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 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.

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.