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Evidence Guide: PMBPREP304C - 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

 

PMBPREP304C - 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.
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 dies.

  1. Set machine conditions for new die.
  2. Restart machine as per procedure.
  3. Dry cycle machine and die according to enterprise procedures.
  4. Check operation of die against product quality specifications.
  5. Check the first off sample for compliance with required standards.
  6. Fine tune settings and other production variables as required.
  7. Note any equipment variances between actual production and documented set up conditions.
  8. Complete workplace documentation and report to appropriate personnel.
Set machine conditions for new die.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Restart machine as per 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

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 ability to change and set a die in a manner which will put the moulding machine back into full production of in specification product in standard time. In particular it is essential that the operator can:

select, install and check the performance of dies and cores

apply safety precautions appropriate to the task

recognise potential situations requiring action and then implement appropriate action.

Consistent performance should be demonstrated. For example, look to see that:

standards are met consistently

problems are appropriately resolved.

Assessment method and context

Assessment will occur on equipment using simple dies and will be undertaken in a work-like environment.

Competence in this unit may be assessed:

by using an appropriate, industrial moulding machine requiring demonstration of die change and die setting procedures

in a situation allowing the generation of evidence of the ability to perform die change and die setting procedures and to recognise and resolve 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.

Required Skills and Knowledge

This describes the essential skills and knowledge and their level required for this unit.

Competence in this unit includes the ability for the practical completion of the job to apply and/or explain the:

organisation procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards

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

methods of connecting dies to machines, such as bolting to platens, slots etc.

the function of each machine setting and the appropriate ranges of settings for a given die

equipment and process sufficient to recognise conditions which may lead to out of specification production

impact of incorrect or faulty fitting

correct selection and use of equipment and procedures

hazards of the removal and fitting process and appropriate hazard control procedures

relevant information and workplace records

safety precautions appropriate to the task.

use PPE, safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task.

It also requires skills in the safe, precise and efficient removal of simple dies and their correct installation and the ability to plan their own work, including predicting consequences and identifying improvements.

Language, literacy and numeracy requirements

This unit requires the ability to read and interpret typical production orders and die set-up information.

Writing is required to the level of completing workplace forms and production reports.

Basic numeracy is required, eg to monitor and set displays, gauges and dials to correct values according to set-up sheet.

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 includes the setting and removal of simple dies. It does not include advanced and complex dies

This competency applies to all work environments and sectors within the plastics, rubber and cablemaking industry which use moulding dies. It includes the operation of all relevant ancillary equipment.

Die

A former used to give the required shape to the product and used under pressure. Dies are typically used in the extrusion, injection, blow moulding and general rubber sectors. Dies used which are not subject to pressure are referred to as 'moulds' in this Training Package.

Simple die

A two plate die including any ejection system operating in the mould open axis, but excluding moulds with molten material retained within the mould between cycles. Products are simple, straight drawn items. Typical features may include: force, cavity, back plates, support plates, cold runner, sprue, nozzle seat, locating ring-tab, sub, fan, diaphragm and direct gating, ejector pins and sleeves, ejector plate and stripper plate, simple drilling for mould cooling.

Advanced die

A two or three plate die 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. Excludes moulds which retain molten material within the mould between cycles. Typical features may include: sliding blocks or cores actuated by skew pins or cams; baffled, spiral, tube, and heat pipe cooling systems; rising cores; and internally actuated unscrewing systems.

Complex die

Dies which use at least one external power and control source to actuate product forming components, which move in a direction other than the mould open axis, and require sequencing with the mould operation. Includes moulds which retain molten material within the mould between cycles. Typical features may include: hot runners; insulated runners; externally actuated sliding blocks, cores, and unscrewing systems; safety interlocks.

Requirements

Requirements for the die change may include checking the die dimensions such as mould height and required ejector stroke to ensure it is compatible with the selected machine

Setting

Setting of the machine conditions may include setting the mould height on the machine, the clamp force, the mould safety system, the ejector system, the mould opening and closing distances, speeds and forces and the injection unit.

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

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:

hand carts and trolleys

hoists/lifting equipment not requiring any special permits or licences

basic hand tools

relevant personal protective equipment.

Hazards

Typical hazards include:

hazardous materials

manual handling hazards

hot surfaces.

Anticipate problems

Anticipate problems includes taking a proactive approach to a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures, and endeavouring to learn from the problem so that it does not recur.

Typical die setting problems may include:

lack of cleaning of die surface and cooling channels, leading to corrosion

inadequate fitting of the dies to the platens, causing poor alignment or movement during production

fine adjustments of die movements, to optimise production.

All operations are performed in accordance with procedures.

Variables

Key variables, and their causes, to be monitored include:

time/effort required to set a die

number of attempts to produce a first off within specification

the need to reset/adjust a die during then production run.