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PMBPREP305B

Change extrusion die and setup

Unit Descriptor This competency covers the removal and refitting of dies, pins, sizing dies (calibrator), vacuum blocks and seals in preparation for production. This competency applies to extrusion, and similar, dies. For all other dies use PMBPREP304A Change equipment dies. This competency is typically performed by advanced operators demonstrating some relevant theoretical knowledge and using a range of well-developed skills requiring some discretion and judgement.

ELEMENTPERFORMANCE CRITERIA
1 . Prepare to change dies or cores.
  1. Plan process for closing down machinery and inform relevant personnel.

  2. Take last-off samples as required for die reports.

  3. Select dies or cores to match product/process specification.

  4. Implement measures to control identified hazards in line with procedures and duty of care.

2 . Shut down extruder.
  1. Stop downstream equipment.

  2. Stop feed, drop temperatures, stop vacuum pump and purge the extruder.

  3. Activate isolating locks, disconnect power to heaters.

3 . Change setup.
  1. Remove, clean and store die according to workplace procedures.

  2. Fit replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification.

  3. Remove and re-fit calibrator sleeve and seals as required.

  4. Set heats according to pre-start procedures.

4 . Restart and test-run the new setup.
  1. Check operation of die against product quality

  2. Compare machine setting ranges against documented requirements.

  3. Check the first-off sample for required standards

  4. Fine-tune settings and other production variables as required.

  5. Note variances between standard operating procedures and actual production run.

  6. Complete workplace documentation and report to appropriate personnel.

5 . Anticipate and solve problems
  1. Recognise a problem or a potential problem.

  2. Determine problems needing priority action.

  3. Refer problems outside area of responsibility to appropriate person, with possible causes.

  4. Seek information and assistance as required to solve problems.

  5. Solve problems within area of responsibility

  6. Follow through items initiated until final resolution has occurred.





Key CompetencyExamples of ApplicationPerformance
Level
How can information be collected, analysed and organised?
How are ideas and information communicated within this competency?
How are activities planned and organised?
How are problem solving skills applied?
How are mathematical ideas and techniques used?
How is use of technology applied?
How is team work used within this competency?

Range Statement

Context

This competency unit includes the selection and fitting of dies and cores.

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

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 competency includes use of equipment and tools such as:

Hazards

Typical hazards include:

Problems

Typical process and product problems may include:

Variables

Key variables to be monitored include:


Evidence Guide

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 perform a die-change smoothly and methodically, which will put the extruder back into full production of in-specification product in standard time. In particular it is essential that the operator can:

Consistent performance should be demonstrated. For example, look to see that production standards are met consistently.

Assessment method and context

It is preferred that assessment takes place on an industrial extruder in a work environment.

Competence in this unit may be assessed:

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