Simulated workplaceCAQA Polyform Plastics and Cable is a fictional business created by CAQA for training and assessment. It is not a real company and no person, client or record here is real.About this simulation
PMBCAQA PolyformSimulated workplace
Simulated workplace
Scenario · Tooling and Maintenance

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

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

Advanced5 to 7 hours8 tasks
Start the tasksAll scenarios
Home/Scenarios/Investigate the T-104 short shots and analyse the tool trial data
The situation

What has happened

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.

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.
Read the work request in your inbox
Tasks

Deliverables

  • 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

Documents to use

Systems to use

Quality Nonconformance Register

Records nonconforming product, process deviations, cable test failures and customer complaints with disposition and corrective action.

Tool 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.

Production Job Cards

Tracks every production, trial and site service job from release through setup, first-off approval, running, inspection and packing.

Raw Materials and Compounds Stock

Keeps the stock record for resins, masterbatch, copper rod, rubber ingredients, compounds and chemicals with lot numbers, quantities and locations.

For trainers and assessors

Units of competency

Current on training.gov.au for the Plastics, Rubber and Cablemaking as at 10 September 2026.

PMBTECH406EDiagnose production equipment problems
PMBTECH502EAnalyse production trials
PMBTECH501EAnalyse equipment performance
PMBTECH506EAnalyse the design of products and tools for polymer injection moulding
PMBTECH301EOptimise polymer processing operations

Qualifications

PMB40121Certificate IV in Polymer Technology
PMB50121Diploma of Polymer Technology
Assessor notes

What to look for

Evidence guide

Look for the root cause reached with evidence from the tool inspection and the process records, not assumed from the symptom, and for an explanation of why more pressure did not help. The disposition must follow the procedure and the corrective actions must address the overdue service. The trial analysis must compare settings against results systematically and the draft setting sheet values must be traceable to the trial data.

The student's evidence summary lists every record they created or changed in the systems named above, their notes and the tasks they ticked. Verify it against the deliverables and your own assessment tool.