Elements and Performance Criteria

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 advanced or complex dies. It does not include simple dies or moulds.
This competency applies typically to the injection moulding and blow moulding sectors. It requires an understanding of the operation of all relevant equipment and processes but does not necessarily require them to be used personally.
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.
Die
A die is a former used to give shape to the product and used under pressure. Dies are typically used in the extrusion, injection, blow moulding and general rubber sectors. Dies which are not subject to pressure are referred to as 'moulds' in this Training Package.
Advanced dies
Advanced dies are 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. Typical features may include:
sliding blocks or cores actuated by skew pins or cams
baffled, spiral, tube, and heat pipe cooling systems
rising cores
internally actuated unscrewing systems.
Complex dies
Complex dies are dies which:
use at least one external power and control source to actuate product forming components
move in a direction other than the mould open axis
require sequencing with the mould operation.
They include moulds which retain polymer melt within the mould between cycles.
Typical features may include:
hot runners
insulated runners
externally actuated sliding blocks, cores and unscrewing systems
safety interlocks.
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.
Die and machine preparation
The die and machine preparation may include making connections such as:
hydraulic
pneumatic
electrical.
Die fitting
Die fitting includes the placement, attachment and adjustment of dies against predetermined specifications, but does not include the modification of dies or equipment to make them fit against new specifications or to change their performance as might be done by a toolmaker or similar metals tradesperson. Repairs to dies are also not covered by this unit.


Die operations
Die operations may include:
die temperature control
die component stroke
clamping force
speed
pressure
sequencing
interlocks
Machine operations
Machine operations may include:
machine movement speed and stroke
pressure
sequencing
interlocks.
Ancillary equipment operations
Ancillary equipment operations may include:
hot-runner temperature control
hydraulic or pneumatic power supply for actuation of equipment such as cores or sliding blocks
mould temperature control.
Tools and equipment
This 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.

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 the procedures and the importance of critical die characteristics be understood. Competence must be demonstrated in the ability to recognise potential situations requiring action and then in implementing appropriate action.
Consistent performance should be demonstrated. For example, look to see that at least one type of advanced or complex die has been correctly set and removed and that there is evidence that other types of advanced or complex dies can also be set/removed.
Assessment method and context
Assessment will occur on equipment using complex dies and will be undertaken in a work-like environment.
Competence in this unit may be assessed using an appropriate, industrial moulding machine:
requiring demonstration of start-up, operation and emergency stop procedures
requiring demonstration of changing and setting procedure for an advanced or complex die
in a situation allowing the generation of evidence of the ability to recognise and resolve problems
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.