Set the new T-131 tool and run its first trial

You are a setter running a new tool trial with the senior setter, the toolroom and the technical team.

Simulated workplaceIntermediate missionCAQA Polyform Plastics and Cable

What is going on

New tool T-131, a two cavity air duct mould with a hydraulic core pull for Southern Cross Automotive Components, is due for its first trial under job card JC-26-3322. The tool has arrived from the toolmaker with drawings and suggested settings. Machine IM-12 has a light curtain fault logged in the WHS register and is tagged out, so the trial is likely to move to IM-10, which has a different platen size and controller. The Tooling and Maintenance Manager and the Technical, Quality and WHS Manager will attend. The trial must be planned with a Job Safety Analysis, the die set under lock out to the procedure, the process built up from the toolmaker's data and everything recorded on the trial report.

Josh Kowalski, Injection Moulding Setter
Subject: New tool trial T-131 on Wednesday

The new Southern Cross air duct tool T-131 arrives for its first trial on Wednesday under job card JC-26-3322. IM-12 has a light curtain fault logged so we are likely to move to IM-10. I want you to plan and run the trial with me: write the Job Safety Analysis, build the starting settings from the toolmaker's data, do the die set under lock out to the procedure, run the trial and record everything on the Production Trial Report Template. Kylie and Wei will be there. Check the tool register and the WHS register before you plan anything.

Your brief

Plan the trial with a Job Safety Analysis, confirm the machine, set the tool under isolation to the Die Change and Process Setup Procedure, establish a starting process from the toolmaker's data, run the trial recording every change and observation, measure the parts against the drawing and complete the Production Trial Report with a recommended decision.

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.

Check the Tool and Die Register entry for T-131 and the WHS register entry for the IM-12 light curtain and decide with the Tooling and Maintenance Manager which machine the trial runs on, recording the reasons.
Complete the Job Safety Analysis Form for the trial covering the die set, the hydraulic core pull, hot runner leads, first shots with an unproven tool and the people present.
Read the Die Change and Process Setup Procedure and describe the isolation and lock out steps for the die set on the chosen machine, including the energy sources specific to a hydraulic core pull.
Build the starting settings on a draft Process Setting Sheet from the toolmaker's data and the material supplier's processing guide, stating any values you have chosen to start conservatively and why.
Run the trial in semi-automatic, recording on the trial report every change to speed, pressure, temperature or timing, the reason and the effect, and observations of filling, venting, core pull sequence and ejection.
Measure five parts from each cavity against the drawing and check appearance, and record the results with photographs of any defect.
Consult the Technical, Quality and WHS Manager on the results and agree the decision: accepted, accepted with modifications, or repeat, with the tool modifications and actions listed with owners and dates.
Complete the Production Trial Report, update the Tool and Die Register entry and the job card, and file the draft setting sheet for validation.

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

What someone in this role would produce

Machine selection record and Job Safety Analysis
Isolation and die set record
Draft Process Setting Sheet with starting settings
Completed Production Trial Report with measurements and decision
Updated tool register and job card entries

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