.
This describes the essential skills and knowledge and their level required for this unit.
Application of an operational knowledge of the materials, equipment and process sufficient to recognise out of specification products, process problems and materials faults. For example if all products are suddenly short (underfilled) for several cycles and getting shorter, this could mean that there is insufficient polymer flow, which could be due to a broken heater band etc. The heater bands would all be checked to ensure proper functioning.
Knowledge of the enterprise's procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards. For example when monitoring process conditions, action must only be taken if the cushion varies by more than say 2mm.
Application of the knowledge of managing risks using the hierarchy of controls applied to the injection 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:
production workflow sequences and materials demand
the reasons for checking process control panels and reporting readings which are outside of normal range of process variability
accurately monitoring equipment operation and product quality
the potential effects of variations in raw materials and equipment operation in relation to quality of product
processing behaviour of polymers and the role of additives
waste management and knowing the importance of reusing non-conforming products wherever possible
correct selection and use of equipment, materials, processes and procedures
explain the effect of unauthorised or emergency shutdown in relation to safety and production requirements
identify factors which may affect product quality or production output and appropriate remedies.
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 injection moulding process.
Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets, procedures, basic machine control panels, 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 25 kg bags are needed to make up a requirement for 50 kg.
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 injection moulding operations within the plastics and rubber sectors. It includes the operation of all relevant additional equipment where that equipment is integral to the injection 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.
Tools and equipment
This unit of competency includes use of equipment and tools such as:
injection moulding machines (such as electrical, mechanical, electromechanical and hydraulic)
components of injection moulding machines (such as base, material supply systems, barrel and screw plastification unit, injection units)
dies/tools (such as pneumatic, or hydraulic actuation of cores, slides ejector systems)
ancillary equipment (such as chillers, die heating equipment, hopper driers, mixing hoppers, dehumidifying driers, air compressors, dosing machines, blending and mixing equipment and conveyors where they are integral to the operation of the injection moulder)
hand tools used in the injection moulding process
material loading equipment used for loading of raw materials
relevant personal protective equipment.
Hazards
Typical hazards include:
spills
dusts/vapours
slip and fall (such as due to spilt granules)
temperature (such as due to heated barrel, nozzle and hot runner moulds)
hazardous substances (including decomposing polymer during start up and shut down)
moving equipment (such as moving moulds, robots and ancillary equipment)
manual handling hazards.
Problems
'Respond to routine problems' means 'apply known solutions to a limited range of predictable problems'. Typical process problems may include:
equipment malfunction
variations in cycle time, temperature, pressure, speed
variations in materials or contamination of materials
die/tooling problems such as damage to die.
Typical product problems may include routine injection moulding faults such as:
short mouldings
flash
sink marks
voids
burn marks
splay/splash marks/silver streaking
blistering
flow marks
poor surface finish
weld lines
poor colour dispersion
colour contamination
black spots
ejection damage.
Appropriate action for non-routine problems may be reporting to designated person or other action specified in the procedures.
Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.
Observation Checklist