Setting plastic injection moulding machines for production
URN: SEMMPF360
Business Sectors (Suites): Materials Processing and Finishing Suite 3
Developed by: Enginuity
Approved on:
2020
Overview
| This standard identifies the competencies you need to check and set up plastic injection moulding machines for production, in accordance with approved procedures. You will obtain the correct mould tools for the production activity and check that they are free from damage or non-conformance that could impair the quality of the mouldings produced. You will be expected to mount the moulds in the machines, using safe and approved techniques and procedures. You will need to check that all services required to operate the machine are connected and fully operational. You will be required to set all the machine operating conditions and to test all the delivery/collection and safety systems that are in place on the machine and confirm that they are operational. Your responsibilities will require you to comply with organisational policy and procedures for the setting of the plastic injection moulding machines and to report any problems with the machines, materials or equipment in use that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a minimum of supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you carry out. Your underpinning knowledge will show a good understanding of your work and will enable you to adopt an informed approach to the setting of plastic injection moulding machines. You will understand the different types of moulding tools used, how the moulds are located and secured to the machine, and how the machine conditions are set to achieve the optimal results. Your knowledge will enable you to identify any faults in the moulds, the machine or the connected services and you will understand the actions that are required to correct these faults. You will understand the safety precautions required when setting up plastic injection moulding machines and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace and towards the environment. |
Performance criteria
You must be able to:
| 1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines 2. follow the relevant material processing specification and job instructions 3. set up and prepare equipment for processing, ensuring safety mechanisms are in place 4. check consumables required are available and suitable for the work to be carried out 5. set the equipment operating parameters to achieve the required material property changes and meet the processing specification 6. produce plastic injection mouldings to specifications 7. check that plastic injection mouldings comply with specifications 8. deal promptly and effectively with problems within your control and report those that cannot be solved 9. ensure that work records are completed, stored securely and available to others, as per organisational requirements 10. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements |
Knowledge and Understanding
You need to know and understand:
| 1. the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) 2. the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you 3. the hazards associated with the activities, and how to minimise them and reduce risks 4. the personal protective equipment and clothing (PPE) to be worn during the activities 5. how to obtain the job instructions for the machine setting operations and how to interpret the information 6. the basic parts and functions of plastic injection moulding machines and moulds (to include mould location points; mould heating/cooling arrangements; machine controls; hydraulic, pneumatic and electricity supplies; material delivery and collection systems; guards and other safety devices) 7. the types of mould tools that are used and their typical applications 8. to the importance of checking the moulds for damage or other non-conformance prior to mounting them to the machine 9. the methods that are used to locate the moulds and associated parts in the injection moulding machine 10. the different types of component delivery/collection systems that are used on plastic injection moulding machines and their setting up requirements 11. the machine operating parameters that require setting up (such as temperature, pressure, speed/timings and distance) and how these are achieved 12. the effects that changes to operating settings will have on the quality of the components produced 13. the different types of materials used in the plastic injection moulding process 14. preparations that need to be carried out on the materials, in order to ensure that the completed components meet the required specification 15. the temperature range of the material being moulded and the mould being used 16. methods of checking the finished mouldings to ensure that they are to the required specification 17. identification of moulding defects, their causes and methods of prevention how to make adjustments to machine settings to deal with flashing, short shot, distortion and colour problems 18. the organisational quality control checks to be carried out on the prepared injection moulding machine (cleanliness, completeness, freedom from foreign bodies, damage or defects) 19. the importance of keeping the plastic injection moulding equipment clean and free from damage, good housekeeping of tools and equipment and maintaining a clean and unobstructed working area 20. the extent of your own authority and whom you should report to if you have problems that you cannot resolve 21. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Set up the plastic injection moulding machines by carrying out the following activities: 1. adhere to health and safety regulations, systems and procedures to realise a safe system of work 2. follow the defined setting-up procedures leave the work area in a safe condition on completion of the activities 2. Mount and secure two of the following types of mould tools, using the correct location devices: 1. two-plate tools 2. split tools 3. three-plate tools 4. unscrewing tools 5. combination/composite tools 3. Prepare and set two of the following component delivery/collection systems: 1. robotic 2. conveyor 3. separators 4. collection chute/bin 4. Prepare the machine for use, by carrying out all of the following activities: 1. check that mould tools are free from damage and are correctly and securely mounted 2. ensure all machine services are connected and operational (water, electrical, pneumatic, hydraulic) 3. set the mould tool heating and cooling arrangements 4. set and check that the material feed systems are operating correctly 5. set and check that all machine safety mechanisms and features are operating correctly (such as guards, emergency stop) set the mould protection pressure safety conditions 6. set up the machine operating conditions to suit the moulds being produced 7. check that all the machine controls function correctly 5. Set and adjust all of the following moulding parameters to meet the component specification: 1. temperature 2. pressure 3. speed/timings 4. distance 6. Check the materials used meet all of the following requirements: 1. the required materials are available in sufficient quantities 2. the materials meet the component specification 3. the materials have been correctly prepared and mixed for the moulding operation 7. Produce plastic injection mouldings from two of the following types of material: 1. acrylonitrile-butadiene-styrene (ABS) 2. polystyrene 3. nylon 4. polyethelene 5. polycarbonate 6. acetal 7. polypropylene 8. other specific material 8. Check a number of sample or trial mouldings and identify two of the following: 1. mouldings which meet the required specification 2. mouldings which have defects 3. mouldings that require further investigation 9. Adjust machine settings, to deal with three of the following component defects: 1. flashing 2. short shot 3. distortion 4. burning 5. colour deviation 10. Check the set the plastic injection moulding machines, comply with one of the following standards: 1. organisational guidelines and codes of practice 2. equipment manufacturer's operation range 3. current industry standards and codes of practice 4. international standards 5. customer standards and requirements |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
2023
Validity
Current
Status
Original
Originating Organisation
SEMTA
Original URN
MPF3.60
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; setting; machine; injection moulding; parameters; feeds; speeds; safety; materials