Application
Application of this unit
This competency applies to operators who are involved in assembling moulds for production of products, typically in the rotational moulding, urethane foam, thermoforming and composites sector. The key factors are the selection of correct mould parts, assembling of the mould and dismantling of mould after production. It includes:
checking job sheets for work to be done
setting up moulds
dismantling moulds and replacing worn parts
maintaining mould part stock controls.
Prerequisites
Prerequisites
This unit has no prerequisites.
Elements and Performance Criteria
ELEMENT ELEMENT | PERFORMANCE CRITERIA Performance Criteria describe the required performance needed to demonstrate achievement of the Element. Assessment of performance is to be consistent with the Evidence Guide. |
1. Check work requirements. | 1.1 Identify the type of product required. 1.2 Check for any special requirements. 1.3 Recognise mould parts required. 1.4 Interpret mould and part dimensions. 1.5 Check with supervisor/appropriate person if requirements are not in accordance with usual practice. |
2. Assemble mould. | 2.1 Select and check required mould parts. 2.2 Use correct mould set-up jig. 2.3 Assemble mould as per procedures. 2.4 Check position of mould in relation to rest of machine. 2.5 Check mould will open and close. 2.6 Apply release agent. 2.7 Check breather/vent system for safe functioning. 2.8 Pack breather/vent system with material to avoid spillages. |
3. Dismantle mould. | 3.1 Use correct mould dismantling jig. 3.2 Dismantle mould as per work instructions. 3.3 Strip mould of release agent. 3.4 Clean mould to remove contaminants in accordance with procedures. 3.5 Dry out mould. 3.6 Store mould parts in appropriate place. |
4. Identify and replace worn parts. | 4.1 Identify worn parts. 4.2 Check condition of other mould parts. 4.3 Replace worn mould parts. 4.4 Record details of worn parts. |
5. Maintain mould part stocks. | 5.1 Check stocks of spare parts. 5.2 Advise supervisor of stock required, parts used and date of completed mould. |
Required Skills
This describes the essential skills and knowledge and their level required for this unit.
Application of knowledge of the materials, equipment and process sufficient to recognise out of specification products, process problems and materials faults.
Knowledge of organisation procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.
Application of the knowledge of managing risks using the hierarchy of controls applied to the 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:
different mould part types
types of releasing agents
role of releasing agents
procedures
identifying factors which may affect product quality or production output and appropriate remedies
distinguishing between causes of problems, such as use of incorrect mould parts, incorrect positioning of mould parts, worn/damaged mould parts.
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 process.
Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets, procedures, 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.
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:
recognise the importance of material properties and qualities apply approved procedures
take appropriate action to resolve faults or report faults to appropriate personnel.
Consistent performance should be demonstrated. For example, look to see that:
production standards are met consistently
upstream and downstream communication is timely
effective operating procedures and work instructions are read and interpreted correctly
problems are identified and appropriate action is taken (ie the problem is fixed or reported)
all safety procedures are followed.
Assessment method and context
Assessment will occur using industrial mould(s)/equipment and will be undertaken in a work-like 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 respond to problems
by using a suitable simulation and/or a range of case studies/scenarios
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 practical/simulation 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 studies/scenarios 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 and/or 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 applies to all work environments and sectors within rotational moulding, polyurethane, composites and thermoforming where moulds are used. It includes the operation of all relevant additional equipment where that equipment is integral to the 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. These may include:
assembling cast and prefabricated moulds (typically made from metal or composite materials)
using hand tools as required
interpreting production schedules/ work cards as appropriate.
Tools and equipment
This competency includes use of equipment and tools such as:
handling aid such as handcarts, hoists, jigs and gantries
pedestrian forklifts
hoists, jigs and gantries
powered equipment/aids such as sanders and sand blasting equipment
relevant personal protective equipment.
It does not cover the use of equipment requiring special licences.
Hazards
Typical hazards include:
noise, light, energy sources
humidity, air temperatures, radiant heat
stationary and moving machinery, parts or components
manual handling hazards.
Problems
'Respond to routine problems' means 'apply known solutions to a limited range of predictable problems'. Typical process and product problems may include:
matching moulds to production requirements
servicing of moulds
recognising parts requiring replacement
selecting correct parts for replacement
using incorrect mould parts
incorrect positioning of mould parts
worn/damaged mould parts.
Sectors
Not applicable.
Employability Skills
This unit contains employability skills.
Licensing Information
Not applicable.