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Testing Requirements Injection Molding |
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1.0 Introduction
2.0 Classification Requirements
2.1 Setup/Mold Trainee
2.1.1 Classroom/Written Portion
2.2 Process Mold Trainee
2.2.1 Practical Portion
2.2.2 Classroom/Written Portion
2.3 Setup/Mold Technician Level I
2.3.1 Practical Portion
2.3.2 Classroom/Written Portion
2.4 Setup/Molding Technician Level II
3.1 Setup/Mold Trainee
3.2 Mold Setup/Process Technician
3.3 Mold Setup/Process Technician Level
I
3.4 Mold Setup/Process Technician Level
II
4.0 Testing
4.1 Mechanical Aptitude Test - Setup/Mold
Trainee
4.2 Practical Test - Setup/Mold Process
Trainee
4.3 Practical Evaluation Test - Setup/Mold
Process Technician Level I
4.4 Practical Evaluation Test - Setup/Mold
Process Technician Level II
This training procedure is written for the training and qualification of Setup/Molding Technicians in an injection molding environment. It was written specifically for a company and it's products and processes. The procedure can be modified to fit a variety of environments in the injection molding environment.
For practical testing requirements we require that they are performed on the day shift. If an issue arises that an employee submits a testing request on the off shift(s) and must wait until his/her rotation is completed, that employee will be retroactively compensated monetarily at the new pay scale starting 10 days after the date that the test request has been submitted provided the employee has passed the test. The employee will not advance to the next classification unless all 30 hours of training has been completed and all classroom/written training has been completed and passed. Also the practical testing will be done only during the week unless there are special considerations made. A maximum of 1 person at a time will be trained and a maximum of 1 hour per day can be utilized on the Paulson Interactive (classroom) trainer. The trainer will be available only during weekdays, again unless special considerations are made.
2.0 Classification Requirements Index, Home
2.1 Setup/Mold Trainee Index, Home
Applicant must pass a mechanical aptitude test to enter this classification. The applicant will be required to pass a practical on the job test. Subjects to be included in the tests (written and practical) will include:
Mold core sequences
Schematics
Safety
Hanging molds
Water line hookups and routings
Hydraulic line hookups and routings
Mold and machine thermocouples
Proper tool handling techniques
Lockout procedures
Thermolator/chiller hookup and operation
Knock out bar installation
Housekeeping
Die height adjustment
Mold clamp adjustment
Proper crane operation
Machine safety bar settings
Limit switch settings
Proper lift truck operation
Mold weight calculation
2.1.1 Classroom/Written Portion Index, HomeApplicants must pass 100% of all practical test requirements and obtain a minimum mark of 70% on all written tests. As part of the passing criteria for practical testing, all adjustments for tooling and/or machine process must result in product at a minimum of the current quality standards. Employees grand fathered into the process Mold Trainee classification will be required to pass all requirements for Setup Mold trainee before being allowed to advance to the next classification.
Inside the molding machine
Parts of a typical molding machine
Typical molding machine sequence
A detailed look at the parts and controls on the injection molding machine
Screw drive motor
Hydraulic injection cylinder
Hopper
Heating barrel
Plasticating screw
Non return valve (check ring)
Nozzle
Clamping systems
Machine and mold operating conditions
Inside the mold
Most common types of molds
two plate molds
Three plate molds
Runnerless molds
Parts of the mold
Sprue bushing
Locating ring
Cavity plate
Core plate
Support plate
Support pillars
Guide pins
Clamp plate
Sprue puller pin
Ejector pins
Ejector housing
Ejector plate and ejector retainer plate
Coolant passages
Insulation board
Plastic flow passages in the mold
Runners
Gates
Functions of the mold
Provide flow passages
Provide for escape of air
Cool the plastic
Eject parts
The nature of plastics
General characteristics of plastics
Types of plastics
Physical properties of plastics
How are plastics made
What plastics are made from
Making a plastic
Basic types of plastic structure
Thermoplastics
Thermoset
Copolymers
Blends
Raw material problems encountered when molding plastics
Contamination
Causes of contamination
Moisture contamination
Thermal degradation
Additives
Reinforcements
Regrind
Flow behavior of plastics
Machine operating controls
Typical molding cycle
Filling rate controls
Injection pressure controls
Timer controls
Temperature controls
Injection unit controls
Clamp controls
2.2 Process Mold Trainee Index, Home
As part of the passing criteria for practical testing, all adjustments for tooling and/or machine process must result in product at a minimum of the current quality standards. Subjects to be included in the tests (written and practical) will include:
2.2.1
Practical Portion Index,
Home
Short shots
Gas burns
Drooling (string)
Cracks
Splay
Shear
Contamination
Sprue sticking
Flash (bleeding)
Weight
Sink
Pin push
Wave
Scratches
Black (swirls and specks)
Optical clarity
Glass (filled material, glass rising to surface of part)
Cycle consistency
Machine trouble shooting
Cushion consistency
Check ring
Hydraulics
Hydraulic consistency (other than cushion)
Heater bands
Dryers
Screw rpm
Back pressure
Actual melt temperature
Actual tool temperature
2.2.2
Classroom/Written Portion Index,
Home
Startup procedures
Pre production checks
Rules for machine control settings
Setting fill rate controls
Setting pressure controls
Setting cycle timers
Setting screw rotation speed
Setting clamp force
Setting mold temperature
Applicants must pass 100% of all practical test requirements and obtain a minimum mark of 70% on all written tests before advancing into the next classification.Optimizing molding operations
Operating procedures
Safety and efficiency
Molding economics
2.3 Setup/Molding Technician Level I Index, Home
As part of the passing criteria for practical testing, all adjustments for tooling and/or machine process must result in product at a minimum of the current quality standards. subjects to to be included in the tests (written and practical ) will include:
2.3.1 Practical Portion Index, Home
Warp
Bubbles
Dimensional
Reflectivity
Fish hooks
Gloss (shine)
Flow lines
Bonding of inserts
Internal voids
Optimize process
2.3.2 Classroom/Written Portion Index, HomeWeight
Mold clamp pressure
Cycle time
Manufacturing polymers
Molecular arrangements
Effects of crystalline, amorphous and oriented structure
Polymer molecules
Flow behavior of plastics
How polymer molecules flow
Molding from the plastic's point of view
Effects of heating
Effects of flow
Molded part structure caused by flow and cooling
Packing
Cooling
Molded part structure
compressive and tensile stress
Plastic processing conditions on orientation
Plastic processing conditions on internal stress
Applicants must pass 100% of all practical test requirements and obtain a minimum mark of 70% on all written tests before advancing into the next classification.Machine injection rate
First stage injection pressure
Velocity to pressure transfer setting (VPT set point)
Injection (packing) pressure
Holding pressure
Timers
Temperature controls
Mold temperature controls
Clamp force/part shrinkage
Machine control changes
Raw material
2.4 Setup/Molding Technician Level II Index, Home
Training in this classification may include subjects such as:
Gas Assist
Low Pressure molding
In film molding
Liquid Gas Assist
Controlled Density Molding
Co-injection
Foaming Agents
and will include subjects such as:
New tool start up given no previous information
Dual shot
General D.O.E. training as it relates to the classification
Note:
All procedures and guidelines at minimum will encompass all requirements
as stipulated in the Collective Agreement.
Employees with a Setup/Molding Technician Backup classification will be
required to progress to Process Mold Trainee at minimum. Employees
in this classification may advance to Setup/Molding Technician level I
and II if they complete all requirements successfully. Backups will
be required to complete all courses and written evaluations as required
and the practical on the job training will be accumulated according
to the time that the employee has worked as a Backup in the Setup/Molding
Technician classification.
3.0
Mold Setup/Process Technician
Responsibility
Guidelines
3.1
Setup Mold Trainee Index, Home
Item | Duties | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
1 | Complete mold changes as required by Production control on a timely basis, assure that water and hydraulic lines are hooked up properly, all bolts and clamps are properly aligned, all parameter sheets, books, etc. are at press and all parameter settings put in. Understand water, pneumatics, and hydraulic systems used in molding process. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
2 | Perform prescribed safety check out procedure with 1/2 hour of shift startup and immediately after setup completed. Understand all safety features on equipment related to the molding process. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
3 | At completion of run prepare tool evaluation and obtain last-offs and transport to designated area in Q.C. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
4 | Proper housekeeping practices must be followed after mold changes, setting up area, adjustments or purging takes place. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
5 | Ensure all hoses, clamps and auxiliary equipment is stored in its proper location after usage. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
6 | Ensure that all oil spills are cleaned up immediately. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
7 | Check to ensure that all support equipment is functioning at all times. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
8 | Schedule break and lunch periods independent from other setup persons to ensure that one setup person is on the floor at all times. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
9 | Responsible for the transportation of all mold to and from the storage area in an organized manner. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
10 | Operate the cranes in a safe and efficient manner. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
11 | Responsible for
reporting for start u procedures (Sunday night) as directed by the schedule.
A. Setup personnel shift beginning at 11:00 Sunday evening must start work at 8:00pm Sunday evening unless excused by supervisor. B. Setup personnel for the afternoon shift are expected to come in and assist at start u beginning at 10:00pm for four hours unless also excused y the supervisor of the start up shift. |
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12 | Inform Maintenance or supervisor of any equipment problems and prepare the work order for supervisory authorization. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
13 | Perform other duties as required by the supervisor. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
14 | Observe al safety rules and procedures and continually work in a safe manner. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
15 | Perform safety checks on lift trucks and overhead cranes prior to every use. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
16 | Understand S.P.C. practices. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
17 | Follow the philosophies of the quality policy and follow the procedures as set forth by QS9000. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
18 | Proper mold handling
techniques are as follows:
A. Molds will only be suspended fro floor when being transported to and from the molding machines. All stationary molds will be on the floor or on lift truck forks that are on the floor. B. All molds which are on the floor will be supported by a minimum of two wooden blocks with proper length, spacing and height to adequately support the mold. C. Lift trucks used to transport molds shall have the proper load rating required per the mold weight. D. Molds in storage and staked on each other will have a minimum of two wooden blocks between molds of proper length, spacing and h eight to adequately support the mold. E. Molds should be stacked a maximum of 2 high. F. Molds which need to be flipped or rotated will be supported by a minimum of two wooden blocks of proper length, spacing and height to adequately support the mold and caution signs are to be posted. The wooden blocks shall be positioned to provide complete protection for fittings, ejector locks, cylinders, etc., or any other mold features that require protection. These features (fittings, ejector locks, cylinders, etc.) should at no time support any tool weight. G. A minimum of 2 mold straps (1 each side) shall be installed at all times when transporting, installing or un-installing the m old. Bolts/screws used for mold straps will have full engagement. H. When transporting molds down ramped grades the lift truck will be driven backwards and up ramped grades will be driven forwards to ensure that the mold is secured on the forks of the lift truck. I. All molds that will fit into press sizes of 400 tons of clamp force or less may be stored on the lower level of the train shed. Molds that will fit into press sizes of over 400 tons of clamp force must be stored on the upper level of the warehouse. under no circumstances will any tool that fits in a press size of over 400 tons clamp force be stored on any mold rack on the top level. For a list of machine sizes refer to machine listing in the setup book in the general foreman's office. J. All tools must be stored on the floor using a minimum of two 4" x 4" wooden blocks of proper length and spacing. Tools being stored will be stacked no higher than 2 high. Tools will also be stored in a neat and orderly fashion. K. Chains are to be left on the mold and chain tension must be be applied until mold is fully clamped and bolted into press. |
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19 | Proper crane handling
procedures will include:
A. At each crane operation the brake function for each lateral and vertical travel position will be checked to assure proper performance. B. At each crane operation the crane yearly safety check will be reviewed to assure proper validation date has not expired. C. Crane shall be operated in a safe manner as to not incur any injury or damage. D. Mold weight will at no time will exceed the rating capacity of the crane. E. Proper use of crane controls. Slow feed will be used when required. Crane will not be jogged on fast feed. F. At no time while transporting a mold should anyone stand or pass underneath. |
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20 | Mold clamp safety
will include:
A. All clamps and bolts will be inspected to assure that they are not cracked or have any obvious defects that would degrade their performance or retention of the mold. Bolts and clamps that are deemed unsafe will not be used and discarded. B. All bolts will have a minimum depth of engagement of 1-1/2 times the diameter of the bolt into the platen and all threads will be inspected for damage and wear to assure proper retention. C. The number of clamps required to secure the mold will be determined by the following table:
D. Threaded holes in the platen will be inspected for wear, galling or fouling with debris. Maintenance will be notified of any threaded holes that are not acceptable via a work order. Threaded holes deemed unacceptable will not be used. E. The clamp will be parallel to the plate. F. There will be a minimum of 1/4" from the bottom of the clamp to the platen surface. G. The clamp should be fully engaged into t he molds' clamp slot. I. The clamp should be square to the mold with the clamp's tip as far into the mold's clamp slot as possible. J. Mold straps will be taken off the mold before opening mold in the press. K. All bolts will have adequate torque applied to properly secure the mold to the platens.. All lamp bolts should be torqued to the same value by using a torque wrench, set to the values in the table below for socket head cap screws:
* Taken from Injection Mold Setting, WJT Associates, Copyright 1993. |
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21 | If trainee has any problems they are to contact their supervisor. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
22 | Trainee will be required to comply to the proper lock out procedures. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
23 | Learn and demonstrate the ability to perform and conform to the following duties and practical testing requirements. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
24 | The applicant must pass 100% of all requirements for the practical test. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
25 | The setup/mold trainee will be required to setup 5 tools as assigned by management without mistakes in the time slot allowed. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
26 | All secondary equipment must be hooked up and ready to function. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
27 | Area is to be neat and clean, ready for start-up, with all paper work etc. competed. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
28 | There must be no safety concerns. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
29 | If trainee fails any section of the test, the test will be stopped and the trainee will be assessed a failing grade. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
30 | As part of testing trainee is required to explain to evaluator the steps he/she is using to complete task(s). | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
31 | mold core sequences set properly and functioning properly. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
32 | Understands schematics. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
33 | Water line hookups and routings installed properly and functioning properly. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
34 | hydraulic line hookups and routings installed properly and functioning properly. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
35 | Mold thermocouples properly installed and functioning properly. Machine thermocouples functioning properly. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
36 | Proper tool handling techniques utilized. Mold lamps properly installed. Proper number of mold clamps installed. mold stored correctly in storage area. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
37 | Mold weight calculation correct. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
38 | Lockout procedures adhered to properly. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
39 | Thermolator/chiller hookup is proper and functioning properly. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
40 | Knock out bas are installed properly and functioning properly. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
41 | Proper housekeeping techniques are being utilized. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
42 | Die height adjustment is correct. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
43 | Mold clamp adjustment is correct. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
44 | Proper crane operation. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
45 | Proper lift truck operation. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
46 | Mold weight calculation correct. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
47 | Machine safety mechanisms functioning properly. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
48 | Limit switch settings set properly and functioning properly. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
49 | All paperwork completed and all job documentation in place. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
50 | Area has been cleaned and proper housekeeping techniques followed. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
51 | No safety issues. | |||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||||
52 | Classroom/written portions. |
3.2
Mold Setup/Process Technician
Responsibility
Guidelines
Mold
Setup/Process Technician Index, Home
Item | Duties |
1 | Ability to communicate with team members. |
2 | Setup and start a process in a timely and efficient manner. |
3 | Able to adjust processes to ensure product quality. |
4 | Have good technical ability to monitor molding process. |
5 | Assist the Setup Mold Trainee with difficult processes and relate corrective actions. |
6 | Ensure all adjustments made to equipment are properly documented and reasons recorded. |
7 | React to out of control conditions when S.P.C. charts are used. |
8 | Inspect and provide the first off part to meet customer specifications to the Quality Personnel. |
9 | Proper handling of purgings using heat resistant gloves. Gloves are required to cover the forearm. |
10 | When purging barrel and nozzle, heats must be checked to ensure that they are at the proper heat settings for the material used. Proper heat settings must be used to avoid damage to machine or injury. Supervisor and Maintenance (via work order) will be notified of malfunctioning heat zones. |
11 | When purging barrel purge guard must be used properly. |
12 | Purgings are not to exceed approximately 5 lbs. |
13 | Long sleeves must be work when purging the barrel. |
14 | Technician will follow Master Setup Sheets for all jobs. Master Setup Sheets are located in the General Foreman's office. |
15 | Technician will double check press safety. |
16 | Technician is also required to conform to all duties of the Setup/Mold Trainee. |
17 | If technician has any problems they are to contact their supervisor. |
18 | Learn and demonstrate
the ability to perform and conform to the following duties and practical
test requirements:
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19 | Trainee must demonstrate
the ability to correct the following problems:
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3.3
Mold Setup/Process Technician
Responsibility
Guidelines
Mold
Setup/Process Technician Level I Index,
Home
Item | Duties |
1 | Monitor function of equipment and recommend maintenance if required. |
2 | Assist with production layout in order to meet manufacturing goals and objectives. |
3 | Possess a good understanding of the plastic resins used as it relates to the molding process. Distinguish between different types of resins. |
4 | Assist lower levels in the classification with difficult processes and relate corrective actions taken. |
5 | Develop a good understanding of tooling as it relates to the injection molding process. |
6 | Adjust and oversee a process to ensure product quality. |
7 | Be able to troubleshoot processes while in a productive mode. |
8 | Learn and demonstrate
the ability to perform and conform to the following duties:
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9 | Trainee must demonstrate
the ability and correct for the following:
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10 | Technician is required to perform and abide by the responsibility guidelines and requirements for the Setup Mold Trainee and Mold/Setup Process Technician. |
3.4
Mold Setup/Process Technician
Responsibility
Guidelines
Mold
Setup/Process Technician Level II Index,
Home
Item | Duties |
1 | Direct lower Level technicians. |
2 | Perform mold tryouts and communicate concerns with ENgineering. |
3 | Assist the lower levels in the classification with difficult processes and relate corrective actions. |
4 | Communicate with Quality Assurance Department regarding statistical process control. |
5 | Control and monitor molding process. |
6 | Possess a complete knowledge of equipment related to the molding process. |
7 | Understand and recommend changes to a mold. |
8 | Possess excellent understanding of tooling as it relates to the injection molding process. |
9 | Communicate effectively. |
10 | Ensure equipment is in good mechanical condition to provide safe operation. |
11 | Identify and recommend maintenance if required. |
12 | Start and trouble shoot a process to ensure production standards are maintained. |
13 | Start a new job without any previous setup information. |
14 | Obtain an understanding of the complete and entire Dual Shot process. |
15 | Understand and obtain general D.O.E. training as it relates to the classification. |
16 | Training may also
include:
A. Gas Assist B. Low Pressure molding C. In film molding D. Liquid Gas Assist E. Controlled Density molding F. Co-injection G. Foaming agents |
17 | Technician is required to perform and abide by the responsibility guidelines and requirements for the Setup Mold Trainee, Mold/SEtup Process Technician and Setup/Mold Process Technician Level I. |
4.1
Mechanical Aptitude Test
Injection
Molding
Setup/Mold
Trainee Index, Home
Example Y
Which weighs more? (if equal, mark C.) |
Example X shows
a picture of two people carrying a typewriter on a board and asks, which
person has the heavier load? (If equal, mark C.) Person B has the
heavier load because the weight is closer to him than to person A.
Therefore, the answer is B.
Example Y asks, which weighs more? (If equal, mark C.) As the scale is perfectly balanced, A and B must weigh the same so the answer is C. On the following questions there are more pictures and questions. Read each question carefully, look at the picture, and mark your answer on the Answer Sheet. Do not forget that there is a third choice for every question. You will have 30 minutes for this test. Work as quickly and accurately as you can. Accuracy is more important than speed. For every answer that is incorrect, a 1/2 mark will be subtracted from your score. For example: Number of correct
answers: 46
Score on test:
46 - (14 x 1/2) =
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1.
Which truck will turn over more easily? (If no difference, mark C.) |
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2.
Which is the better way to lift the vacuum cleaner? (If no difference, mark C.) |
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3.
Which picture shows how a clock looks when seen in a mirror? |
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4.
When these cadets march around the corner, which one goes farther? (If no difference, mark C.) |
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5.
Which gear turns the least number of times in a minute? |
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6.
Which ironing board will tip over more easily? (if no difference, mark C.) |
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7.
Which way will the pin go after the bowling ball hits it? |
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8.
When the bottom pulley turns in the direction shown, which way does the top pulley turn? (If either, mark C.) |
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9.
Which person has to pull harder? (If no difference, mark C.) |
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10.
Which tread must go slower for the tank to turn in the direction shown? (If neither, mark C.) |
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11.
Which helicopter can lift the heavier load? (If equal, mark C.) |
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12.
Which chain alone will hold up the sign? (If either, mark C.) |
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13.
Which gear turn most times in a minute? |
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14.
If the driver turns in the direction shown, which way will the pulley "X" turn? (If either, mark C.) |
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15.
Which wheel turn around more times in going a block? (If no difference, mark C.) |
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16.
In which picture will the spring hold the handle where it is now? (If both, mark C.) |
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17.
Which shelf is stronger? (If no difference, mark C.) |
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18.
Which tread should be run more rapidly in order to turn the tractor in the direction shown? (If neither, mark C.) |
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19.
Which weighs less? (If equal, mark C.) |
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20.
From which chair will a listener hear the best stereo sound? |
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21.
On which part of this race track will a very fast car make the turn? (If either, mark C.) |
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22.
When the left-hand gear turns in the direction shown, which way does the right-hand one turn? (If either, mark C.) |
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23.
Which wheel will turn more slowly? (If equal, mark C.) |
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24.
Which door will swing better on its hinges? (If no difference, mark C.) |
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25.
Which hinge is more likely to pull out of the brick wall? (If neither, mark C.) |
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26.
Which weighs more? (If equal, mark C.) |
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27.
When this car is slowed by the brakes, the load on the front wheels is: (A) less; (B) greater; (C) unchanged. |
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28.
In which picture can the man see what is happening behind him? (If no difference, mark C.) |
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29.
Which shaft will turn most slowly? |
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30.
Which archway is stronger? (If no difference, mark C.) |
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31.
When the wind blows, in which direction will these cups turn? (If either, mark C.) |
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32.
When the bicycle wheel stops moving, which arrow shows where the tire valve will stop? |
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33.
Which way should the handle be moved to push the point against the plate? (If either, mark C.) |
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34.
Which picture shows the easier way to lift the pipe? (If no difference, mark C.) |
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35.
In which picture are the children pressed more firmly against the seats? (If no difference, mark C.) |
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36.
With which pump can you blow up a tube for swimming (or an air mattress) more quickly? (If no difference, mark C.) |
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37.
In which picture will the cart pull harder on the rope? (If no difference, mark C.) |
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38.
With which windlass can the heavier weight be lifter? (If no difference, mark C.) |
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39.
Which way should the handle be turned to press juice from fruit? (If either, mark C.) |
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40.
When the upper wheel turns in the direction shown, the top of the lower wheel will move: (A) steadily to the left; (B) by jerks to the right; (C) by jerks to the left. |
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41.
Which metal container will hold more sugar? (If no difference, mark C.) |
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42.
Which part will wear out more quickly if both wheel "A" and "B" are made of iron? (If equal, mark C.) |
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43.
Where can the arrow be shot farther? (A) On the moon. (B) On the earth. (C) Both the same. |
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44.
Which shaft cannot be the driver? |
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45.
Which cup of coffee will cool more rapidly? (If no difference, mark C.) |
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46.
Which picture shows how oil and water would be after standing for a while? |
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47.
Which picture shows how the two children will balance better? (If no difference, mark C.) |
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48.
Which gear turns the same way as shaft "X"? (If both, mark C.) |
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49.
Which one piece of chain is needed to support the mail box? |
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50.
Which child can swing back and forth more times in a minute? (If no difference, mark C.) |
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51.
Which gear turns opposite to the driver? |
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52.
Which picture shows how this wooden circle will stand? (If neither, mark C.) |
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53.
Which windlass must be turned more times to lift the weight five feet? (If no difference mark C.) |
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54.
In which picture is it easier for the person to turn the crank? (If no difference, mark C.) |
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55.
In which picture will more pressure be required at point "X" in order to lift the weight? (If equal, mark C.) |
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56.
Which liquid is heavier? (If equal, mark C.) |
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57.
In which picture will the wedge lift the stone block more easily? (If no difference, mark C.) |
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58.
Which picture shows the path of a thrown ball? (If either, mark C.) |
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59.
Which will carry more water, the two pipes in A or the one pipe in B? (If no difference, mark C.) |
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60.
With which mirror can the driver see more of what is behind her? (If no difference, mark C.) |
4.2
Practical Evaluation Test
Injection
Molding
Setup/Mold
Trainee To
Setup/Mold
Process Trainee Index, Home
Item | Evaluation Requirements |
1 | Trainee will be evaluated on the problems and guidelines listed on the attached sheets. |
2 | The applicant must pass 100% of all requirements for the test. |
3 | The setup/mold trainee will be required to setup 5 tools as assigned by management without mistakes in the time slot allowed. |
4 | All secondary equipment must be hooked up and ready to function. |
5 | Area is to be neat and clean, ready for start-up, with all paper work etc. completed. |
6 | There must be no safety concerns. |
7 | If trainee fails any section of the test, the test will be stopped and the trainee will be assessed a failing grade. |
8 | As part of testing trainee is required to explain to evaluator the steps he/she is using to complete tasks(s). |
Date/Time:
Employee:
Press #:
Job/Process #:
Time Allotted:
Time Spent:
Evaluator:
Item | Requirement | Pass | Fail |
9 | Mold core sequences set properly and functioning properly. | ||
10 | Understands schematics. | ||
11 | Proper handling of mold. | ||
12 | Water line hookups and routings installed properly and functioning properly. | ||
13 | Hydraulic line hookups and routings installed properly and functioning properly. | ||
14 | Mood thermocouples properly installed and functioning properly. Machine thermocouples functioning properly. | ||
15 | Proper tool handling
techniques utilized.
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16 | Lockout procedures adhered to properly. | ||
17 | Thermolator/chiller hookup is proper and functioning properly. | ||
18 | Knock out bars are installed properly and functioning properly. | ||
19 | Proper housekeeping
techniques are being utilized.
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20 | Die height adjustment is correct. | ||
21 | Mold clamp adjustment is correct. | ||
22 | Proper and safe
crane operation.
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23 | Proper lift truck operation with and without mold on forks. | ||
24 | Mold weight calculation correct. | ||
25 | Machine safety mechanisms functioning properly. | ||
26 | Limit switch settings set properly and functioning properly. | ||
27 | All paperwork completed and all job documentation in place. | ||
28 | Area has been cleaned and proper housekeeping techniques followed. | ||
29 | No safety issues. | ||
30 | Safety check performed properly. | ||
31 | Last off procedure performed properly. | ||
32 | Tool evaluation sheet completed correctly. | ||
33 | Setup check is completed correctly. | ||
34 | Equipment stored in proper locations. | ||
35 | Oil spills cleaned up. | ||
36 | Work order filled out correctly. (Only is required). | ||
37 | Safety check on lift truck performed correctly. | ||
38 | Safety check on crane performed properly. | ||
39 | Proper mold storage
utilized.
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40 | Mold clamps and bolts inspected. Unsafe bolts and clamps not used. | ||
41 | Bolt engagement minimum of 1-1/2 diameter of bolt. | ||
42 | Proper number of mold clamps used. | ||
43 | Threaded plated holes inspected. For unacceptable holes, Work Order submitted and hole not used. | ||
44 | Clamp parallel to plate. | ||
45 | Minimum 1/4" gap from bottom of clamp to platen. | ||
46 | Clamp fully engaged to mold clamp slot. | ||
47 | Clamp square to mold and clamp tip as far as possible into mold clamp slot. | ||
48 | Mold straps un-installed before mold open in press. | ||
49 | Molds flipped properly.
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50 | 2 mold straps installed correctly. Bolts have full engagement. | ||
51 | Lift truck driven (while transporting molds) backwards down ramped grades and forwards up ramp grades. | ||
52 | Chains remain installed on mold and tension applied until mold is properly and fully clamped. | ||
53 | Crane brakes function checked in each lateral and vertical position. | ||
54 | Crane yearly certification verified to ensure it has not expired. | ||
55 | Mold weight does not exceed crane capacity. | ||
56 | Proper torque applied to bolts. | ||
57 | Lock out procedure performed correctly. | ||
58 | Adequate explanation of steps taken were given to Evaluator. |
Comments:
4.3
Practical Evaluation Test
Injection
Molding
Setup/Mold
Process Trainee To
Setup/Mold
Process Technician Level I Index, Home
Item | Evaluation Requirements |
1 | Trainee will be evaluated on the problems on the attached sheets. |
2 | The applicant must pass 100% of all requirements for the test. |
3 | The trainee will be required to successfully adjust for the problems and correct the condition on the part. |
4 | All defects must be corrected within the 10 day testing period. |
5 | Each problem has to be corrected within 210 consecutive molding cycles. |
6 | As part of the passing criteria for practical testing, all adjustments for tooling and/or machine process must result in product at a minimum of the current quality standards and an acceptable cycle time. Adjustments cannot result in damage to equipment for the mold or be attributed to long term damage. |
7 | Each problem must stay corrected for 30 consecutive molding cycles after the final adjustment has been made and the process has stabilized. |
8 | There must be no safety concerns. |
9 | Management reserves the right to setup specific problems for sections of the test. |
10 | If trainee fails any section of the test, the test will be stopped and the trainee will be assessed a failing grade. |
11 | As part of testing trainee is required to explain to evaluator the steps he/she is using to complete task(s). |
Date/Time:
Employee:
Press #:
Job/Process #:
Time Allotted:
Time Spent:
Evaluator:
Item | Requirement To Be Corrected | Pass | Fail |
12 | Short shot | ||
13 | Gas burn | ||
14 | Drooling (string) | ||
15 | Cracks | ||
16 | Splay | ||
17 | Shear | ||
18 | Contamination | ||
19 | Sprue sticking | ||
20 | Flash (bleeding) | ||
21 | Weight | ||
22 | Sink | ||
23 | Pin push | ||
24 | Wave | ||
25 | Scratches | ||
26 | Black (swirls and specs) | ||
27 | Optical clarity | ||
28 | Cycle consistency | ||
29 | Glass (filled material, glass rising to surface of part) | ||
30 | Machine trouble shooting for: | ||
31 | Cushion consistency - check ring | ||
32 | Cushion consistency - hydraulics | ||
33 | Hydraulic consistency (other than cushion) | ||
34 | Proper function of heater bands | ||
35 | Proper function of dryer | ||
36 | Screw rpm function and consistency | ||
37 | Back pressure function and consistency | ||
38 | Actual melt temperature reading | ||
39 | Actual tool temperature reading | ||
40 | Proper handling of purging | ||
41 | Properly recorded process adjustments on SPC chart | ||
42 | Demonstrates ability and follows master setup sheet. | ||
43 | Double checked press safety | ||
44 | Problem(s) corrected with 20 consecutive molding cycles. | ||
45 | Problem(s) stayed corrected for 30 consecutive molding cycles after process has stabilized. |
Comments:
4.4
Practical Evaluation Test
Injection
Molding
Setup/Mold
Process Technician Level I To
Setup/Mold
Process Technician Level II Index,
Home
Item | Evaluation Requirements |
1 | Trainee will be evaluated on the following problems on the attached sheets. |
2 | THe applicant must pass 100% of all requirements for the test. |
3 | The trainee will be required to successfully adjust for the problems and correct the condition on the part. |
4 | All defects must be corrected within the 10 day testing period. |
5 | Each problem has to be corrected within 25 consecutive molding cycles. |
6 | As part of the passing criteria for practical testing, all adjustments for tooling and/or machine process must result in product at a minimum of the current quality standards and an acceptable cycle time. Adjustments cannot result in damage to equipment or the mold be attributed to long term damage. |
7 | Each problem must stay corrected for 30 consecutive molding cycles after the final adjustment has been made and the process has stabilized. |
8 | Management reserves the right to setup specific problems for sections of the test. |
9 | There must be no safety concerns. |
10 | If trainee fails any section of the test, the test will be stopped and the trainee will be assessed a failing grade. |
11 | As part of testing trainee is required to explain to evaluator the steps he/she is using to complete tasks(s) |
Date/Time:
Employee:
Press #:
Job/Process #:
Time Allotted:
Time Spent:
Evaluator:
Item | Requirement to be Corrected | Pass | Fail |
12 | Warp | ||
13 | Bubbles | ||
14 | Dimensional control | ||
15 | Reflectivity control | ||
16 | Fishhooks | ||
17 | Gloss (shine) | ||
18 | Flow lines | ||
19 | Bonding of inserts | ||
20 | Internal voids | ||
21 | Optimize process for weight | ||
22 | Optimize process for mold clamp | ||
23 | Optimize process for cycle time | ||
24 | Problem(s) corrected within 20 consecutive molding cycles | ||
25 | Problem(s) stayed corrected for 30 consecutive molding cycles after process has stabilized. |
Comments: