- Production Job Cards8
- Quality Nonconformance Register8
- WHS Incident and Hazard Register8
- Tool and Die Register8
Formed for purpose
CAQA Polyform Plastics and Cable makes moulded and extruded plastic components, polyethylene and PVC pipe, low voltage power and control cable, and rubber compounds, conveyor belting and linings for customers in building products, water, mining, agriculture and electrical wholesale.
CAQA Polyform Plastics and Cable, plastics, rubber and cable manufacturing
CAQA Polyform Plastics and Cable makes moulded and extruded plastic components, polyethylene and PVC pipe, low voltage power and control cable, and rubber compounds, conveyor belting and linings for customers in building products, water, mining, agriculture and electrical wholesale. The Dandenong South plant runs 14 injection moulding machines from 80 to 1,100 tonnes and three extrusion lines. The Bayswater cable works draws, strands and insulates copper conductor and sheaths finished cable. The Wingfield works compounds rubber, calenders sheet, builds and repairs conveyor belts and sends splicing crews to mine and quarry sites across South Australia.
The business runs three shifts at Dandenong South and Bayswater from Monday to Friday with a weekend shift when order books require it, and a day shift plus site crews at Wingfield. Each production area has a supervisor, setters or technicians and operators, supported by tooling and maintenance, a materials store and a laboratory. Six departments report to the General Manager: Injection Moulding, Extrusion and Film, Cable Works, Rubber and Belting, Tooling and Maintenance, and Technical, Quality and WHS. Production is planned from job cards raised against customer orders and tracked from setup through first-off approval to packing.
Guards on, locks on
Nobody reaches into a machine, mould or press that is not isolated. Every tool change and clearance is done under lock out.
First-off before full run
A run does not continue until the first-off has been measured and approved against the setting sheet and the drawing.
Measure, do not guess
Temperatures, pressures, dimensions and cure times are set from the sheet and recorded, and changes go through the setter and the technical team.
Close the loop
Scrap, regrind, rework and complaints are recorded, costed and fed back so the next run is better than the last.
Services and operations
To form plastics, rubber and cable to specification, safely and without waste, for the customers who build, power and move Australia.
Injection moulding
Custom moulding of engineering and commodity thermoplastics from 80 to 1,100 tonnes, including insert moulding, in-mould labelling and assembly, with tool trials and process validation.
Pipe and profile extrusion
Polyethylene and PVC pipe, conduit and profile extrusion with in-line marking, cutting and coiling, tested to the relevant Australian pipe standards.
Cable manufacture
Wire drawing, bunching and stranding of copper conductor, PVC and cross-linked polyethylene insulation, lay-up and sheathing of low voltage power, control and flexible cables.
Rubber compounding and calendering
Custom natural and synthetic rubber compounds mixed on internal and open mills, calendered into sheet and moulded into linings, seals and wear parts.
Conveyor belting and splicing
Fabric ply and steel cord belt supply, hot and cold vulcanised splicing, belt replacement and carcass and cover repairs by site crews at mines and quarries.
Tooling, trials and technical support
Mould and die maintenance, new tool trials, material selection, compound development and failure analysis for customers moving a product into production.
Six departments, one workplace
Each department has a purpose, a lead, responsibilities, performance measures and the systems it works in. Students are placed in a department by their scenario.
Injection Moulding
Injection Moulding runs the 14-machine moulding hall at Dandenong South on three shifts. Setters change dies and establish the pro...
Visit departmentExtrusion and Film
Extrusion and Film runs the three pipe and profile extrusion lines and the blown film line at Dandenong South. The team changes di...
Visit departmentCable Works
Cable Works at Bayswater draws copper rod to wire, bunches and strands conductors, extrudes PVC and cross-linked polyethylene insu...
Visit departmentRubber and Belting
Rubber and Belting at Wingfield mixes rubber compounds on the internal and open mills, calenders sheet, builds and cures fabric pl...
Visit departmentTooling and Maintenance
Tooling and Maintenance keeps moulds, dies, calibrators, machines and ancillaries in production condition across all three sites. ...
Visit departmentTechnical, Quality and WHS
Technical, Quality and WHS runs the quality management system, the laboratory, material and compound development, customer complai...
Visit departmentWorking systems with real records
Every system is live in your browser: create, update, search, move cards on a board and export what you did. Reset returns the seed data at any time.
Production Job Cards
Tracks every production, trial and site service job from release through setup, first-off approval, running, inspection and packing.
8 recordsQuality Nonconformance Register
Records nonconforming product, process deviations, cable test failures and customer complaints with disposition and corrective action.
8 recordsWHS Incident and Hazard Register
Records injuries, near misses, hazards, chemical events, burns and property damage at all sites and on customer sites with investigation and actions.
8 recordsTool and Die Register
Holds every mould, extrusion die, calibrator and cable die with its version, condition, service history, cavity or size details and storage location.
8 recordsRaw Materials and Compounds Stock
Keeps the stock record for resins, masterbatch, copper rod, rubber ingredients, compounds and chemicals with lot numbers, quantities and locations.
8 recordsInbox
8 work requests from managers and colleagues, each linked to a scenario or a document.
Open inboxEight workplace scenarios
Sign in as a role, read the brief, work through the tasks using the documents and systems, then print an evidence summary for your assessor.
Run the IM-09 moulding cell for a shift
You are a trainee moulding machine operator on the afternoon shift.
Open scenario Entry 3 to 4 hoursStart up extrusion line EX-2 on 110 mm PN16 pipe
You are a trainee extrusion operator working with the line operator.
Open scenario Intermediate 5 to 7 hoursSet 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.
Open scenario Intermediate 4 to 6 hoursProduce the Harbourline twin and earth cable order
You are a cable production operator following an order through the Bayswater works.
Open scenario Intermediate 3 to 5 hoursMix an NR-45 compound batch and calender lining sheet
You are a rubber compounder at the Wingfield works.
Open scenario Intermediate 5 to 7 hoursPrepare for and complete the Goldreef CV-07 belt splice
You are the second technician on a two-person site splicing crew.
Open scenario Advanced 5 to 7 hoursInvestigate the T-104 short shots and analyse the tool trial data
You are a process technician working for the Tooling and Maintenance Manager.
Open scenario Advanced 6 to 8 hoursPropose a material and compound for the Goldreef screen panel
You are a polymer technologist in the Technical, Quality and WHS team.
Open scenarioNotice board All notices
- Safety Never reach into a machine: call a setter
9 September 2026 - Safety Open mill at Wingfield tagged out
4 September 2026 - Quality Die centring check at every reel change on cable lines
5 September 2026
Coming up Calendar
- 15/09Toolbox talk: machine access and calling a setter, all moulding shifts
7:00 am, Moulding hall, Dandenong South - 16/09Goldreef CV-07 belt splice, site crew departs Wingfield
6:00 am, Goldreef Mining Services site - 17/09New tool trial T-131 with toolroom and technical
8:00 am, Machine IM-12 or IM-10, Dandenong South - 18/09Weekly production and quality meeting: open nonconformances
2:00 pm, Meeting room, Dandenong South
Mapped to the Plastics, Rubber and Cablemaking
Every scenario lists the current units of competency and qualifications it supports, with assessor notes and a printable evidence summary. Use it with your own assessment tools or ask CAQA for a matched kit.