Free Plastic Moulding Operator Course (6Months)

Plastic Moulding Operator/Technician:

Brief Job Description

This role primarily involves managing the specifications of the plastic and its granules, setting up and operating the moulding machinery and forming & finishing the output.

Personal Attributes

Reading, writing and communication skills, ability to plan and prioritize, quality consciousness, safety orientation, Physique to sustain strenuous conditions, Dexterity, Ability to use fingers, hands and feet with ease to complete the assigned task (Dexterity), high precision and sensitivity to problem solving 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.

The Machine Operator Injection Molding Bundle - Paulson Training Programs

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

Understand plastic moulding job requirements and related processes:

Elements and Performance Criteria

Understand the work order and the process requirements

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

PC1..    understand the work order ( work output) required from the process and discuss the same with the supervisor

PC2..    refer all sketches/ work orders/ process related documents to understand dimensions and properties of the required work output

PC3..    understand the process requirements in terms of temperature of the heater, hydraulic pressure/ air pressure/ vacuum pressure, rotating speed of the screw pressure, regulating current, injection time, refilling time etc. as mentioned in the work instruction/ sop/ control diagrams

PC4..    clearly understanding the does and donts of the manufacturing process as defined in SOPs/ work instructions or defined by supervisors

Arrange for the material to be moulded and apparatus required for the same

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

PC5..    understand the moulding procedure and process to be adopted for completing the work order from the supervisor by referring the work instruction document/ SOP manual

PC6..    set the various moulding parameters like temperature of the heaters, hydraulic pressure/ air pressure/ vacuum pressure, rotating speed of the screw, screw pressure, regulating current, flow of coolant/ water etc. before starting the process. moulding parameters are mentioned in the work instructions/ SOP manual

PC7..    understand the raw material like plastics granules, bonding additives etc. required for executing the activity

PC8..    ensure that the required material is procured from the store before starting the process

PC9..    understand the type of die required for executing the required moulding operation and ensure that the same is available for moulding operations

PC10.. understand the number of heaters required for the moulding operations, heater temperature and current required for the heating operations as mentioned in the work instructions/ sop manual

Clean the apparatus and the components before executing the process

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

PC11.. ensure cleaning of dies and machine runners by spraying or brushing surfaces with parting agents to ensure smoothness and prevent clogging of plastic in the machine parts/ dies

PC12.. ensure cleaning of the other moulding machine tools, auxiliaries(if any) before the initiation of the moulding and trimming process

PC13.. ensure cleaning of the area around the apparatus for any oil, grease, combustible substances etc. so as to prevent any accident

Check materials and apparatus for Operations

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

PC14.. use weighing machines to measure the quantity of granules and ensure that the correct quantity of granules are put in the hopper

PC15.. check the parameters temperature, pressure, current, screw speed etc. in line with the work instructions/ sops

PC16.. setup the moulding apparatus as per the selected moulding process and the moulding standards used in the automobile industry

PC17.. adjust the temperature and other parameters of the moulding apparatus as per the values given in work instructions/ sops

PC18.. ensure availability of the coolant and working of valves to circulate the coolant to cool and solidify plastic

Escalations of queries on the given job

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

PC19.. refer the queries to supervisor if they cannot be resolved by the operator

PC20.. confirm self – understanding to the supervisor once the query is resolved so that all doubts & queries can be resolved before the actual process execution

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.    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 timeetc. and the impact of these parameters on the process output

KU5.    various types of plastics like thermoplastics/ thermosetting plastics and the additives to be used

KU6.    different types of tools and machinery to mould the plastic and trim the output

KU7.    various types of coolants and their properties

KU8.    geometry and dimension measurement of the product output

KU9.    sketches and engineering drawings

KU10. how to visualize final product output and hence decide on the key steps to be followed

KU11. different types of cleaning techniques, moulding processes and associated equipments

KU12. measuring instruments like verniercallipers, micrometres

KU13. hazards and safety aspects involved in moulding activities and usage of relevant PPEs

Generic Skills (GS)

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

GS1.    document information from the sketches and engineering drawings

GS2.    prepare draft drawings for the final output product

GS3.    write information documents to internal departments/ internal teams or enter the information in online ERP systems under guidance of the supervisor

GS4.    read and interpret engineering drawing and sketches

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

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

GS7.    read internal drawings send by internal customers ( other functions within the organization)

GS8.    discuss task lists, schedules, and work-loads with co-workers

GS9.    question internal customers/ Moulding shop supervisor appropriately in order to understand the nature of the problem and make a diagnosis

GS10. avoid using jargon, slang or acronyms when communicating with a customer, unless it is required

GS11. plan and organize the work order and jobs received from the internal customers

GS12. plan and organize the design documents received from internal customers

GS13. organize all process/ equipment manuals so that sorting out information is fast

GS14. use common sense and make judgments during day to day basis

GS15. use reasoning skills to identify and resolve basic problems

GS16. use intuition to detect any potential problems which could arise during operations

GS17. follow instructions and work on areas of improvement identified

GS18. complete the assigned tasks with minimum supervision

GS19. complete the job defined by the supervisor within the timelines and quality norms

GS20. detect problems in day to day tasks

GS21. support supervisor in using specific problem solving techniques and detailing out the problems

GS22. discuss possible solution with the supervisor for problem solving

GS23. make decisions in emergency conditions in case the supervisor is not available( as per the authority matrix defined by the organization)

Perform the moulding related operations and monitor process parameters:

Elements and Performance Criteria

Check the operations of the equipment used in the moulding process

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

PC1..    check for operation of molding apparatus like hopper, pouring nozzles, heaters, reciprocating screws, plungers etc. as per the checklist provided

PC2..    fix the desired die to the extrusion apparatus in order to achieve the desired shape as per the work instructions/ sops

PC3..    make modifications in the molding parameters ( by selecting the right program from the machine control system) if required and ensure alignment with the prescribed standards

Feed the plastic granules in the hopper and conduct a test process

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

PC4..    perform preheating of plastic granules to improve their tensile strength

PC5..    ensure that the plastic granules are mixed with additives (if any) before being fed into the hopper

PC6..    turn valves of machines to regulate speed and quantity of the plastic coming out of the hopper

PC7..    ensure pouring in line with the defined standards and specifications

PC8..    record the feeding observations like parting leak, interrupted pouring or any abnormality

PC9..    conduct a test process and produce a sample output as per the sketches/ engineering drawing shared with the operator

PC10.. check the first piece for geometry, material & dimensional parameters as per the control plan before starting the production

PC11.. ensure that the dimensions of the output product are measured as per the process given in the work instructions/ SOP

PC12.. in case the test product matches the dimensions and quality of the final output, start the production process

Conduct the actual moulding process

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

PC13.. feed the required operation code in the apparatus for heaters to melt the plastic granules at the predefined temperature

PC14.. adjust the screw speed and the screw pressure to force the molten plastic into the die to create the desired output shape

PC15.. turn valves of machines to regulate speed and quantity of the plastic coming out of the hopper

PC16.. ensure feeding in line with the defined standards and specifications

PC17.. record the feeding observations like parting leak, interrupted pouring or any abnormality

PC18.. ensure the proper functioning of screen pack for uniform melting of plastic and removal of the contaminants (if any)

PC19.. monitor the molding process (parameters like temperature, pressure etc.) by observing and analyzing the readings on various panels/ meters to prevent machine breakdown and deviations of the output from desired specifications

PC20.. observe and analyze any irregularity in the process and take preventive steps

PC21.. 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

PC22.. 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

PC23.. clean the plastic molding to remove runners/ gates or extra materials through de-gating and de -flashing processes

PC24.. ensure stamping of the molding with the identifying information (wherever required) and send the same for further processing

PC25.. instruct the helper to cut the output molding as per the desired geometric specifications ( removal of runners)

Perform the visual inspection of the output to further finish the moulding

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

PC26.. measure the final plastic product and compare the dimensions as prescribed in the work order/ engineering drawing

PC27.. in case the parts are not as per the given measurements, send the same for further processing in terms of cutting, finishing etc.

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.    how to read 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.    number of heaters required to generate the given temperature/ current requirements

KU8.    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

KU9.    various types of plastics like thermoplastics/ thermosetting plastics and their properties

KU10. various types of coolants. and their properties

KU11. moulding defects and how they are generated, how they can be prevented, different consumables used in the melt shop

KU12. extruder operation, melting process, and safety process of handling hot moltenplasticand control mechanisms for the extrusion machine

KU13. measuring instruments like vernier callipers, micrometers and other tools

KU14. impact of operators work on moulding quality at in house and at customers, how to improve customers satisfaction

KU15. geometry and dimension measurement

KU16. sketches and engineering drawings

KU17. how to visualize final product output and hence decide on the key steps to be followed

KU18. 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 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.    prepare draft drawings for the final output product

GS4.    write drawings to internal customers on the requirement of moulding plastic, moulding apparatus etc.

GS5.    note measurements, equipment panel readings for various process parameters in the required reporting formats

GS6.    read and interpret engineering drawing and sketches

GS7.    read equipment manuals and process documents to understand the equipment and processes better

GS8.    read instructions especially safety instructions especially symbols while using the equipment in the plant area

GS9.    read internal drawings send by internal customers ( other functions within the organization)

GS10. discuss task lists, schedules, and work-loads with co-workers

GS11. question internal customers/ Moulding shop supervisor appropriately in order to understand the nature of the problem and make a diagnosis

GS12. plan and organize the work order and jobs received from the internal customers

GS13. plan and organize the design documents received from internal customers

GS14. organize all process/ equipment manuals so that sorting out information is fast

GS15. organize apparatus etc. in an orderly manner at proper designated areas

GS16. visualize the final job product after understanding the given drawing/ sketches

GS17. carefully measure the moulding so in terms of the geometrical dimensions so that the final output is as pre the given drawing

GS18. finalize the optimum levels of physical parameters so that the job output meets the prescribed job standards

GS19. detect problems in day to day tasks

GS20. support supervisor in using specific problem solving techniques and detailing out the problems

GS21. discuss possible solution with the supervisor for problem solving

GS22. make decisions in emergency conditions in case the supervisor is not available( as per the authority matrix defined by the organization)

GS23. follow instructions and work on areas of improvement identified

GS24. complete the assigned tasks with minimum supervision

GS25. complete the job defined by the supervisor within timelines and quality norms

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.
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