PLASTIC MACHINE OPERATION NC III – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR PLASTIC MACHINE OPERATION NC III

The TESDA Course in PLASTIC MACHINE OPERATION NC III consists of competencies that a person must achieve to change equipment dies, prepare and start equipment for production and produce injection molded products. It also include competency to produce blow molded products. Likewise the person involved in this qualification is in-charge of overall equipment set-up and readiness-check for production operation.

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 III is competent to be:

• Plastic Machine Operation Team Leader; or
• Plastic Machine Operation Supervisor

PLASTIC MACHINE OPERATION NC III – TRAINING AND REGULATION MODULE

Course Title: PLASTIC MACHINE OPERATION
Level: NC III
Nominal Training Duration : 145 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: Change equipment dies; Prepare and start equipment for production and Produce injection molded products. It also include competency to produce blow molded products. Likewise the person involved in this qualification is in-charge of overall equipment set-up and readiness-check for production operation.

TRAINEE ENTRY REQUIREMENTS

Trainees or students should possess the following requirements:

• Must possess the Plastic Machine Operation National Certificate II
• can communicate both orally and in writing;
• physically and mentally fit; and
• with experience in basic machining

COMPETENCIES REQUIRED IN PLASTIC MACHINE OPERATION NC III

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

To obtain this TESDA Course in PLASTIC MACHINE OPERATION NC III, all units prescribed below for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (105 hours)
ALT823308	Change Equipment Dies
ALT823309	Prepare and Start Equipment for Production
ALT823310	Produce Injection Molded Products
ALT823311	Produce Blow Molded Products
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 (20 hours)
500311109	Lead Workplace Communication
500311110	Lead Small Teams
500311111	Develop and Practice Negotiation skills
500311112	Solve Problems Related to Work Activities
500311113	Use Mathematical Concepts and Techniques
500311114	Use Relevant Technologies

CORE COMPETENCIES

This section gives the details of the contents of the core units of competency required in PLASTIC MACHINE OPERATION NC III

UNIT OF COMPETENCY: CHANGE EQUIPMENT DIES
UNIT CODE : ALT823308

This competency covers the removal and refitting of dies in preparation for production. It applies typically to the areas of the industry such as injection and blow molding.

This competency is typically performed by operators demonstrating some relevant theoretical knowledge and using a range of well developed skills requiring some discretion and judgment.

1. Prepare to change dies
   • Procedure for machine close-down is followed and concerned personnel are informed as per workplace procedures.
   • Last-off samples are taken as required for die reports
   • Machine is shut down in accordance with workplace procedures and/or manufacturer’s instructions
   • Isolating locks are activated, power is disconnected and relevant signage are posted as per workplace procedures
   • Dies or cores are selected to match product/ process specification
   • Tools and equipment are checked for safe, effective operation.
2. Change dies
   • Removal process is planned to ensure no injury to self or others, and damage equipment
   • Die is removed, cleaned and stored according to workplace procedures
   • Replacement die is fitted ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification
   • Dies and immediate machinery are cleaned, corrosion protection applied if required.
3. Test fitting of dies
   • Machine is restarted as per procedure
   • Operation of die is checked against product quality specifications
   • Machine setting ranges is compared against documented requirements
   • First off sample is checked the for required standards
   • Settings and other production variables are fine-tuned as required
   • Variances between standard operating procedures and actual production run is noted
   • Workplace documentation is completed and reported to appropriate personnel.
4. Respond to problems
   • Possible routine and non-routine problems in the equipment, materials or process are identified
   • Problems needing action is determined according to workplace procedures
   • Possible fault causes are determined according to workplace procedures
   • Problems within area of responsibility are rectified using appropriate solutions
   • Problems outside area of responsibility are reported to designated person.

UNIT OF COMPETENCY : PREPARE AND START EQUIPMENT FOR PRODUCTION
UNIT CODE : ALT823309

This competency covers the pre-start preparations and start-up operations to bring a production machine from ‘power-off’ to first-off product and handover to the operator to continue the production run (for Injection and blow molding machine).

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

1. Perform prestart checks
   • Emergency stops, guards, controls are checked in accordance with workplace procedures
   • Copy of the product data sheet is collected
   • Requirements for materials, quality, production run are identified
   • Head/die bolts, etc, are retightened as required
   • Equipment set-up is checked in accordance with workplace procedures
2. Carry out prestart operations
   • Power is restored to the machine and ancillary equipment as per workplace procedures and/or manufacturer’s instruction
   • Ancillary equipment/heater circuit is started up and the temperature and other controllers to the condition stated on the setup information card is set in accordance with workplace procedures and/or manufacturer’s instruction
   • Machine settings is checked against setup information card and machine switch on in accordance with workplace procedures and/or manufacturer’s instruction
   • Machine is brought to operational readiness in accordance with workplace procedures
   • Material is selected and loaded in accordance with workplace procedures
   • Machine is charged, purged and cleaned as required.
3. Start machine and hand over to operator
   • Machine is started and checked in accordance with workplace procedures and/or manufacturer’s instruction
   • Machine is adjusted to bring to machine to operational speed/condition, as required
   • Machine is checked and ran until a quality product is obtained
   • Adjustments to machine and extra equipment is made in line to produce an acceptable product
   • Required adjustments are made to ensure the machine and its upstream and downstream extra equipment in line are in balance
   • Operator is given all necessary instructions and machine is handed over to the operator

UNIT OF COMPETENCY: PRODUCE INJECTION MOLDED PRODUCTS
UNIT CODE : ALT823310

This competency covers the operation and adjustment of injection molding processes and the solving of non-routine problems. It does not cover die setting.

This competency is typically performed by operators demonstrating some relevant theoretical knowledge and using a range of well developed skills requiring some discretion and judgment.

1. Plan own work requirements
   • Tools and equipment and processes used for production process and upstream and downstream operations from production plan or request are identified in accordance with workplace procedures
   • Materials required are identified including additives as per production requirements
   • Hazards are recognized and appropriate hazard control / minimization methods are followed
   • Emergency stops, guards and controls are identified and checked in accordance with workplace procedures
   • Requirements for materials, quality, production and equipment checks are identified in accordance with workplace procedures
   • Materials, waste management and housekeeping needs are identified in accordance with workplace procedures
2. Check injection molding process setup
   • Equipment requirements are determined in accordance with workplace
   • Process is set to specifications as required
   • Injection molding equipment settings and adjustments are checked as required
   • Materials are checked as per job requirements
   • Nonconforming materials are discarded, or adjustments are made to the process
   • Date, batch and materials markings are set up to specifications, as required
   • Other pre-start checks are completed in accordance with procedures.
3. Operate and make adjustments as required to the injection molding process
   • Injection molding equipment is operated, noting key variables in accordance with procedures.
   • Controls/displays/terminals for production/process data are monitor in accordance with procedures.
   • Product/process quality is monitored in accordance with procedures
   • Adjustments are made to remedy faults and nonconformity to standard as required
   • Continuity of process is maintained in accordance with production requirements
   • Scrap/trimming and other materials are collected and reprocessed/ discarded in accordance with procedures
   • Equipment is cleaned, adjusted and lubricated as required
   • Equipment is paused or stopped in an emergency, following workplace and emergency procedures.
4. Respond to problems
   • Possible routine and non-routine problems in the equipment, materials or process identified in accordance with procedures
   • Problems needing action are determined in accordance with procedures
   • Possible fault causes are determine in accordance with procedures
   • Problems are rectified using appropriate solutions within area of responsibility
   • Problems outside area of responsibility are reported to designated person.

UNIT OF COMPETENCY : PRODUCE BLOW MOLDED PRODUCTS
UNIT CODE : ALT823311

This competency covers the operation and adjustment of blow molding processes and the solving of non-routine problems.

This competency is typically performed by operators demonstrating some relevant theoretical knowledge and using a range of well developed skills requiring some discretion and judgment

1. Plan own work requirements
   • Equipment and processes used for production process and upstream and downstream operations are identified from production plan or request
   • Materials required including additives are identified based on work requirements
   • Hazards are recognized and appropriate hazard control/ minimization methods are followed
   • Emergency stops, guards and controls are identified and checked
   • Requirements for materials, quality, production and equipment checks are identified based on work requirements
   • Waste management and housekeeping needs are identified in accordance with workplace procedures and/or OH & S requirements.
2. Set up and conduct pre start checks
   • Equipment is set up to specifications
   • Blow molding equipment is set up and adjusted for shot size, parison control, die gap, temperature, screw speed, cycle speed, slow close setting (or cushion) and timing to specifications
   • Safety gates and guards are checked in their correct working positions and emergency stops are identified and checked as required
   • Equipment, raw material and mould are verified to match job requirement
   • Date, batch and material markings are set up according to procedures.
   • Other pre-start checks are complete according to procedures
   • Equipment is started up and ‘dry run’ is performed to warm hydraulics and components to operating temperature before production, as required.
3. Operate and make adjustments as required to the blow molding process
   • Condition of equipment is checked and raw materials is introduced as required
   • Blow molding equipment is operate and key variables noted in accordance with workplace procedures
   • Controls/displays/terminals for production/process data are monitored in accordance with workplace procedures
   • Product/process quality is monitored according to procedures
   • Adjustments are made to remedy faults and nonconformity to standard as required
   • Continuity of process is maintained in accordance with workplace procedures
   • Scrap/trimming and other materials are collected and reprocessed/discarded according to procedures
   • Equipment is cleaned, adjusted and lubricated as required
   • Logs and records are completed as required
   • Equipment is paused or stopped in an emergency following standard operating procedures.
4. Respond to problems
   • Possible routine and non-routine problems in the equipment, materials or process are identified in accordance with workplace procedures
   • Problems needing action are determined in accordance with workplace procedures
   • Possible fault causes are determine in accordance with workplace procedures
   • Problems within area of responsibility are rectified using appropriate solutions
   • Problems outside area of responsibility are reported to designated person.

COMMON COMPETENCIES (AUTOMOTIVE MANUFACTURING-PARTS MANUFACTURING)

UNIT TITLE: 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 : ALT723204

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

The BASIC COMPETENCIES refer to non-technical skills (knowledge, skills and attitudes) that everybody will need in order to perform satisfactorily at work and in society and are considered portable and transferable irrespective of jobs and industrial settings.

UNIT OF COMPETENCY : LEAD WORKPLACE COMMUNICATION
UNIT CODE : 500311109

This unit covers the knowledge, skills and attitudes required to lead in the dissemination and discussion of ideas, information and issues in the workplace.

1. Communicate information about workplace processes
   • Appropriate communication method is selected
   • Multiple operations involving several topics areas are communicated accordingly
   • Questions are used to gain extra information
   • Correct sources of information are identified
   • Information is selected and organized correctly
   • Verbal and written reporting is undertaken when required
   • Communication skills are maintained in all situations
2. Lead workplace discussions
   • Response to workplace issues are sought
   • Response to workplace issues are provided immediately
   • Constructive contributions are made to workplace discussions on such issues as production, quality and safety
   • Goals/objectives and action plan undertaken in the workplace are communicated
3. Identify and communicate issues arising in the workplace
   • Issues and problems are identified as they arise
   • Information regarding problems and issues are organized coherently to ensure clear and effective communication
   • Dialogue is initiated with appropriate personnel
   • Communication problems and issues are raised as they arise

UNIT OF COMPETENCY : LEAD SMALL TEAMS
UNIT CODE : 500311110

This unit covers the knowledge, skills and attitudes to lead small teams including setting and maintaining team and individual performance standards.

1. Provide team leadership
   • Work requirements are identified and presented to team members
   • Reasons for instructions and requirements are communicated to team members
   • Team members’ queries and concerns are recognized, discussed and dealt with
2. Assign responsibilities
   • Duties, and responsibilities are allocated having regard to the skills, knowledge and aptitude required to properly undertake the assigned task and according to company policy
   • Duties are allocated having regard to individual preference, domestic and personal considerations, whenever possible
3. Set performance expectations for team members
   • Performance expectations are established based on client needs and according to assignment requirements
   • Performance expectations are based on individual team members duties and area of responsibility
   • Performance expectations are discussed and disseminated to individual team members
4. Supervised team performance
   • Monitoring of performance takes place against defined performance criteria and/or assignment instructions and corrective action taken if required
   • Team members are provided with feedback, positive support and advice on strategies to overcome any deficiencies
   • Performance issues which cannot be rectified or addressed within the team are referenced to appropriate personnel according to employer policy
   • Team members are kept informed of any changes in the priority allocated to assignments or tasks which might impact on client/customer needs and satisfaction
   • Team operations are monitored to ensure that employer/client needs and requirements are met
   • Follow-up communication is provided on all issues affecting the team
   • All relevant documentation is completed in accordance with company procedures

UNIT OF COMPETENCY : DEVELOP AND PRACTICE NEGOTIATION SKILLS
UNIT CODE : 500311111

This unit covers the skills, knowledge and attitudes required to collect information in order to negotiate to a desired outcome and participate in the negotiation.

1. Plan negotiations
   • Information on preparing for negotiation is identified and included in the plan
   • Information on creating non verbal environments for positive negotiating is identified and included in the plan
   • Information on active listening is identified and included in the plan
   • Information on different questioning techniques is identified and included in the plan
   • Information is checked to ensure it is correct and up-to- date
2. Participate in negotiations
   • Criteria for successful outcome are agreed upon by all parties
   • Desired outcome of all parties are considered
   • Appropriate language is used throughout the negotiation
   • A variety of questioning techniques are used
   • The issues and processes are documented and agreed upon by all parties
   • Possible solutions are discussed and their viability assessed
   • Areas for agreement are confirmed and recorded
   • Follow-up action is agreed upon by all parties

UNIT OF COMPETENCY : SOLVE PROBLEMS RELATED TO WORK ACTIVITIES
UNIT CODE : 500311112

This unit of covers the knowledge, skills and attitudes required to solve problems in the workplace including the application of problem solving techniques and to determine and resolve the root cause of problems.

1. Identify the problem
   • Variances are identified from normal operating parameters; and product quality
   • Extent, cause and nature are of the problem are defined through observation, investigation and analytical techniques
   • Problems are clearly stated and specified
2. Determine fundamental causes of the problem
   • Possible causes are identified based on experience and the use of problem solving tools / analytical techniques.
   • Possible cause statements are developed based on findings
   • Fundamental causes are identified per results of investigation conducted
3. Determine corrective action
   • All possible options are considered for resolution of the problem
   • Strengths and weaknesses of possible options are considered
   • Corrective actions are determined to resolve the problem and possible future causes
   • Action plans are developed identifying measurable objectives, resource needs and timelines in accordance with safety and operating procedures
4. Provide recommendation/s to manager
   • Report on recommendations are prepared
   • Recommendations are presented to appropriate personnel.
   • Recommendations are followed-up, if required

UNIT OF COMPETENCY : USE MATHEMATICAL CONCEPTS AND TECHNIQUES
UNIT CODE : 500311113

This unit covers the knowledge, skills and attitudes required in the application of mathematical concepts and techniques.

1. Identify mathematical tools and techniques to solve problem
   • Problem areas are identified based on given condition
   • Mathematical techniques are selected based on the given problem
2. Apply mathematical procedure/solution
   • Mathematical techniques are applied based on the problem identified
   • Mathematical computations are performed to the level of accuracy required for the problem
   • Results of mathematical computation is determined and verified based on job requirements
3. Analyze results
   • Result of application is reviewed based on expected and required specifications and outcome
   • Appropriate action is applied in case of error

UNIT OF COMPETENCY : USE RELEVANT TECHNOLOGIES
UNIT CODE : 500311114

This unit of competency covers the knowledge, skills, and attitude required in selecting, sourcing and applying appropriate and affordable technologies in the workplace.

1. Study/select appropriate technology
   • Usage of different technologies is determined based on job requirements
   • Appropriate technology is selected as per work specification
2. Apply relevant technology
   • Relevant technology is effectively used in carrying out function
   • Applicable software and hardware are used as per task requirement
   • Management concepts are observed and practiced as per established industry practices
3. Maintain/enhance relevant technology
   • Maintenance of technology is applied in accordance with the industry standard operating procedure, manufacturer’s operating guidelines and occupational health and safety procedure to ensure its operative ability
   • Updating of technology is maintained through continuing education or training in accordance with job requirement
   • Technology failure/ defect is immediately reported to the concern/responsible person or section for appropriate action

DEFINITION OF TERMS

• 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’.
• OH & S – Occupational health and safety
• 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.