Paxton Engineering
Testing Requirements
Injection Molding
Setup/Molding Technician

Index

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

3.0   Responsibility Guidelines

    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

1.0 Introduction Index, Home

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, Home

  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
Applicants 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.

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
  Mold setup verification

2.2.2 Classroom/Written Portion Index, Home
  Startup procedures

  Pre production checks
  Rules for machine control settings
  Setting machine controls
  Setting fill rate controls
  Setting pressure controls
  Setting cycle timers
  Setting screw rotation speed
  Setting clamp force
  Setting mold temperature
  Operation methods and economics
  Optimizing molding operations
  Operating procedures
  Safety and efficiency
  Molding economics
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.

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

  Weight
  Mold clamp pressure
  Cycle time
2.3.2 Classroom/Written Portion Index, Home
  Structure of molded parts
  Manufacturing polymers
  Molecular arrangements
  Effects of crystalline, amorphous and oriented structure
  Plastic flow behavior
  Polymer molecules
  Flow behavior of plastics
  How polymer molecules flow
  How Temperature, Flow and Cooling Affect Part Structure
  Molding from the plastic's point of view
  Effects of heating
  Effects of flow
  How molded in stress affects part properties
  Molded part structure caused by flow and cooling
  Packing
  Cooling
  Plastic Processing Conditions
  Molded part structure
  compressive and tensile stress
  Plastic processing conditions on orientation
  Plastic processing conditions on internal stress
  Using machine controls to control plastic behavior
  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
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.

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.
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.
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.
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:
 
Press Number No. of Clamps on Cavity No. of Clamps on Core
1 4 4
2 4 4
4 4 4
5 4 4
6 4 6
7 4 4
8 4 6
9 4 6
10 4 6
11 4 6
12 4 6
13 4 4
14 4 6
15 4 6
18 8 8
19 4 6
22 4 4
23 4 4
24 4 4
25 4 4
26 4 4
27 4 4
28 4 4
29 4 4
Note: Number of claps ar minimum values only.  Ideally use 4 clamps on the cavity and 6 clamps on core on all presses over 500 tons of clamps force.  These values are a guide only and each tool needs to be assessed on an individual basis to ensure adequate clamp.
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:
 
Minimum Tensile Strength (psi) 170,000
Proof Load (psi) 136,000
Bolt Diameter (inches) Torque (lb ft)
1/4 16
5/16 33
3/8 59
7/16 95
1/2 145
9/16 210
5/8 290
3/4 510
7/8 825
1 1235
Note:  Use only when manufacturer's specifications are not available.  These values are for stiff metal to metal joints and are based on 90% of proof load.  Do not use for gasketed joints or joints of soft materials.
* Taken from Injection Mold Setting, WJT Associates, Copyright 1993.
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.
Note:  Management reserves the right to revise and amend these requirements as required.

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:
The applicant must pass 100% of all requirements for the practical test.
The trainee will be required to successfully adjust for part/process problems and correct the condition.
All defects must be corrected within the 10 day testing period.
Each problem has to be corrected within 20 consecutive molding cycles.
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 or be attributed to long term damage.
Each problem must stay corrected for 30 consecutive molding cycles after the final adjustment has been made and the process has stabilized.
There must be no safety concerns.
Management reserves the right to setup specific problems for sections of the test.
If trainee fails any section of the test, the test will be stopped and the trainee will be assessed a failing grade.
As part of testing, the trainee is required to explain to evaluator the steps he/she using to complete task(s).
19 Trainee must demonstrate the ability to correct the following problems:
Short shot
Gas burn
Drooling (string)
Cracks
Splay
Shear
Contamination
Sprue sticking
Flash (bleeding)
Weight
Sink
Pin Push
Wave
Scratches
Black (swirls and specs)
Optical clarity
Cycle consistency
Glass (filled material, glass rising to surface of part)
Machine trouble shooting for:
A. Machine consistency for cushion (check ring and hydraulics)
B. Hydraulic consistency (other than cushion)
C. Heater bands
D. Dryers
E. Screw RPM
F. Back pressure
G. Actual melt temperature
H Actual tool temperature
Classroom written requirements
Technician is required to perform and abide by the responsibility guidelines and requirements for the Setup Mold Trainee.
Note: Management reserves the right to revise and amend these requirements as required.

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:
The applicant must pass 100% of all requirements for the practical test.
The trainee will be required to successfully adjust for part/process problems and correct the condition.
All defects must be corrected within the 10 day testing period.
Each problem has to be corrected within 25 consecutive molding cycles.
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 or be attributed to long term damage.
Each problem must stay corrected for 30 consecutive molding cycles after the final adjustment has been made and the process has stabilized.
Management reserves the right to setup specific problems for the sections of the test
There must ben o safety concerns.
If the trainee fails any section of the test, the test will be stopped and the trainee will be assessed a failing grade.
9 Trainee must demonstrate the ability and correct for the following:
Warp
Bubbles
Dimensional control
Reflectivity control
Fish hooks
Gloss (shine)
Flow lines
bonding of inserts
Internal voids
Optimize process for weight
Optimize process for mold clamp
Optimize process for cycle time
Classroom/written portion
10 Technician is required to perform and abide by the responsibility guidelines and requirements for the Setup Mold Trainee and Mold/Setup Process Technician.
Note: Management reserves the right to revise and amend these requirements as required.

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.
Note: Management reserves the right to revise and amend these requirements as required.
 
 

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
Number of incorrect answers: 14

Score on test:     46 - (14 x 1/2)  =
                            46 - 7               =
                            39


 
1.
Which truck will turn over more easily?
(If no difference, mark C.)
2.
Which is the better way to lift the vacuum cleaner?
(If no difference, mark C.)
3.
Which picture shows how a clock looks when seen in a mirror?
4.
When these cadets march around the corner, which one goes farther?
(If no difference, mark C.)
5.
Which gear turns the least number of times in a minute?
6.
Which ironing board will tip over more easily?
(if no difference, mark C.)
7.
Which way will the pin go after the bowling ball hits it?
8.
When the bottom pulley turns in the direction shown, which way does the top pulley turn?
(If either, mark C.)
9.
Which person has to pull harder?
(If no difference, mark C.)
10.
Which tread must go slower for the tank to turn in the direction shown?
(If neither, mark C.)
11.
Which helicopter can lift the heavier load?
(If equal, mark C.)
12.
Which chain alone will hold up the sign?
(If either, mark C.)
13.
Which gear turn most times in a minute?
14.
If the driver turns in the direction shown, which way will the pulley "X" turn?
(If either, mark C.)
15.
Which wheel turn around more times in going a block?
(If no difference, mark C.)
16.
In which picture will the spring hold the handle where it is now?
(If both, mark C.)
17.
Which shelf is stronger?
(If no difference, mark C.)
18.
Which tread should be run more rapidly in order to turn the tractor in the direction shown?
(If neither, mark C.)
19.
Which weighs less?
(If equal, mark C.)
20.
From which chair will a listener hear the best stereo sound?
21.
On which part of this race track will a very fast car make the turn?
(If either, mark C.)
22.
When the left-hand gear turns in the direction shown, which way does the right-hand one turn?
(If either, mark C.)
23.
Which wheel will turn more slowly?
(If equal, mark C.)
24.
Which door will swing better on its hinges?
(If no difference, mark C.)
25.
Which hinge is more likely to pull out of the brick wall?
(If neither, mark C.)
26.
Which weighs more?
(If equal, mark C.)
27.
When this car is slowed by the brakes, the load on the front wheels is:
(A) less;
(B) greater;
(C) unchanged.
28.
In which picture can the man see what is happening behind him?
(If no difference, mark C.)
29.
Which shaft will turn most slowly?
30.
Which archway is stronger?
(If no difference, mark C.)
31.
When the wind blows, in which direction will these cups turn?
(If either, mark C.)
32.
When the bicycle wheel stops moving, which arrow shows where the tire valve will stop?
33.
Which way should the handle be moved to push the point against the plate?
(If either, mark C.)
34.
Which picture shows the easier way to lift the pipe?
(If no difference, mark C.)
35.
In which picture are the children pressed more firmly against the seats? (If no difference, mark C.)
36.
With which pump can you blow up a tube for swimming (or an air mattress) more quickly?
(If no difference, mark C.)
37.
In which picture will the cart pull harder on the rope?
(If no difference, mark C.)
38.
With which windlass can the heavier weight be lifter?
(If no difference, mark C.)
39.
Which way should the handle be turned to press juice from fruit?
(If either, mark C.)
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.
41.
Which metal container will hold more sugar?
(If no difference, mark C.)
42.
Which part will wear out more quickly if both wheel "A" and "B" are made of iron?
(If equal, mark C.)
43.
Where can the arrow be shot farther?
(A) On the moon.
(B) On the earth.
(C) Both the same.
44.
Which shaft cannot be the driver?
45 45.
Which cup of coffee will cool more rapidly?
(If no difference, mark C.)
46.
Which picture shows how oil and water would be after standing for a while?
47.
Which picture shows how the two  children will balance better?
(If no difference, mark C.)
48.
Which gear turns the same way as shaft "X"?
(If both, mark C.)
49.
Which one piece of chain is needed to support the mail box?
50.
Which child can swing back and forth more times in a minute?
(If no difference, mark C.)
51.
Which gear turns opposite to the driver?
52.
Which picture shows how this wooden circle will stand?
(If neither, mark C.)
53.
Which windlass must be turned more times to lift the weight five feet?
(If no difference mark C.)
54.
In which picture is it easier for the person to turn the crank?
(If no difference, mark C.)
55.
In which picture will more pressure be required at point "X" in order to lift the weight?
(If equal, mark C.)
56.
Which liquid is heavier?
(If equal, mark C.)
57.
In which picture will the wedge lift the stone block more easily?
(If no difference, mark C.)
58.
Which picture shows the path of a thrown ball?
(If either, mark C.)
59.
Which will carry more water, the two pipes in A or the one pipe in B?
(If no difference, mark C.)
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.
Transportation
Placement on floor
Proper lift truck used.  (Proper load rating)
Correct number and size of wooden blocks used
Proper spacing of blocks used
Molds flipped properly
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.
Wipe down press
Clean up
etc.
20 Die height adjustment is correct.
21 Mold clamp adjustment is correct.
22 Proper and safe crane operation.
Crane not jogged on fast feed.
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.
Small molds on lower level of train shed
Large molds on upper level and stacked 2 high maximum
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.
Wood blocks used properly
Mold protection acceptable
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.
Note: Management reserves the right to revise and amend these requirements required.

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).
Note: Management reserves the right to revise and amend these requirements as required.

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.
Note: Management reserves the right to revise and amend these requirements as required.

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)
Note: Management reserves the right to revise and amend these requirements as required.

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.
Note: Management reserves the right to revise and amend these requirements as required.

Comments: