View Unit : Setting Plastic Injection Moulding Machines for Production

Work safely at all times, complying with health and safety and other relevant regulations and guidelines

Carry out all of the following during the setting up of the plastic injection moulding machines:

• comply with job instructions, equipment setting-up documentation, relevant COSHH sheets and risk assessment documentation
• use appropriate personal protective equipment at all times during the setting-up operations
• follow the defined setting-up procedures, and apply safe working practices and procedures at all times
• leave the work area in a safe condition on completion of the activities

Follow the relevant material processing specification and job instructions for the processing operations being performed

Determine what processing operations are to be performed and how the equipment will be prepared and set up to achieve this

Check that any consumables required are available and that they are suitable for the work to be carried out

Set the equipment operating parameters to achieve the required material property changes and processing specification

Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations

Mount and secure two of the following types of mould tools, using the correct location devices:

• two-plate tools
• three-plate tools
• combination/composite tools
• split tools
• unscrewing tools

Prepare and set two of the following component delivery/collection systems:

• robotic       
• conveyor    
• separators  
• collection chute/bin

Prepare the machine for use, to include carrying out all of the following:

• check that mould tools are free from damage and are correctly and securely mounted
• ensure all machine services are connected and operational (such as water, electrical, pneumatic, hydraulic)
• set the mould tool heating and cooling arrangements
• set and check that the material feed systems are operating correctly
• 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
• set up the machine operating conditions to suit the moulds being produced
• check that all the machine controls function correctly

Set and adjust all of the following moulding parameters to meet the component specification:

• temperature
• pressure     
• speed/timings         
• distance

Check the materials used during the production cycle, to include all of the following:  

• the required materials are available in sufficient quantities
• the materials meet the component specification
• the materials have been correctly prepared and mixed for the moulding operation

Produce plastic injection mouldings from two of the following types of material:

• acrylonitrile-butadiene-styrene (ABS)
• nylon
• polycarbonate
• polypropylene         
• polystyrene
• polyethelene
• acetal
• other specific material

Visually inspect a number of sample or trial mouldings, and identify two of the following:

• moulding which meet the required specification
• mouldings which have defects
• mouldings that require further investigation

Make adjustments to the machine settings, to deal with three of the following component defects:

• flashing
• short shot
• distortion
• burning
• colour deviation

Complete all relevant documentation, to include two of the following:

• production documentation
• quality control documentation
• records of machine settings

Set the plastic injection moulding machines, to comply with one of the following standards:

• organisational guidelines and codes of practice
• equipment manufacturer’s operation range
• BS and/or ISO standards

Deal promptly and effectively with problems within their control and report those that cannot be solved

Describe the hazards and specific safety precautions to be taken when checking and setting plastic injection moulding machines, and associated delivery and collection systems, and how they can be minimised  

Describe the emergency procedures that are in place to deal with a machine malfunction when setting up the plastic injection moulding machine 

Explain the COSHH regulations relating to the materials used in the injection moulding activities (such as mould sprays, mould lubricants and moulding materials) 

Explain what personal protective equipment (PPE) should be used, and how to obtain it

Explain how to obtain the necessary job instructions for the machine setting operations, and how to interpret the information

Explain 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) 

Describe the various types of mould tools that are used and their typical applications

Explain why it is important to check the moulds for damage or other non-conformance prior to mounting them to the machine

Explain the various methods that are used to locate the moulds and associated parts in the injection moulding machine 

Describe the different types of component delivery/collection systems that are used on plastic injection moulding machines, and their setting up requirements

Describe the various machine operating parameters that require setting up (such as temperature, pressure, speed/timings and distance), and how these are achieved

Explain the effects that changes to these settings will have on the quality of the components produced

Describe the different types of materials used in the plastic injection moulding process

Explain what preparations need to be carried out on the materials, in order to ensure that the completed components meet the required specification

Describe the temperature range of the material being moulded and the mould being used

Explain the methods of checking the finished mouldings to ensure that they are to the required specification

Explain how to identify moulding defects, their causes, and methods of prevention

Explain how to make adjustments to machine settings to deal with such things as flashing, short shot, distortion and colour problems

Explain the company quality control checks to be carried out on the prepared injection moulding machine (such as cleanliness, completeness, freedom from foreign bodies, damage or defects)

Explain why it is important to keep the plastic injection moulding equipment clean and free from damage, to practice good housekeeping of tools and equipment, and to maintain a clean and unobstructed working area

Describe the extent of their own authority and whom they should report to if they have problems that they cannot resolve when setting up plastic injection moulding machines