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Simulated workplace
Scenario · Injection Moulding

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.

Intermediate5 to 7 hours8 tasks
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The situation

What has happened

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.

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.
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Tasks

Deliverables

  • 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

Documents to use

Systems to use

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.

WHS 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.

Production Job Cards

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

Quality Nonconformance Register

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

For trainers and assessors

Units of competency

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

PMBPREP304ESet a die for injection moulding production
PMBPROD430ETrial a new injection moulding die
PMBTECH301EOptimise polymer processing operations
PMBTECH406EDiagnose production equipment problems
PMBPROD385EProgram computer-controlled equipment

Qualifications

PMB30121Certificate III in Polymer Processing
PMB40121Certificate IV in Polymer Technology
Assessor notes

What to look for

Evidence guide

Look for the machine decision made from the register entries rather than assumed, a Job Safety Analysis that covers the core pull and the unproven tool, isolation steps that include hydraulic core energy, and a trial record where every change has a reason and an effect. Measurements must be per cavity against the drawing. The decision must be agreed with the technical team, not made alone.

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.