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 · Extrusion and Film

Start up extrusion line EX-2 on 110 mm PN16 pipe

You are a trainee extrusion operator working with the line operator.

Entry3 to 4 hours8 tasks
Start the tasksAll scenarios
Home/Scenarios/Start up extrusion line EX-2 on 110 mm PN16 pipe
The situation

What has happened

The 110 millimetre PN16 die and calibrator have been fitted to line EX-2 and the PE100 black pipe compound lot is in the silo. Job card JC-26-3315 for Riverbend Water Corporation is at First-off pending. Yesterday the line ran for twenty minutes before a wall thickness was recorded and a process deviation was logged. A burn from a purging on this line earlier in the week has put long gloves at every line. The supervisor wants the line started up to the procedure, the pipe brought to specification and measured at four points, the marking checked and the start-up scrap weighed before the job card moves to Running.

Your brief. Start up EX-2 under the Pipe Extrusion Line Start-up and Shutdown Procedure, thread the line safely, bring the pipe to the standard's dimensions, check and record the marking, weigh the start-up scrap, complete the first-off and move the job card to Running only when the pipe conforms.
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Tasks

Deliverables

  • Pre-start checklist with die, calibrator and lot confirmation
  • Written heating, purging and threading sequence with safety points
  • Dimension and marking records on the job card with adjustments
  • Start-up scrap record and first-off approval

Documents to use

Systems to use

Production Job Cards

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

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.

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.

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.

PMBPREP303ESet up equipment for continuous operation
PMBPROD213EOperate polymer extruders
PMBPROD313EProduce extruded polymer products
PMBPROD306EPrepare and start equipment for production

Qualifications

PMB20121Certificate II in Polymer Processing
PMB30121Certificate III in Polymer Processing
Assessor notes

What to look for

Evidence guide

Look for the die soak and purge handled safely, hands kept clear during threading, dimensions measured at four points against stated tolerances and adjustments made only within the sheet limits and recorded. The job card must not move to Running before the first-off conforms. The marking check must cover every required element.

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.