PLASTIC MACHINE OPERATION NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR PLASTIC MACHINE OPERATION NC II

The TESDA Course in PLASTIC MACHINE OPERATION NC II consists of competencies that a person must achieve to prepare molds for composites production, prepare materials for formulae, assemble materials and equipment for production, operate injection molding equipment and blow molding equipment, It also include competency to monitor process operations and to finish products and components

This Qualification is packaged from the competency map of the Automotive Industry (Manufacturing sector)

A student who has achieved this TESDA Course in PLASTIC MACHINE OPERATION NC II is competent to be:

• Plastic Machine Operator

PLASTIC MACHINE OPERATION NC II – TRAINING AND REGULATION MODULE

Course Title: PLASTIC MACHINE OPERATION
Level: NC II
Nominal Training Duration : 143 Hours

This course is designed to enhance the knowledge, skills and attitudes of an individual in the field of automotive manufacturing in accordance with industry standards. It covers competencies such as: Prepare molds for composites production, prepare materials to formulae, assemble materials and equipment for production, operate injection and blow molding equipment, monitor process operations and finish products and components.

TRAINEE ENTRY REQUIREMENTS

This section specifies the qualifications of trainees and educational experience. Other requirements like health and physical requirements are also stated. Passing entry written examinations may also be indicated if necessary.

• can communicate both oral and written;
• physically and mentally fit;
• with good moral character; and
• with experience in basic machining

This list does not include specific institutional requirements such as educational attainment, appropriate work experience, and others that may be required of the trainees by the school or training center delivering the TVET program.

COMPETENCIES REQUIRED IN PLASTIC MACHINE OPERATION NC II

This units of competency comprising this qualification include Basic, Common, Elective and Core Competencies.

To obtain this TESDA course in PLASTIC MACHINE OPERATION NC II, all units prescribed for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (105 Hours)
ALT823301	Prepare Molds for Composites Production
ALT823302	Prepare Materials for Formulae
ALT823303	Assemble Materials and Equipment for Production
ALT823304	Operate Injection Molding Equipment
ALT823305	Operate Blow Molding Equipment
ALT823306	Monitor Process Operations
ALT823307	Finish Products and Components
UNIT CODE	COMMON COMPETENCIES (20 Hours)
ALT742201	Read & Interpret Engineering Drawings
ALT311202	Perform Mensuration and Calculation
ALT723203	Read, Interpret and Apply Specifications and Manuals
ALT723205	Perform Shop Maintenance
UNIT CODE	BASIC COMPETENCIES (18 Hours)
500311105	Participate in workplace communication
500311106	Work in a team environment
500311107	Practice career professionalism
500311108	Practice occupational health and safety procedures

CORE COMPETENCIES

UNIT OF COMPETENCY: PREPARE MOLDS FOR COMPOSITES PRODUCTION
UNIT CODE : ALT823301

This competency covers the demolding and preparation of composites molds (single and multi-cavity molds) for the application by hand or machine of gel coating, or other first coat, in preparation for composites production. It also covers the inspection and temporary repair of minor mold surface defects.

This competency is typically performed by operators working either independently or as part of a work team.

1. Prepare surfaces
   • Surfaces are prepared according to industry standard procedures
   • Temporary repairs are made as needed
   • Tools and equipment and work area are cleaned up when surface preparation is completed
2. Apply mold release system
   • Mold release system is selected for the job
   • Mold release system is applied to mold surfaces as per manufacturer’s specifications
   • Surface release system undergone tape-test according to workplace standard operating procedure.
3. Mask-up mold
   • Suitable masking tape is selected
   • Masking tape and other materials is applied to mold according to standard operating procedures.

UNIT OF COMPETENCY: PREPARE MATERIALS TO FORMULAE
UNIT CODE : ALT823302

This competency covers preparing materials to formulate for production or product finishing.

This competency is typically performed by operators working either independently or as a part of a work team.

1. Identify requirements to handle materials
   • Specifications are read and interpreted and materials are identified
   • Units of measurement and matching measuring equipment and tools are identified
   • Tolerances of measuring equipment is determined the and related them to the impact of over/under measurement of ingredients on production process and quality
   • Procedures are followed to prevent/control the identified hazards
   • Workplace procedures is read, understood and used to plan work sequence.
2. Prepare for assembly of ingredients
   • Appropriate measurement scales are identified
   • Equipment for measurement is calibrated to zero
   • Required personal protection equipment is worn according to company standard operating procedure
   • Equipment for assembly undergone pre-start checking and ensured safe guards for emergencies situations are in place.
   • Work area is checked for cleanliness
   • Sources of potential contamination are identified and steps to minimize/eliminate contamination risk are taken
3. Assemble ingredients
   • Ingredients are collected, weighed/measured according to procedure and formula sheet
   • Correctness of color is checked if conforms to standard
   • Action is taken in procedures if materials/assembled ingredients do not appear to meet requirements
   • Standard operating procedures and appropriate safety measures is followed and observed when conducting work
   • Appropriate workplace-approved sequence is follow for combination of materials
   • Workplace records is complete according to company standard operating procedures
   • Unused ingredients are cleaned and stored

UNIT OF COMPETENCY: ASSEMBLE MATERIALS AND EQUIPMENT FOR PRODUCTION
UNIT CODE : ALT823303

This competency covers the interpretation of product specifications, selection of required materials and equipment, organizing delivery and confirmation of material/equipment delivery to the production area in preparation for production.

This competency is typically performed by operators working either independently or as a part of a work team.

1. Identify required materials and equipment
   • Product specifications is interpreted according to job requirement and work instruction
   • Required materials including additives are identified based on the given specifications
   • Trade names for required product is identified according to job order
   • Quantity of materials required for product is determined without error
   • Required equipment including handling, control and material preparation equipment and tools are identified based on the given work instruction
2. Select materials and equipment
   • Required materials, equipment and machinery are located and made available
   • Items are marked-off on checklist as required and without error
   • Holding area is identified and prepared according to work requirements.
3. Assemble materials and equipment
   • Good manual handling practices are used in accordance with company standard operating procedures
   • Required procedures, particularly OHS procedures, codes and practices is followed and observed per identified hazards.
   • Materials are collected and organized in a manner that ensures storage compatibility
   • Materials are checked visually according to enterprise requirements
   • Holding sample are collected according to enterprise requirements
   • Details of specification and sample are recorded as required
4. Organize internal workplace delivery of materials/equipment
   • Placement of material are organize to required locations using enterprise procedures
   • Delivery is notified and confirmed as per enterprise requirements/procedures
   • Workplace procedures is followed as required by enterprise
5. Store materials for production
   • Storage requirements is identified according to job requirement
   • Holding area conditions is checked to meet material requirements
   • Materials are stored as required for production and to meet health and safety needs
   • Required workplace documentation/records are completed

UNIT OF COMPETENCY: OPERATE INJECTION MOLDING EQUIPMENT
UNIT CODE : ALT823304

This competency covers the operation of injecting molding equipment and the resolving routine problems to produce plastic products.

This competency is typically performed by operators working either independently or as a part of a work team.

1. Check work requirements
   • Work requirements are identified based on procedures
   • Product, materials and equipment requirements are identified based on the job requirements.
   • Hazards are recognize and precautionary steps are adopted to ensure safety
   • Requirements are checked with supervisor/appropriate person if found not in accordance with normal practice
2. Conduct prestart checks as required
   • Safety gates and guards are checked if in position and in working condition
   • Raw materials are checked for correctness based on product specifications.
   • Other pre-start checks are undertaken in accordance with procedures
3. Operate equipment
   • Machine is started safely and correctly when required based on equipment operating instruction
   • Process is check if within the required limits based on product specifications
   • Mold products are collected and stored as required
   • Product/process are checked if within specification/ as to required quality standard
   • Supply of materials is maintain as required
   • Logs and records are completed when required
   • Collection and reprocessing/discarding scrapping/trimming of materials are undertaken in accordance with procedures
   • Equipment and work area are cleaned up in accordance with company procedures
   • Equipment is stopped/paused in an emergency, following workplace and emergency procedures
4. Resolve routine problems
   • Routine problems/ faults likely to occur are identified during the operation and appropriate precautionary measures are readied according to company standard operating procedures.
   •  Appropriate records and log books of equipment operations are ensure and maintained according to company procedures
   • Non-routine problems are identified and reported to designated person

UNIT OF COMPETENCY: OPERATE BLOW MOLDING EQUIPMENT
UNIT CODE : ALT823305

This competency covers the operation of blow molding equipment and the resolving of routine problems to procedure.

This competency is typically performed by operators working either independently or as part of a work team.

1. Check work requirements
   • Work requirements is identified based on procedures
   • Product, materials and tools and equipment are identified based on job requirements
   • Hazards are recognized and steps required to ensure safety are adopted and considered.
   • Requirements are checked with supervisor/appropriate person if found not in accordance with normal practice
2. Conduct prestart checks as required
   • Safety gates and guards are checked if in position and in working condition
   • Raw materials are check based on listed specification
   • Other pre-start checks are undertaken in accordance with procedures
3. Operate equipment
   • Condition of equipment is checked and raw materials are introduced as required by procedures
   • Product/process is checked if within required limits based on work instruction
   • Mold products are collected and stored as required
   • Product/process is checked if within specification/ as to required quality standard
   • Supply of materials is maintain as required
   • Logs and records are completed as required and in accordance with company standard operating procedure
   • Materials are collected, reprocessed/discarded, scraped/trimmed in accordance with procedures
   • Equipment and work area is clean up in accordance with procedures
   • Equipment operation is stopped/paused in an emergency, following workplace and emergency procedures
4. Resolve routine problems
   • Faults that likely to occur are identified during the operation
   • Causes of routine problems/faults are identify and actions are taken on in accordance with procedures
   • Appropriate records and log books of equipment operations are maintained to meet procedures
   • Non-routine problems and report are identified including persons designated to respond to problems.

UNIT OF COMPETENCY: MONITOR PROCESS OPERATIONS
UNIT CODE : ALT823306

This competency covers the use of production processing equipment. This competency is typically performed by all operators working either independently or as part of a work team.

1. Identify equipment control and procedures
   • Work requirements are identified from workplace operating procedures.
   • Operating procedures and controls are checked and approved adjustments are made based on company operating parameters
   • Actions to be used in the event of faulty production is established according to company operating procedures
   • Procedures for obtaining materials for the process is identified and approved according to company standard  operating procedure
   • Hazards and environmental issue that might surround the operation are identified and dealt with according to company standard operating procedure on safety and emergency, provision on Philippine Clean Air Act and other existing environmental legislations
2. Prepare for work/job
   • Ancillary tools and equipment are assembled based on equipment operating instruction
   • Inspection procedures are identified
   • Finishing activities are identify
   • Any hazards connected with materials and process are identified and appropriate safety procedures are readied in accordance with equipment operating instruction, workplace reference materials including materials safety data sheets and equipment instructions
   • Risks from the identified hazards are considered and appropriate measures are taken to minimize them.
   • Location and function of equipment emergency stops and ensure guards are establish the and appropriate inspection are undertaken to ensure that they are in place
   • Requirements are identified and noted or checking:
     • materials inputs and outputs
     • ancillary supplies and equipment
     • product quality requirements for the relevant process stage(s)
   • Access to any required supplementary equipment for product quality testing or routine lubrication and adjustment are obtained or arranged according to company standard operating procedure
3. Maintain operations
   • Process operations is checked, including noting product quality, production outputs and waste, in accordance with workplace practices
   • Product outputs are collected, checked for conformity/stored, and necessary adjustments to the equipment are made (where appropriate)
   • Material which is able to be reprocessed and reused are collected, and procedure for waste and scrap management is undertaken in accordance with workplace procedures (where applicable)
   • Check readouts against standard statistical process information and enter production data into the control system
   • Clean up equipment and work area and manage waste in accordance with workplace procedures
4. Identify product quality requirements
   • Monitor process and note conditions which may affect product quality standards
   • Report process variations within workplace procedures
   • Note and implement authorized changes in standard operating procedures and specifications

UNIT OF COMPETENCY : FINISH PRODUCTS AND COMPONENTS
UNIT CODE : ALT823307

This competency covers a range of processes subsequent to the actual making of the product which have been grouped together under the heading of “finishing”. It applies to the finishing of products for customer use and the finishing components for use by a subsequent process or organization which may then further process or assemble these components into a finished product, and similar activities. It applies across all sectors of the industry.

This competency is typically performed by personnel working either independently or as part of a work team.

1. Establish requirements for the finishing process
   • Work requirements are identify from procedures
   • Equipment and consumables for the finishing process are assemble
   • Workplace procedures and materials safety data sheets are consulted to confirm the work planning process
   • Safety equipment are checked and ensured to be available and in sound condition
   • Products are removed from equipment if required using enterprise standard handling methods
   • End-of-product run are recognize.
2. Check quality of product
   • Products are inspected to identify for routine or non-routine finishing requirements.
   • Significant fining, flash or other quality problems are identified and reported to appropriate person for investigation of mold/die closure/alignment.
   • Modifications are check with appropriate personnel regarding to finishing process.
   • Non-conforming products are identified and processed in accordance with workplace procedures.
3. Undertake the finishing operation
   • Products are trimmed as required
   • Other secondary process operations are undertaken as required
   • Waste and recycling procedures are followed according to company standard operating procedures
   • Finished products are inspected and compared to specifications for suitability for further processing or for customer delivery
   • Finished products are assembled and sorted in accordance with procedures
   • Products are packed as required and according to packaging/stacking specifications
   • Product data are recorded as required
   • Work area are cleaned up and housekeeping is performed
4. Identify and rectify routine product imperfections
   • Range of routine imperfections that can occur during the production process are identified
   • Routine product imperfections are determined and rectified in accordance with procedures
   • Appropriate records and log books are maintained and ensure to meet procedures/work instructions.
   • Non-routine product imperfections are identified and reported to designated person.

COMMON COMPETENCIES (AUTOMOTIVE MANUFACTURING-PARTS MANUFACTURING)

UNIT OF COMPETENCY : READ, INTERPRET AND APPLY ENGINEERING DRAWINGS.
UNIT CODE : ALT742201

This unit deals with identifying, interpreting and applying specification from Engineering blue prints or drawings that provides the measurements of the product and pattern that is to be produced.

1. Identify and access engineering drawings/specification
   • Appropriate Engineering drawings are identified and accessed as per job requirements.
   • Version and date of drawing is checked to ensure correct specification and procedure are identified.
2. Interpret drawings
   • Relevant dimensions and sections of the drawings/specifications are located in relation to the work to be conducted
   • Information in the manual are interpreted in accordance to industry practices
3. Apply information in the drawings & specifications
   • Engineering drawing is interpreted according to job requirements
   • Work steps are correctly identified in accordance with the specifications in the drawings.
   • Dimensional data and shape are applied according to the given task
4. Store drawings
   • The drawings and specification are stored properly to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY : PERFORM MENSURATION AND CALCULATION
UNIT CODE : ALT311202

This unit includes identifying, caring for, handling, using and maintaining measuring instruments.

1. Select measuring instruments
   • Object or component to be measured is identified
   • Correct specifications are obtained from relevant source
   • Appropriate measuring instrument is selected according to job requirements
2. Carry out measurements and calculation
   • Measuring tools are selected in line with job requirements
   • Accurate measurements are obtained to job
   • Calculation needed to complete work tasks are performed using the four basic process of addition (+), subtraction (-), multiplication (x) and division (/).
   • Calculations involving fractions, percentages and mixed numbers are used to complete workplace tasks.
   • Numerical computation is self-checked and corrected for accuracy
   • Instruments are read to the limit of accuracy of the tool.
3. Maintain measuring instruments
   • Measuring instruments are kept free from corrosion
   • Measuring instruments are not dropped to avoid damage
   • Measuring instruments are cleaned before and after using.

UNIT OF COMPETENCY : READ, INTERPRET AND APPLY SPECIFICATION AND MANUALS.
UNIT CODE : ALT723203

This unit deals with identifying, interpreting and applying service specification manuals, maintenance procedure manuals and periodic maintenance manual.

1. Identify and access manual/specification
   • Appropriate manuals are identified and accessed as per job requirements.
   • Version and date of manual is checked to ensure correct specification and procedure are identified.
2. Interpret manuals
   • Relevant sections, chapters of manuals/specifications are located in relations to the work to be conducted
   • Information and procedure in the manual are interpreted in accordance to industry practices
3. Apply information in manual
   • Manual is interpreted according to job requirements
   • Work steps are correctly identified in accordance with manufacturer specification
   • Manual data is applied according to the given task
   • All correct sequencing and adjustments are interpreted in accordance with information contained on the manual or specifications
4. Store manuals
   • Manual or specification are stored appropriately to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY : PERFORM SHOP MAINTENANCE
UNIT CODE : ALT723205

This unit deals with inspecting and cleaning of work area including tools, equipment and facilities. Storage and checking of tools/ equipment and disposal of used supplies/materials are also incorporated in this competency.

1. Inspect/clean tools and work area
   • Cleaning solvent used as per workshop/tools cleaning requirement
   • Work area is checked and cleaned
   • Wet surface/spot in work area is wiped and dried
2. Store/arrange tools and shop equipment
   • Tools/equipment are checked and stored in their respective shelves/location
   • Corresponding labels are posted and visible
   • Tools are safely secured and logged in the records
3. Dispose wastes/used lubricants
   • Containers for used lubricants are visibly labeled
   • Wastes/used lubricants are disposed as per workshop SOP
4. Report damaged tools/equipment
   • Complete inventory of tools/equipment is maintained
   • Damaged tools/equipment/facilities are identified and repair recommendation is given
   • Reports prepared has no error/discrepancy

BASIC COMPETENCIES

UNIT OF COMPETENCY : PARTICIPATE IN WORKPLACE COMMUNICATION
UNIT CODE : 500311105

This unit covers the knowledge, skills and attitudes required to gather, interpret and convey information in response to workplace requirements.

1. Obtain and convey workplace information
   • Specific and relevant information is accessed from appropriate sources
   • Effective questioning, active listening and speaking skills are used together and convey information
   • Appropriate medium is used to transfer information and ideas
   • Appropriate non- verbal communication is used
   • Appropriate lines of communication with supervisors and colleagues are identified and followed
   • Defined workplace procedures for the location and storage of information are used
   • Personal interaction is carried out clearly and concisely
2. Participate in workplace meetings and discussions
   • Team meetings are at ended on time
   • Own opinions are clear expressed and those of others are listened to without interruption
   • Meeting inputs are consistent with the meeting purpose and established protocols
   • Workplace interactions are conducted in a courteous manner
   • Questions about simple routine workplace procedures and matters concerning working conditions of employment are asked and responded to.
   • Meetings outcomes are interpreted and implemented
3. Complete relevant work related documents
   • Range of forms relating to conditions of employment are completed accurately and legibly
   • Workplace data is recorded on standard workplace forms and documents
   • Basic mathematical processes are used for routine calculations
   • Errors in recording information on forms/documents are identified and properly acted upon
   • Reporting requirements to supervisor are completed according to organizational guidelines

UNIT OF COMPETENCY : WORK IN TEAM ENVIRONMENT
UNIT CODE : 500311106

This unit covers the skills, knowledge and attitudes to identify role and responsibility as a member of a team.

1. Describe team role and scope
   • The role and objective of the team is identified from available sources of information
   • Team parameters, reporting relationships and responsibilities are identified from team discussions and appropriate external sources.
2. Identify own role and responsibility within team
   • Individual role and responsibilities within the team environment are identified.
   • Roles and responsibility of other team members are identified and recognized.
   • Reporting relationships within team and external to team are identified.
3. Work as a team member
   • Effective and appropriate forms of communications used and interactions undertaken with team members who contribute to known team activities and objectives.
   • Effective and appropriate contributions made to complement team activities and objectives, based on individual skills and competencies and workplace context.
   • Observed protocols in reporting using standard operating procedures.
   • Contribute to the development of team work plans based on an understanding of team’s role and objectives and individual competencies of the members.

UNIT OF COMPETENCY : PRACTICE CAREER PROFESSIONALISM
UNIT CODE : 500311107

This unit covers the knowledge, skills and attitudes in promoting career growth and advancement.

1. Integrate personal objectives with organizational goals
   • Personal growth and work plans are pursued towards improving the qualifications set for the profession
   • Intra- and interpersonal relationships is are maintained in the course of managing oneself based on performance evaluation
   • Commitment to the organization and its goal is demonstrated in the performance of duties
2. Set and meet work priorities
   • Competing demands are prioritized to achieve personal, team and organizational goals and objectives.
   • Resources are utilized efficiently and effectively to manage work priorities and commitments
   • Practices along economic use and maintenance of equipment and facilities are followed as per established procedures
3. Maintain professional growth and development
   • Trainings and career opportunities are identified and availed of based on job requirements
   • Recognitions are sought/received and demonstrated as proof of career advancement
   • Licenses and/or certifications relevant to job and career are obtained and renewed

UNIT OF COMPETENCY : DEVELOP CAREER AND LIFE DECISIONSUNIT OF COMPETENCY : PRACTICE  OCCUPATIONAL HEALTH AND SAFETY PROCEDURES
UNIT CODE : 500311108

This unit covers the outcomes required to comply with regulatory and organizational requirements for occupational health and safety.

1. Identify hazards and risks
   • Safety regulations and workplace safety and hazard control practices and procedures are clarified and explained based on organization procedures
   • Hazards/risks in the workplace and their corresponding indicators are identified to minimize or eliminate risk to co-workers, workplace and environment in accordance with organization procedures
   • Contingency measures during workplace accidents, fire and other emergencies are recognized and established in accordance with organization procedures
2. Evaluate hazards and risks
   • Terms of maximum tolerable limits which when exceeded will result in harm or damage are identified based on threshold limit values (TLV)
   • Effects of the hazards are determined
   • OHS issues and/or concerns and identified safety hazards are reported to designated personnel in accordance with workplace requirements and relevant workplace OHS legislation
3. Control hazards and risks
   • Occupational Health and Safety (OHS) procedures for controlling hazards/risks in workplace are consistently
     followed
   • Procedures for dealing with workplace accidents, fire and emergencies are followed in accordance with organization OHS policies
   • Personal protective equipment (PPE) is correctly used in accordance with organization OHS procedures and practices
   • Appropriate assistance is provided in the event of a workplace emergency in accordance with established organization protocol
4. Maintain OHS awareness
   • Emergency-related drills and trainings are participated in as per established organization guidelines and procedures
   • OHS personal records are completed and updated in accordance with workplace requirements

DEFINITION OF TERMS

• Mold – A former used to give the required shape to the product and which is not subject to pressure during use. Molds are typically used in the composites and rotational moulding industry. Moulds used for injection moulding, blow moulding, etc, are referred to as ‘dies’ in this Training Package.
• Die – A former used to give the required shape to the product and which is 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.
• PPE Personal Protective Equipment – the last line of defense against workplace hazards – includes things like safety boots, gloves, goggles, ear muffs.
• Routine Problems – To ‘rectify routine problems’ means ‘apply known solutions to a limited range of predictable problems’.
• OHSW – Occupational health, safety and welfare.
• Composites – Products consisting of a polymer matrix and a continuous layered reinforcing media. The reinforcing media include fiber, filament and cloth. The product is generally hand or machine fabricated.
• Calibration – Instruments and other measuring equipment are calibrated to make sure the readings they yield are correct.
  • To calibrate an instrument/item of equipment is a high level unit of competency.
  • To check the calibration of an instrument/item of equipment is a routine part of using it and may be as simple as checking the date the calibration certificate expires.
• Engineering Control – A subset of the hierarchy of control.
• Hierarchy of Control – The preferred order of risk control measures from most to least preferred,
  that is:
  • elimination
  • substitution
  • engineering controls
  • administrative controls
  • personal protective equipment.
• Integral – Equipment which forms part of the operation of a main item of equipment is regarded as ‘integral’ to that main item.
  Examples include feed hoppers (and even blending feed hoppers) and heating and cooling devices.
  Typically equipment will be regarded as being ‘integral’ to the main item if:
  • it is close/attached to the main item
  • it has simultaneous operation with the main item
  • it does not require significant additional knowledge or skills.
    Equipment is not integral if it has independent operation of its own.