Investigate the T-104 short shots and analyse the tool trial data

You are a process technician working for the Tooling and Maintenance Manager.

Simulated workplaceAdvanced missionCAQA Polyform Plastics and Cable

What is going on

Gutter clip tool T-104 is in the toolroom after short shots appeared on cavities 6 and 11 of 16 during job card JC-26-3308, with 1,800 parts in quarantine under nonconformance NCR-26-088. The tool is 38,000 shots overdue for service and the setter increased injection pressure within the sheet limits without effect. Separately, three trial reports from the T-131 and T-118 trials need to be analysed to decide the settings for validation. The Tooling and Maintenance Manager wants one report by Friday covering the T-104 investigation with a recommended disposition and corrective action, and the trial analysis with recommended validated settings.

Kylie Brennan, Tooling and Maintenance Manager
Subject: T-104 short shots and the trial data from last month

Two things. The gutter clip tool T-104 is in the toolroom with short shots on cavities 6 and 11 and it is 38,000 shots overdue for service, and job card JC-26-3308 is on hold with 1,800 parts in quarantine. I want the nonconformance investigated properly with the setter's process records, the tool history and a vent inspection, and a disposition recommended. Second, I need the three trial reports from the T-131 and T-118 trials analysed so we can decide the settings for validation. Give me one report covering both by Friday.

Your brief

Investigate the T-104 short shot nonconformance to root cause using the process records, tool history and a vent inspection, recommend the disposition of the quarantined parts and the corrective actions, and analyse the three trial reports to recommend validated settings and a setting sheet for each tool.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the Nonconformance and Rework Procedure and the Quality Policy and state what the investigation must establish and who decides the disposition.
Review NCR-26-088, job card JC-26-3308, the setter's process records and the Tool and Die Register history for T-104 and list every fact relevant to the short shots on cavities 6 and 11.
Inspect the tool in the toolroom with the toolmaker: vents, gates, cooling channels and cavity condition for cavities 6 and 11 against a good cavity, and record what you find with photographs.
Analyse the possible causes across tool, material, machine and process using a structured method, and state the root cause with the evidence, including why the pressure increase did not work.
Recommend the disposition of the 1,800 quarantined parts with reasons, and the corrective actions for the tool, the service schedule and the process, with owners and dates.
Analyse the three trial reports: tabulate the settings, changes and results, identify the settings that produced conforming parts at the best cycle time, and identify any result that needs a repeat trial.
Draft the validated Process Setting Sheet values for T-131 and the revised values for T-118 using the template, with setter adjustment ranges.
Write the combined report for the Tooling and Maintenance Manager and update the nonconformance and tool register entries.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Fact list from records and tool inspection record
Root cause analysis with evidence
Disposition recommendation and corrective actions
Trial data analysis table
Draft setting sheet values and combined report

Printing this is a record of what you explored. It is not a certificate or a qualification.