Free Plastic Moulding Assistant Course (4Months)

Plastic Moulding Assistant/Helper:

Brief Job Description

Moulding Helper will be involved in cutting the plastic moulding as per the desired shapes, supporting the operator moulding operations and storing the output at the designated place.

Personal Attributes

Reading, writing and communication skills, quality consciousness, safety orientation, Dexterity, Physique to sustain strenuous conditions, Ability to use fingers, hands and feet with ease to complete the assigned task (Dexterity), high precision and sensitivity towards safety for self and equipment.

Maintain a safe and healthy working environment:

Elements and Performance Criteria

Identify and report the risks identified

To be competent, the user/individual on the job must be able to:

PC1..   Identify activities which can cause potential injury through sharp objects, burns, fall, electricity, gas leakages, radiation, poisonous fumes, chemicals ,loud noise

PC2.    Inform the concerned authorities about the potential risks identified in the processes, workplace area/ layout, materials used etc

PC3.    Inform the concerned authorities about machine breakdowns, damages which can potentially harm man/ machine during operations

PC4.    Create awareness amongst other by sharing information on the identified risks

Create and sustain a Safe, clean and environment friendly work place

To be competent, the user/individual on the job must be able to:

PC5..   Follow the instructions given on the equipment manual describing the operating process of the equipments

PC6..   Follow the Safety, Health and Environment related practices developed by the organization

PC7.    Operate the machine using the recommended Personal Protective Equipments (PPE)

PC8. . Maintain a clean and safe working environment near the work place and ensure there is no spillage of chemicals, production waste, oil, solvents etc

PC9.    Maintain high standards of personal hygiene at the work place

PC10. Ensure that the waste disposal is done in the designated area and manner as per organization SOP.

PC11. Inform appropriately the medical officer/ HR in case of self or an employees illness of contagious nature so that preventive actions can be planned for others

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. relevant standards, procedures and policies related to Health, Safety and Environment followed in the company

KU2. basic knowledge of Safety procedures( fire fighting, first aid) within the organization

KU3. knowledge of various types of PPEs and their usage

KU4. basic knowledge of risks/hazards associated with each occupation in the organization

KU5. how to safely operate various tools and machines and risksassociated with the tools/ equipment

KU6. knowledge of personal hygiene and how an individual an contribute towards creating a highly safe and clean working environment

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.    write basic level notes and observations

GS2.    read safety instructions put up across the plant premises

GS3.    read safety precautions mentioned in equipment manuals and panels to understand the potential risks associated

GS4.    effectively communicate information to team members

GS5.    informemployees in the plant and concerned functions about events, incidents & potential risks observed related to Safety, Health and Environment.

GS6.    question operator/ supervisor in order to understand the safety related issues

GS7.    attentively listen with full attention and comprehend the information given by the speaker during safety drills and training programs

GS8.    use common sense and make judgments during day to day basis

GS9.           use reasoning skills to identify and resolve basic problems

GS10. use common sense and make judgments during day to day basis

GS11. use reasoning skills to identify and resolve basic problems

Maintain 5S at the work premises:

Elements and Performance Criteria

Ensure sorting

To be competent, the user/individual on the job must be able to:

PC1..    follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and unnecessary items are not cluttering the workbenches or work surfaces.

PC2..    ensure segregation of waste in hazardous/ non hazardous waste as per the sorting work instructions

PC3..    follow the technique of waste disposal and waste storage in the proper bins as per sop

PC4..    segregate the items which are labelled as red tag items for the process area and keep them in the correct places

PC5.     sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5s guidelines/ work instructions

PC6. .  ensure that areas of material storage areas are not overflowing

PC7.     properly stack the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required

PC8.     return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area

PC9.     follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards

PC10.   follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists

Ensure proper documentation and storage ( organizing , streamlining)

To be competent, the user/individual on the job must be able to:

PC11.   check that the items in the respective areas have been identified as broken or damaged

PC12.   follow the given instructions and check for labelling of fluids, oils. lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc

PC13.   make sure that all material and tools are stored in the designated places and in the manner indicated in the 5s instructions

Ensure cleaning of self and the work place

To be competent, the user/individual on the job must be able to:

PC14.   check whether safety glasses are clean and in good condition

PC15.   keep all outside surfaces of recycling containers are clean

PC16.. ensure that the area has floors swept, machinery clean and generally clean. in case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards

PC17.. check whether all hoses, cabling & wires are clean, in goodcondition and clamped to avoid any mishap or mix up

PC18.. ensure workbenches and work surfaces are clean and in good condition

PC19.   follow the cleaning schedule for the lighting system to ensure proper illumination

PC20.   store the cleaning material and equipment in the correct location and in good condition

PC21.   ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene

Ensure sustenance

To be competent, the user/individual on the job must be able to:

PC22.   follow the daily cleaning standards and schedules to create a clean working environment

PC23.   attend all training programs for employees on 5 s

PC24.   support the team during the audit of 5 s

PC25.   participate actively in employee work groups on 5s and encourage team members for active participation

PC26.   follow the guidelines for what to do and what not to do to build sustainability in 5s as mentioned in the 5s check lists/ work instructions

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    relevant standards, procedures and policies related to 5S followed in the company

KU2.    have basic knowledge of 5S procedures

KU3.    know various types 5s practices followed in various areas

KU4.    understand the 5S checklists provided in the department/ team

KU5.    have skills to identify useful & non useful items

KU6.    have knowledge of labels , signs & colours used as indicators

KU7.    knowledge on how to sort and store various types of tools, equipment, material etc.

KU8.    know , how to identify various types of waste products

KU9.    understand the impact of waste/ dirt/ dust/unwanted substances on the process/ environment/ machinery/ human body

KU10. have knowledge of best ways of cleaning & waste disposal

KU11. understand the importance of standardization in processes

KU12. understand the importance of sustainability in 5S

KU13. have knowledge of TQM process

KU14. have knowledge of various materials and storage norms

KU15. understand visual controls, symbols, graphs etc.

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.    write basic level notes and observations

GS2.    note down observations (if any) related to the process

GS3.    read 5S instructions put up across the plant premises

GS4.    effectively communicate information to team members inform employees in the plant and concerned functions about 5S

GS5.    question the process head in order to understand the 5S related issues

GS6.    attentively listen with full attention and comprehend the information given by the speaker during 5S training programs

GS7.    use common sense and make judgments during day to day basis

GS8.           use reasoning skills to identify and resolve basic problems using 5S

GS9.           persuade co team members to follow 5 S

GS10. ensure that the co team members understand the importance of using 5 S tool

GS11. use innovative skills to perform and manage 5 S activities at the work desk and the shop floor

GS12. exhibit inquisitive behaviour to seek feedback and question on the existing set patterns of work

GS13. do what is right, not what is a popular practices

GS14. follow shop floor rules& regulations and avoid deviations; make 5S an integral way of life

GS15. ensure self-cleanliness on a daily basis

GS16. demonstrate the will to keep the work area in a clean and orderly manner

Cleaning and Lubricating the extrusion machinery and the dies:

Elements and Performance Criteria

Clean and Lubricate the Extrusion machinery and the Dies

To be competent, the user/individual on the job must be able to:

PC1.. clearly understanding the does and donts of the manufacturing process as defined in sops/ work instructions or defined by supervisors

PC2.. inspect the extrusion machinery and dies after moulding operations for left over plastic or other impurities or any clogging

PC3.. load the machinery and dies into cleaning tank with chemicals or manually spray the cleaning agents like caustic solution etc. to ensure that the waste plastic material which has remained in the machine after completion of operations is removed and the machine does not clog

PC4.. lubricate the machinery and dies with oil/ grease in order to prepare it for the next cycle of moulding operations

PC5.. in case of automatic cleaning, adjustable cleaning times are preset and dies are left to be cleaned and lubricated automatically

PC6.. examine machinery and dies to ensure they are clean, smooth, and coated as per the specification/ visual sample to be used for next set of operations

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    relevant standards and procedures followed in the company

KU2.    different types of products manufactured by the company

KU3.    functional processes like Procurement, Store management, inventory management, quality management and key contact points for query resolution

KU4.    quality norms prescribed by the organization for moulding jobs

KU5.    latest cleaning and lubricating agents and chemicals

KU6.    different types of moulding processes and associated equipment

KU7.    different parameters pertinent to cleaning process like preset time, cycle time etc.

KU8.    working of cleaning tools and apparatus

KU9.    different chemicals used in the cleaning process of extrusion machines and dies

KU10. safety precautions to be taken for all types of cleaning activities especially while handling hot , caustic solutions etc.

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.    write drawings to internal customers on the requirement of cleaning and lubricating agents, etc.

GS2.    note measurements, equipment panel readings for various process parameters in the required reporting formats

GS3.    read equipment manuals and process documents to understand the equipment and processes better

GS4.    read instructions (e.g. safety instructions) with symbols while using the equipment in the plant area

GS5.    read internal drawings sent by internal customers ( other functions within the organization)

GS6.    discuss task lists, schedules, and work-loads with co-workers

GS7.    question internal customers/ Moulding shop supervisor appropriately in order to understand the nature of the problem and make a diagnosis

GS8.    plan and organize the work order and jobs received from the internal customers

GS9.    plan and organize the design documents received from internal customers

GS10. organize all process/ equipment manuals so that sorting out information is without much time delay.

GS11. organize apparatus etc. in an orderly manner at designated areas

GS12. understand the requirement of different types of cleaning and lubricating agents for different types of dies

GS13. finalize the optimum levels of physical parameters so that the job output meets the prescribed job standards, visual samples

GS14. think through the problem, evaluate the possible solution and suggest the best possible solution to the operator

GS15. identify immediate or temporary solutions to resolve delay

Support the operator in moulding related operations:

Elements and Performance Criteria

Feed the plastic granules in the hopper

To be competent, the user/individual on the job must be able to:

PC1..    use weighing machines to measure the quantity of granules and ensure that the correct quantity of granules are put in the hopper

PC2..    perform preheating of plastic granules to improve their tensile strength

PC3..    ensure that the plastic granules are mixed with additives (if any) before being fed into the hopper

PC4..    check that the apparatus is being cleaned before starting the moulding operations

PC5..    feed the plastic granules into the hopper as per operators instructions

Support the operator in conducting the actual moulding process

To be competent, the user/individual on the job must be able to:

PC6..    unload the moulding from die post moulding operations

PC7..    remove the output from the machine once the cycle is complete using proper clamps and other handling tools to carefully pick the product from the machine area

PC8..    in case the output has to be separately cooled, ensure that the helper cools it using the cooling process as mentioned in the work instructions/ sops

PC9..    clean the plastic molding to remove runners/ gates or extra materials through degating and deflashing processes

PC10.. stamp the moulding with the identifying information (wherever required) and send the same for further processing

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    relevant standards and procedures followed in the company

KU2.    different types of products manufactured by the company

KU3.    functional processes like Procurement, Store management, inventory management, quality management and key contact points for query resolution

KU4.    quality norms prescribed by the organization for moulding jobs

KU5.    reading panels, meters, indicators etc. to monitor the process

KU6.    different types of moulding processes, associated equipment like dies, screw/ reciprocating screw/ plunger, heaters etc. and their working

KU7.    different parameters pertinent to moulding process like heater temperature, hydraulic pressure/ air pressure/ vacuum pressure, rotating speed of the screw, operating current and voltage, injection time, refilling time etc. and the impact of these parameters on the process

KU8.    various types of plastics like thermoplastics/ thermosetting plastics and their properties

KU9.    various types of coolants like water etc. and their properties

KU10. moulding defects and how they are generated, how they can be prevented, different consumables used in the melt shop

KU11. extruder operation, melting process, and safety process of handling hot liquid plastic and control

KU12. measuring instruments like vernier callipers, micrometer and other

KU13. geometry and dimensions

KU14. sketches and engineering drawings

KU15. safety precautions to be taken for all types of moulding activities

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.    document, interpret information from the sketches and engineering drawings

GS2.    write log book in terms of output quantity, set up parameters, machine setting parameters and loss details etc.

GS3.    note measurements, equipment panel readings for various process parameters in the required reporting formats

GS4.    read and interpret engineering drawing and sketches

GS5.    read equipment manuals and process documents to understand the equipment and processes better

GS6.    read safety instructions especially symbols while use the equipment in the plant area

GS7.    discuss task lists, schedules, and work-loads with co-workers

GS8.    question internal customers/ Moulding shop supervisor in order to understand the nature of the problem and make a diagnosis

GS9.    organize all process/ equipment manuals so that sorting out information is fast

GS10. organize apparatus etc. in an orderly manner at proper designated areas

GS11. visualize the final job product after understanding the given drawing/ sketches

GS12. think through the problem, evaluate the possible solution and suggest the best possible solution to the problem

Finish and deposit finished goods in the designated area:

Elements and Performance Criteria

Cut the moulding

To be competent, the user/individual on the job must be able to:

PC1..    understand the set parameters for dimensions of each of the output

PC2..    cut the moulding as per the desired specifications within the desired timelines

PC3..    keep a count of number of output pieces produced after cutting

Removing the finished goods from the moulding block

To be competent, the user/individual on the job must be able to:

PC4..    inspect the goods for scratches, flashes, marks at the time of removal from moulding block

PC5..    hold the finished goods with necessary equipment like clamps, cranes, hoist etc. for unloading from the moulding block

PC6..    safely lift the finished goods and move them to a designated area to prevent any damage to the finished goods

PC7..    in case the plastic moulding are to be moved forward in the assembly line, ensure that the right hangers are used for transportation of finished goods in a safe manner

Storing the finished goods in the designated area

To be competent, the user/individual on the job must be able to:

PC8..    tag the finished goods with job number, piece number and other markings for identification

PC9..    arrange the goods as per the batch number, piece number etc. into designated packing boxes

PC10.. in case of assembly line, transport the finished goods to the next assembly line process

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. relevant standards and procedures followed in the company for Finished Goods storage

KU2. different types of products manufactured by the company

KU3. functional processes like Procurement, Store management, inventory management, quality management and key contact points for query resolution

KU4. usage of clamps, cranes, hoists for lifting work pieces

KU5. tagging of the finished goods as per batch codes, material/ part codes, piece numbers etc.

KU6. arranging of the tagged goods in the finished goods storage area

KU7. safety precautions to be taken for material movement

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1. write drawings to internal customers on the requirement of moulding apparatus etc.

GS2. note batch codes, material codes, piece number in the prescribed formats and records for the same

GS3. read equipment manuals and process documents to understand the equipment and processes better

GS4. read instructions especially safety instructions especially for using material handling equipment

GS5. read internal information drawings sent by internal customers ( other functions within the organization)

GS6. discuss task lists, schedules, and work-loads with co-workers

GS7. question internal customers/ Moulding shop supervisor appropriately in order to understand the nature of the problem and make a diagnosis

GS8. plan and organize the work order and jobs received from the internal customers

GS9. plan and organize the finished Goods as per the batch/ product number in the designated area

Assessment Guidelines:

  1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Element/ Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each Element/ PC.
  • The assessment for the theory part will be based on knowledge bank of questions created by the SSC.
  • Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS.
  • Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below).
  • Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/ training center based on these criteria.
  • To pass the Qualification Pack assessment, every trainee should score the Recommended Pass % aggregate for the QP.
  • In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.