This unit applies to all pressure die casting machines. All work is carried out to predetermined specifications and standards of quality and safety. Work may be carried out autonomously or as part of a work team.

Band: A

Unit Weight: 4

Path 1

MEM13004B

Work safely with molten metals/glass

ELEMENT

PERFORMANCE CRITERIA

1. Conduct pre-operational checks

1.1. The start-up procedure is conducted according to standard operating procedures.

1.2. If necessary, the shot size is adjusted.

1.3. If applicable, nitrogen and/or vacuum systems are checked

1.4. If applicable, a functional check is made of the picking robot, and the component gripper is adjusted if necessary.

1.5. Die spray nozzles are adjusted as necessary.

1.6. Planning is carried out which ensures efficient flow of finished product i.e. breaking of runners, stacking baskets, bins, conveyors.

2. Operate all functions on machine control panel

2.1. Appropriate knowledge of die casting process is applied to the operation, adjustment and monitoring of machine functions.

3. Operate machine to produce castings

3.1. The die casting machine is operated to standard operating procedures, including maintenance of liquid metal and die operating conditions.

3.2. Runners are broken off correctly.

3.3. Castings are visually inspected for porosity, cracks, tears, splits, sinks, cold shuts, tinning and die surface crazing according to standard operating procedures.

3.4. Castings are handled in a manner that minimises risk of damage to the casting and injury to personnel.

3.5. First-off castings are produced, visually inspected and submitted for checking against specifications.

4. Monitor furnace

4.1. The furnace is maintained at optimum operating condition to standard operating procedures.

Required skills

Look for evidence that confirms skills in:

reading and following information on written job procedures and specifications

performing pre-start checks

adjusting the shot size

checking nitrogen and/or vacuum systems for correct operation

checking and adjusting the picking robot and component gripper

adjusting die spray nozzles

sequencing of operations

starting, operating and shutting down a die casting machine

visually checking for conformance to specifications

handling castings

Required knowledge

Look for evidence that confirms knowledge of:

procedures for pre-start checks

procedures for starting up the die casting machine

adjustments that can be made to ensure correct operation of the machine

procedures for adjusting the shot size

the effects of incorrect shot size on the quality of the die casting

the function of nitrogen and vacuum systems in the die casting process

the procedures for checking/ adjusting nitrogen and/or vacuum systems

the function of a picking robot and the component gripper

procedures for adjusting the picking robot

the effects of adjustments on robot performance

the reasons for spraying the die

procedures for adjusting the die spray nozzles

operations to be performed subsequent to the die casting of the product

tools and equipment

methods of transporting/conveying the die cast product

the die casting process

the effect of adjusting each machine control on the quality of the die casting produced

procedures to adjust the operation of the die casting machine

die casting machine operation

maintenance of liquid levels

operating parameters

procedures to remove runners from the die casting

procedures to inspect die castings

common faults in die castings and probable causes

damage that can be caused to castings through inappropriate handling and storage

procedures for checking first-off castings for conformance to specification

specifications of the die cast product

shut-down procedures

hazards and control measures associated with operating a die casting machine, including housekeeping

safe work practices and procedures

use and application of personal protective equipment

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to operate a pressure die casting machine. Competency in this unit cannot be claimed until all prerequisites have been satisfied.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, that is the candidate is not in productive work, then an appropriate simulation must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team. The assessment environment should not disadvantage the candidate.

This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with operating a pressure die casting machine or other units requiring the exercise of the skills and knowledge covered by this unit.

Method of assessment

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Guidance information for assessment

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. 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) may also be included.

Unit sector

Casting and moulding

This unit contains employability skills.