NTISthis.com

Evidence Guide: PMBPREP304 - Set a die

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

PMBPREP304 - Set a die

What evidence can you provide to prove your understanding of each of the following citeria?

Prepare to change dies

  1. Determine when changeover will be required, and plan requirements for die change
  2. Obtain dies and/or cores and all parts and tools to match the production order
  3. Follow procedure for machine close-down and for informing relevant personnel
  4. Take last-off samples as required for die reports
  5. Close down machine in accordance with procedures
  6. Prepare machine for changeover in accordance with procedures
Determine when changeover will be required, and plan requirements for die change

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Obtain dies and/or cores and all parts and tools to match the production order

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Follow procedure for machine close-down and for informing relevant personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take last-off samples as required for die reports

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Close down machine in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare machine for changeover in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Change dies

  1. Plan removal process to ensure no damage to self, equipment or others
  2. Remove, clean and store die according to workplace procedures applying corrosion protection if required
  3. Attach replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification
  4. Set machine conditions for new die
  5. Restart machine according to procedure
  6. Dry cycle machine and die according to enterprise procedures
  7. Check operation of die against product quality specifications
  8. Check the first-off sample for compliance with required standards
  9. Fine tune settings and other production variables as required
  10. Note any equipment variances between actual production and documented set-up conditions
  11. Complete workplace documentation and report to appropriate personnel
Plan removal process to ensure no damage to self, equipment or others

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove, clean and store die according to workplace procedures applying corrosion protection if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Attach replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set machine conditions for new die

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Restart machine according to procedure

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Dry cycle machine and die according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check operation of die against product quality specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check the first-off sample for compliance with required standards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Fine tune settings and other production variables as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Note any equipment variances between actual production and documented set-up conditions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete workplace documentation and report to appropriate personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Anticipate die setting problems

  1. Identify potential problems which may occur during the die changing and setting process
  2. Determine possible causes of these problems
  3. Identify most likely causes and prioritise appropriate actions
  4. Rectify problems using appropriate solutions within area of responsibility
  5. Recommend improvements in systems or procedures
Identify potential problems which may occur during the die changing and setting process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine possible causes of these problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify most likely causes and prioritise appropriate actions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify problems using appropriate solutions within area of responsibility

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recommend improvements in systems or procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare to change dies

1.1

Determine when changeover will be required, and plan requirements for die change

1.2

Obtain dies and/or cores and all parts and tools to match the production order

1.3

Follow procedure for machine close-down and for informing relevant personnel

1.4

Take last-off samples as required for die reports

1.5

Close down machine in accordance with procedures

1.6

Prepare machine for changeover in accordance with procedures

2

Change dies

2.1

Plan removal process to ensure no damage to self, equipment or others

2.2

Remove, clean and store die according to workplace procedures applying corrosion protection if required

2.3

Attach replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification

3

Set dies

3.1

Set machine conditions for new die

3.2

Restart machine according to procedure

3.3

Dry cycle machine and die according to enterprise procedures

3.4

Check operation of die against product quality specifications

3.5

Check the first-off sample for compliance with required standards

3.6

Fine tune settings and other production variables as required

3.7

Note any equipment variances between actual production and documented set-up conditions

3.8

Complete workplace documentation and report to appropriate personnel

4

Anticipate die setting problems

4.1

Identify potential problems which may occur during the die changing and setting process

4.2

Determine possible causes of these problems

4.3

Identify most likely causes and prioritise appropriate actions

4.4

Rectify problems using appropriate solutions within area of responsibility

4.5

Recommend improvements in systems or procedures

Required Skills and Knowledge

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare to change dies

1.1

Determine when changeover will be required, and plan requirements for die change

1.2

Obtain dies and/or cores and all parts and tools to match the production order

1.3

Follow procedure for machine close-down and for informing relevant personnel

1.4

Take last-off samples as required for die reports

1.5

Close down machine in accordance with procedures

1.6

Prepare machine for changeover in accordance with procedures

2

Change dies

2.1

Plan removal process to ensure no damage to self, equipment or others

2.2

Remove, clean and store die according to workplace procedures applying corrosion protection if required

2.3

Attach replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification

3

Set dies

3.1

Set machine conditions for new die

3.2

Restart machine according to procedure

3.3

Dry cycle machine and die according to enterprise procedures

3.4

Check operation of die against product quality specifications

3.5

Check the first-off sample for compliance with required standards

3.6

Fine tune settings and other production variables as required

3.7

Note any equipment variances between actual production and documented set-up conditions

3.8

Complete workplace documentation and report to appropriate personnel

4

Anticipate die setting problems

4.1

Identify potential problems which may occur during the die changing and setting process

4.2

Determine possible causes of these problems

4.3

Identify most likely causes and prioritise appropriate actions

4.4

Rectify problems using appropriate solutions within area of responsibility

4.5

Recommend improvements in systems or procedures

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 procedures and job specifications

remove, clean and store die according to procedures

select dies, cores, parts and tools and install replacement die to meet specifications

set machine conditions for new die

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/alarm/fault indications, such as:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

product parameters (temperature, flows, pressure and levels)

resolve non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

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

construction of simple dies and their components, including fixed and removable cores, inserts, ejection systems and vents

methods of connecting dies to machines

impact of incorrect or faulty fitting

function of machine settings and appropriate ranges of settings for specific 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.

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:

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.

Simple die

For the purposes of this Training Package a simple die is a two-plate die used to give the required shape to the product and used under pressure to produce simple, straight drawn items. It includes any ejection system operating in the mould open axis.

The following are not considered simple dies:

dies which are not subject to pressure (these are referred to as moulds in this Training Package)

two- or three-plate dies with one or more product forming components which move in a direction other than the mould open axis, and which are driven by the mould rather than external actuation

moulds with molten material retained within the mould between cycles.

Setting

Setting machine conditions for the replacement die must be relevant to the type of equipment/process being used and includes one or more of:

mould height on the machine

clamp force

mould safety system

ejector system

mould opening and closing distances, speeds and forces

injection unit.

These settings may be performed automatically by using an electronic storage device to load settings from a previous run of the product or may be performed by manually setting controls individually.

Tools and equipment

Tools and equipment include one or more of:

hand carts and trolleys

hoists/lifting equipment not requiring any special permits or licences

basic hand tools

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

hot surfaces

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

heat, smoke, dust, vapours or other atmospheric hazards

electricity

gas

gases and liquids under pressure

structural hazards

equipment failures

machinery, equipment and product mass

other hazards that might arise

Non-routine problems

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person.

Non-routine problems are unexpected problems or variations of previous problems and include one or more of:

corrosion of die surface and/or cooling channels

poor alignment of die

movement during production

faulty components

machine malfunction

variation in product.

Operational knowledge includes one or more of:

procedures

training

technical information such as journals, engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.