SlideShare a Scribd company logo
36
CURRICULUM of COMPETENCY UNIT (CoCU)
Sub Sector METAL MACHINING TECHNOLOGY
Job Area MOULD & DIE MANUFACTURING
Competency Unit Title STAMPING DIE ASSEMBLING
Learning Outcome
The person who is competent in stamping die assembling shall be able to assemble stamping die components based
on assembly drawing to produce a complete and functional stamping die for the mass production of high quality and
standardised products. Upon completion of this competency unit, trainees will be able to :-
• Prepare die assembly requirements
• Perform die assembling
• Perform die alignment
• Check die assembling
Competency Unit ID CU01 Level 03
Training
Duration
180 hours Credit Hours 18
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
1. Prepare die
assembly
requirements
i. Content of job
instruction
• Job description
Type of
process by
sequences
• Lead time
(delivery date)
• Company rules &
regulation
Company
policy
ii. Die assembly drawing
• Stamping die
concept
• Types of die
i. Interpret job
instruction
ii. Interpret die assembly
drawing
iii. Select measuring
instrument
iv. Select die assembly
tools
Attitude:
i. Resourceful in
acquiring
information and
data
ii. Precise in
communicating
with internal
staff
iii. Meticulous in
acquiring
information
iv. Meticulous in
interpreting
drawing
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Job description
interpreted
ii. Delivery date
identified
iii. Company rules
& regulation
complied
iv. Die concepts
explained
v. Die
components
name and
quantity listed
vi. Fitting
tolerance,
surface finish
and drawing
37
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
Components
names and
quantity
• Fitting tolerance
• Surface finish
• Drawing symbols
iii. Measuring instrument
iv. Type of tools
• Allen key
• Copper mallet
symbols
identified and
explained
vii. Measuring
instrument
functionality
explained
viii.Measuring
instrument
selected
ix. Type of tools
identified, listed
and selected
2. Perform die
assembling
i. Types of die
• Single die
• Compound die
• Progressive die
• Hot stamping die
ii. Types of stamping
processes such as
• Blanking
• Piercing
• Bending
iii. Die components
• Components
name
• Components
function
• Components
material
• Components
dimension
i. Select types of die
ii. Select types of
stamping processes
iii. Identify type of die
components
iv. Check components
dimension
v. Identify types of die
component material
vi. Identify die references
(datum)
vii. Apply die fitting
technique by
sequence
viii. Assemble upper die
components
ix. Assemble lower die
components
Attitude:
i. Exacting when
using
measuring
instrument
ii. Alert to
electrical
supply
iii. Attentive in
handling die
components
and tools
iv. Adhere to safe
handling
technique
Safety:
i. Ensure
personal
Related
Knowledge
28 hours
Related
skills
56 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Types of dies
selected
ii. Types of
stamping
processes
explained
iii. Type of die
components
and standard
parts listed
iv. Type of die
components
and standard
parts functions
explained
v. Die
components
material listed
vi. Components
dimension
checked and
38
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
iv. Type of standard parts
and functions such as
:-
• Guide post
• Guide bush
• Spring
• Stripper bolts
• Dowel pin
v. Type of die
component materials
such as:
• SKD11/XW42
• SKS3/DF2
• SKD61
vi. Die references
(datum)
• Refer from
drawing
• Refer from die
components
• Mark components
vii. Die fitting technique
• Sliding fit
• Tight fit
viii. Upper die assembly
• Guide bush to top
plate
• Punch to punch
holder
• Punch holder,
backing plate to
top plate
ix. Lower die assembly
• Guide post to
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges &
pinch point
confirmed
vii. Die references
(datum)
checked and
marked
viii. Die fitting
technique
applied
accordance
with fitting
requirements.
ix. Upper die
components
assembled in
accordance
with assembly
drawing
x. Lower die
components
assembled in
accordance
with assembly
drawing
xi. Safety
precaution
applied in
performing die
assembling
39
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
bottom plate
• Die block,
backing plate to
bottom plate
3. Perform die
alignment
i. Die clearance
• Die calculation
ii. Type of gauges/
matching agent
• Filler gauge
• Shim
• Blue matching
• Die light
iii. Die align method
• Forming area
Matching
agents
application
Matching
force
application
• Clearance area
Guide post
align to guide
bush
Filler gauge to
check Punch
and die
clearance
application
iv. Transfer hole location
v. Safety precaution on
die alignment
i. Identify die clearance
ii. Identify gauges/
material agents
iii. Select
gauges/material
agent
iv. Apply die alignment
method
v. Align upper and lower
die
vi. Drill and ream dowel
hole
Attitude:
i. Exacting when
using
measuring
instrument
ii. Alert to
electrical
supply
iii. Attentive in
handling die
components
and tools
iv. Adhere to safe
handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges &
pinch point
Related
Knowledge
16 hours
Related
skills
40 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Die clearance
identified and
confirmed
ii. Type of gauges /
matching agents
selected
iii.Die alignment
method applied
iv.Upper and lower
die set align
demonstrated
and confirmed.
v. Dowel pin
assembled
vi.Safety
precaution
applied in
performing die
alignment
40
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
4. Check die
assembling for
verification
i. Die assembly
drawing
• Type of stamping
die
• Die operation
ii. Die set assembly
iii. Die alignment
process
iv. Die assembly check
sheet
i. Interpret die assembly
drawing
ii. Check die set
assembly
iii. Check die alignment
iv. Update die assembly
check sheet
Attitude:
i. Resourceful in
acquiring
information and
data
ii. Precise in
communicating
with internal
staff
iii. Meticulous in
acquiring
information
Related
Knowledge
4 hours
Related
skills
12 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Die assembly
drawing
interpreted
ii. Die
components
tighten
confirmed
iii. Die alignment
confirmed
iv. Die assembly
check sheet
updated
41
Employability Skills
Core Abilities Social Skills
01.07 Utilize database applications to locate and process information
01.08 Utilize spreadsheets applications to locate and process information
01.09 Utilize business graphic application to process information
01.10 Apply a variety of mathematical techniques
01.11 Apply thinking skills and creativity
02.09 Prepare flowcharts
02.10 Prepare reports and instructions
02.11 Convey information and ideas to people
03.09 Manage and improve performance of individuals
03.10 Provide consultation and counselling
03.11 Monitor and evaluate performance of human resources
03.12 Provide coaching/on-the job training
03.13 Develop and maintain team harmony and resolve conflicts
03.14 Facilitate and coordinate teams and ideas
03.15 Liaise to achieve identified outcomes
03.16 Identify and assess client/customer needs
03.17 Identify staff training needs and facilitate access to training
04.06 Allocate work
04.07 Negotiate acceptance and support for objectives and strategies
05.01 Implement project/work plans
05.02 Inspect and monitor work done and/or in progress
06.07 Develop and maintain networks
1. Communication skills
2. Conceptual skills
3. Interpersonal skills
4. Learning skills
5. Leadership skills
6. Multitasking and prioritising
7. Self-discipline
8. Teamwork
42
Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)
1. Job Instruction
2. Assembly drawing
3. Hand tools
4. Measuring instruments
5. Matching agent
6. Stamping die components
7. Die spotting machine
8. Inspection check sheet
9. Personal Protective Equipment (PPE)
1:1
1:1
1:1
1:1
1:1
1:5
1:25
1:1
1:1
References
REFERENCES
1. Jerry Arnold (2000), Die Maker Handbook, Industrial Press, Inc., ISBN 0-831-3132-2
2. James A. Szumera (2003), The Metal Stamping Process, Industrial Press, Inc. ISBN 0-8311-3164-0
3. Vokota Boljanovic (1987), Die design fundamentals, Industrial Press Inc., ISBN 0-8311-1172-0
4. Donald A. Peterson (1994), Progressive Dies Principles and Practices of Design, Society of Manufacturing Engineers, ISBN 0-87263-448-5
5. Vukota Boljanovic (2004), Sheet Metal Forming Processes and Die Design, Industrial Press Inc., ISBN 0-8311-3182-9
6. David A Smith (1990), Die design Handbook, Society of manufacturing engineers (SME), ISBN 0-87263-375-6
43
CURRICULUM of COMPETENCY UNIT (CoCU)
Sub Sector METAL MACHINING TECHNOLOGY
Job Area MOULD & DIE MANUFACTURING
Competency Unit Title PLASTIC INJECTION MOULD ASSEMBLING
Learning Outcome
The person who is competent in plastic injection mould assembling shall be able to assemble plastic injection mould
components based on assembly drawing to produce a complete and functional mould for the mass production of
high quality and standardised products. Upon completion of this competency unit, trainees will be able to :-
• Prepare plastic injection mould assembly requirements
• Perform mould assembling
• Perform mould matching
• Check mould assembling
Competency Unit ID CU02 Level 03
Training
Duration
180 Hours Credit Hours 18
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
1. Prepare plastic
injection mould
assembly
requirements
i. Job instruction
• Job description
Type of
process by
sequences
• Lead time (delivery
date)
• Company rules &
regulation
Company
policy
ii. Mould assembly
drawing
• Mould concepts
• Types of plastic
injection moulds
• Part names and
quantity
i. Interpret Job
instruction
ii. Interpret Mould
assembly drawing
iii. Select measuring
instruments
iv. Select type of tools
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting
when using
measuring
instrument
iii. Attentive in
handling
mould
components
and tools
iv. Adhere to
safe handling
technique
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Type of job
description
interpreted
ii. Delivery date
identified
iii. Company rules
& regulation
complied
iv. Mould concepts
explained
v. Mould
components
name and
quantity listed
vi. Fitting
tolerance,
surface finish
and drawing
symbols
44
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
• Fitting tolerance
• Surface finish
• Drawing symbols
iii. Measuring
instruments
iv. Type of tools and
function
• Allen key
• Copper mallet
• Oil Stone
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges
identified
vii. Measuring
instrument
identified and
selected
viii.Type of tools
identified, listed
and selected
2. Perform mould
assembling
i. Types of plastic
injection moulds and
function
• Two-plate mould
With side core
without side
core
• Three-plate mould
With side core
without side
core
• Hot runner system
ii. Mould components
and functions
• Top plate
• Core plate
• Core insert
• Cavity plate
• Cavity insert
• Spacer block
• Ejector retainer
plate
• Ejector back plate
i. Identify type mould
and function
ii. Identify element of
mould and function
iii. Identify type of mould
standard parts and
functions
iv. Identify type of mould
components material
v. Check mould
references (datum)
vi. Assemble moving
half
vii. Assemble fixed half
viii. Identify types of
cooling system
ix. Fix ejector system
x. Fix feed system
xi. Check mould
perpendicular
xii. Check mould levelling
xiii. Apply Safety
precaution
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting
when using
measuring
instrument
iii. Alert to
electrical
supply
iv. Attentive in
handling
mould
components
and tools
v. Adhere to
safe handling
technique
Related
Knowledge
28 hours
Related
skills
56 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Types of
plastic injection
moulds
explained
ii. Type of mould
components
and standard
parts listed
iii. Type of mould
components
and standard
parts functions
explained and
differentiated
iv. Mould
components
material listed
v. Components
dimension
confirmed
vi. Mould
references
(datum)
confirmed
45
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
• Bottom plate
iii. Type of standard parts
and functions such as
:-
• Locating ring
• Sprue bush
• Guide pillar
• Guide bush
• Spring
• Ejector pin
• Return pin
iv. Type of mould
components material
such as:
• Stavax
• 718
• Rmax
v. Mould references
(datum)
• Refer from drawing
• Refer from
components
• Mark component
vi. Mould fitting technique
• Moving half
Core insert
Core plate
Ejector plate
Ejector pin
Return pin
Support plate
Spacer block
Bottom plate
• Fixed half
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges
& pinch point
vii. Mould fitting
technique
demonstrated
viii. Moving half
assembled
ix. Fixed half
assembled
x. Types of
cooling system
identified
xi. Ejector system
fixed
xii. Feed system
fixed
xiii. Mould
perpendicular
checked and
confirmed
xiv. Mould Level
checked and
confirmed
xv. Safety
precaution
applied in
performing
mould
assembly
46
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
Cavity insert
Cavity plate
Top plate
Sprue bush
Locating ring
vii. Types of cooling
system
• Direct
• Buffle
• Spiral
viii. Types of injector
system
• Pin
• Stripper
• Slant block
ix. Feed system
• Sprue
• Runner
• Gate
x. Mould fitting method
• Perpendicular
• Flatness
xi. Safety precaution on
mould assembling
3. Perform mould
matching
i. Mould matching area
ii. Type of gauges/
matching agent such
as:-
• Filler gauge
• Shim
• Blue matching
• Lead
• Modelling clay
• Wax
i. Identify mould
matching area
ii. Identify type of
gauges/ matching
agent
iii. Select gauges/
matching agent
iv. Identify mould parting
line
v. Identify Wall thickness
Attitude:
i. Exacting
when using
measuring
instrument
ii. Alert to
electrical
supply
iii. Attentive in
handling
Related
Knowledge
16 hours
Related
skills
40 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Mould
matching area
checked and
confirmed
ii. Type of
gauges/
matching agent
listed and
selected
iii. Mould parting
47
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
iii. Mould matching
method
• Parting line
• Wall thickness
iv. Matching process
• Matching agents
• Die spot force
• Surface contact
area
v. Safety precaution on
mould matching
vi. Apply matching agent
vii. Apply matching force
viii. Check match area
transferred
mould
components
and tools
iv. Adhere to
safe handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation
& Standard
ii. Beware of
sharp edges
& pinch
point
line identified
and confirmed
iv. Wall thickness
identified
v. Matching agent
applied
vi. Matching force
applied
vii. Matching area
transfer,
checked and
confirmed
viii. Safety
precaution
applied in
performing
mould matching
4. Check mould
assembling
i. Mould assembly
drawing
• Type of mould
• Mould operation
ii. Mould assembly set
iii. Mould matching
process
iv. Mould assembly check
sheet
i. Interpret mould
assembly drawing
ii. Check mould set
assembly
iii. Check mould
matching
iv. Mould assembly
check sheet
Attitude:
i. Resourceful in
acquiring
information
and data
ii. Precise in
communicating
with internal
staff
iii. Meticulous in
acquiring
information
Related
Knowledge
4 hours
Related
skills
12 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Mould
assembly
drawing
interpreted
ii. Mould
components
tighten
confirmed
iii. Mould
matching
checked and
confirmed
iv. Mould
assembly
check sheet
updated
48
Employability Skills
Core Abilities Social Skills
01.07 Utilize database applications to locate and process information
01.08 Utilize spreadsheets applications to locate and process information
01.09 Utilize business graphic application to process information
01.10 Apply a variety of mathematical techniques
01.11 Apply thinking skills and creativity
02.09 Prepare flowcharts
02.10 Prepare reports and instructions
02.11 Convey information and ideas to people
03.09 Manage and improve performance of individuals
03.10 Provide consultation and counselling
03.11 Monitor and evaluate performance of human resources
03.12 Provide coaching/on-the job training
03.13 Develop and maintain team harmony and resolve conflicts
03.14 Facilitate and coordinate teams and ideas
03.15 Liaise to achieve identified outcomes
03.16 Identify and assess client/customer needs
03.17 Identify staff training needs and facilitate access to training
04.06 Allocate work
04.07 Negotiate acceptance and support for objectives and strategies
05.01 Implement project/work plans
05.02 Inspect and monitor work done and/or in progress
06.07 Develop and maintain networks
1. Communication skills
2. Conceptual skills
3. Interpersonal skills
4. Learning skills
5. Leadership skills
6. Multitasking and prioritising
7. Self-discipline
8. Teamwork
49
Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)
1. Job Instruction
2. Assembly drawing
3. Hand tools
4. Measuring instruments
5. Matching agent
6. Mould components
7. Die spotting machine
8. Inspection check sheet
9. Lifting equipment
10. Personal Protective Equipment (PPE)
1:1
1:1
1:1
1:1
1:1
1:5
1:25
1:1
1:25
1:1
References
REFERENCES
1. Gunter Mennig (1998), Mould Making Handbook, Hanser / Gardner publication, ISBN 1-56990-261-5
2. Eric V. Buckleitner (1995), Plastics Mold Engineering Handbook, Chapman & Hall, ISBN 0-412-98951-4
3. Georg Menges/Paul Mahren (1993), How to make Injection Molds, Hanser Publishers, ISBN 3-446-16305-0
4. Donald V. Rosato/Dominick V. Roasato (1995), Injection Molding Handbook, Chapman & Hall, ISBN 0-412-99381-3
5. E. Lindner and P. Unger (1993), Injection Mold 108 Proven Designs, Hanser Publishers, ISBN 3-446-15682-8
6. Michael L. Berins (1991), Plastics Engineering Handbook, Chapman & Hall, ISBN 0-412-99181-0
50
CURRICULUM of COMPETENCY UNIT (CoCU)
Sub Sector METAL MACHINING TECHNOLOGY
Job Area MOULD & DIE MANUFACTURING
Competency Unit Title STAMPING DIE TRY-OUT & TROUBLESHOOT
Learning Outcome
The person who is competent in stamping die try-out & troubleshoot shall be able to setup the stamping die to
machine to ensure the stamping die is functional in accordance with design requirements and to produce samples
that meet product specifications. Upon completion of this competency unit, trainees will be able to :-
• Prepare stamping die try-out requirements
• Set up stamping die to machine
• Set up machine parameters
• Produce product sample
• Inspect product sample
• Check die try out and troubleshooting
Competency Unit ID CU03 Level 03
Training
Duration
160 Hours Credit Hours 16
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
1. Prepare
stamping die
try-out
requirements
i. Content of job
instruction
• Job description
Type of
process by
sequences
• Lead time (delivery
date)
• Company rules &
regulation
Company
policy
ii. Product drawing
• Product dimensions
• Product material
iii. Measuring instruments
i. Interpret job
instruction
ii. Interpret product
drawing
iii. Select
measuring
instruments
iv. Select type of
tools
v. Identify stamping
die
vi. Identify stamping
machine
specification
vii. Identify stamping
machine and
Attitude:
i. Resourceful in
acquiring
information and
data
ii. Precise in
communicating
with internal staff
iii. Meticulous in
acquiring
information
iv. Meticulous in
interpreting
drawing
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Job instruction
interpreted
ii. Product
dimensions
identified
iii. Product material
selected
iv. Measuring
instrument
selected
v. Type of tools listed
and selected
vi. Type of stamping
die identified and
selected
vii. Stamping machine
51
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
• Micrometer
• Vernier calliper
• Pin gauges
iv. Type of tools such as:
• Allen key
• Copper mallet
• Oil stone
v. Type of stamping die
vi. Stamping machine &
accessories
• Machine
specification
• Machine function
• Type of accessories
accessories
functional
specification
identified and
selected
viii. Stamping machine
function explained
2. Set up
stamping die
on stamping
machine
i. Stamping machine and
accessories
• Machine tonnage
• Machine Shut-
height
• Machine and
accessories
conditions
• Type of feeders
ii. Type of clamping
devices
iii. Stamping die setting
method
• With shank
• Without shank
• Clamping technique
iv. Machine safety
precaution
i. Check stamping
machine and
accessories
conditions
ii. Select stamping
machine and
accessories
iii. Select type of
feeders
iv. Select type of
clamping devices
v. Set stamping die
on machine
Attitude:
i. Exacting when
using
measuring
instrument
ii. Alert to
electrical
supply
iii. Attentive in
handling die
components
and tools
iv. Adhere to safe
handling
technique
Safety:
i. Ensure
personal
protective
Related
Knowledge
16 hours
Related
skills
32 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Machine &
accessories
conditions
confirmed
ii. Stamping machine
tonnage and shut-
height selected
and confirmed
iii. Type of feeders
selected
iv. Type of clamping
devices selected
v. Stamping die clamp
to machine secured
vi. Machine safety
precaution
complied in
performing die
setup
52
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges
& pinch point
3. Set up
machine
parameters
i. Die shut height
• Top dead centre
• Bottom dead
centre
ii. Machine pressure
• Air pressure inlet
• Machine tonnage
• Cushion pressure
iii. Test run
• Stamping die
condition
• Stamping machine
condition
iv. Feeder system
• Manual feeder
• Roller
• Transfer
v. Safety devices
• Sensor
• Mechanical safety
devices
i. Set die shut
height
ii. Set machine
pressure
iii. Perform test run
iv. Check stamping
die functionality
v. Confirm machine
condition
vi. Set feeder
system
vii. Set safety
devices
Attitude:
i. Resourceful in
acquiring
information and
data
ii. Alert to
electrical supply
iii. Attentive in
handling die and
tools
iv. Adhere to safe
handling
technique
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Top dead centre
identified
ii. Bottom dead
centre confirmed
iii. Air pressure inlet
adjusted and
confirmed
iv. Machine tonnage
set
v. Cushion pressure
set and confirmed
vi. Stamping die
functionality
checked and
confirmed
vii. Stamping machine
condition
confirmed
viii. Feeder system set
ix. Safety devices set
53
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
4. Produce
product
sample
i. Product material
• Type of material
• Material
specification
ii. Product Sample
• Product
appearance
• Product profile
iii. Type of product defect
• Burrs
• Wrinkle
• Crack
iv. Causes of product
defects
v. Corrective actions
• Rework
Touch up
Re-grind
Re-machining
• Replace
i. Select strip
material
ii. Produce product
sample
iii. Check product
abnormalities
iv. Identify type of
product defect
v. Identify type of
causes
vi. Identify problem
solving
vii. Perform
corrective actions
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting when
using
measuring
instrument
iii. Alert to
electrical
supply
iv. Attentive in
handling die
components
and tools
v. Adhere to safe
handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges &
pinch point
Related
Knowledge
8 hours
Related
skills
24 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Product material
selected
ii. Product sample
produced
iii. Type of product
abnormality
checked, identified
and listed
iv. Type of causes
listed
v. Problem solving
listed and
explained
vi. Corrective actions
applied
vii. Safety precaution
applied during
producing product
sample
54
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
5. Inspect
product
sample
i. Product Drawing
• Product dimension
• Product profile
• Product
specification
ii. Type of measuring
instrument
• Micro meter
• Vernier calliper
• Go No Go gauge
• Profile projector
iii. Product sample
• Dimension
• Profile
• Appearance
iv. Product inspection
check sheet
i. Interpret product
drawing
ii. Select type of
measuring
instrument
iii. Check product
sample
dimension
iv. Check product
sample profile
v. Check product
sample
appearance
vi. Fill up product
inspection check
sheet
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting when
using
measuring
instrument
iii. Alert to
electrical supply
iv. Attentive in
handling mould
components
and tools
v. Adhere to safe
handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges
Related
Knowledge
4 hours
Related
skills
8 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Product drawing
interpreted
ii. Type of measuring
instrument listed
and functional
described
iii. Product sample
dimension
checked and
confirmed
iv. Product sample
profile checked
and confirmed
v. Product sample
appearance
checked and
confirmed
vi. Measurement
method applied
vii. Product inspection
check sheet Filled
up
55
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment Criteria
6. Check die try
out &
troubleshoot
i. Stamping Die set up
ii. Machine parameter set
up
iii. Product quality
• Product sample
• Product check
sheet
iv. Die try out check sheet
i. Check stamping
die set up
ii. Confirmed
machine
parameter set up
iii. Check product
quality
iv. Update die try
out check sheet
Attitude:
i. Resourceful in
acquiring
information and
data
ii. Precise in
communicating
with internal
staff
iii. Meticulous in
acquiring
information
Related
Knowledge
4 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Stamping Die set
up checked and
clamp secured
ii. Machine
parameter set up
confirmed
iii. Product quality
checked and
confirmed
iv. Die try out check
sheet updated
56
Employability Skills
Core Abilities Social Skills
01.07 Utilize database applications to locate and process information
01.08 Utilize spreadsheets applications to locate and process information
01.09 Utilize business graphic application to process information
01.10 Apply a variety of mathematical techniques
01.11 Apply thinking skills and creativity
02.09 Prepare flowcharts
02.10 Prepare reports and instructions
02.11 Convey information and ideas to people
03.09 Manage and improve performance of individuals
03.10 Provide consultation and counselling
03.11 Monitor and evaluate performance of human resources
03.12 Provide coaching/on-the job training
03.13 Develop and maintain team harmony and resolve conflicts
03.14 Facilitate and coordinate teams and ideas
03.15 Liaise to achieve identified outcomes
03.16 Identify and assess client/customer needs
03.17 Identify staff training needs and facilitate access to training
04.06 Allocate work
04.07 Negotiate acceptance and support for objectives and strategies
05.01 Implement project/work plans
05.02 Inspect and monitor work done and/or in progress
06.07 Develop and maintain networks
1. Communication skills
2. Conceptual skills
3. Interpersonal skills
4. Learning skills
5. Leadership skills
6. Multitasking and prioritising
7. Self-discipline
8. Teamwork
57
Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)
1. Job Instruction
2. Assembly drawing
3. Hand tools
4. Measuring instruments
5. Matching agent
6. Stamping die components
7. Die spotting machine
8. Inspection check sheet
9. Personal Protective Equipment (PPE)
1:1
1:1
1:1
1:1
1:1
1:5
1:25
1:1
1:1
References
REFERENCES
1. Jerry Arnold (2000), Die Maker Handbook, Industrial press, Inc., ISBN 0-831-3132-2
2. James A Szumera (2003), The Metal Stamping Process, Industrial press, Inc. ISBN 0-8311-3164-0
3. Richard M. Lead (2002), Tool and Die Making Troubleshoot, Society of Manufacturing Engineers, ISBN 978-0-87263-643-9
4. Vokota Boljanovic (1987), Die design fundamentals, Industrial Press Inc., ISBN 0-8311-1172-0
5. Donald A. Peterson (1994), Progressive Dies Principles and Practices of Design, Society of Manufacturing Engineers, ISBN 0-87263-448-5
6. Vukota Boljanovic (2004), Sheet Metal Forming Processes and Die Design, Industrial Press Inc., ISBN 0-8311-3182-9
7. David A Smith (1990), Die design Handbook, Society of manufacturing engineers (SME), ISBN 0-87263-375-6
58
CURRICULUM of COMPETENCY UNIT (CoCU)
Sub Sector METAL MACHINING TECHNOLOGY
Job Area MOULD & DIE MANUFACTURING
Competency Unit Title PLASTIC INJECTION MOULD TRY-OUT & TROUBLESHOOT
Learning Outcome
The person who is competent in Plastic Injection Mould Try-Out & Troubleshoot shall be able to setup injection
moulding machine to ensure the mould is functional in accordance with design requirements and to produce samples
that meet product specifications. Upon completion of this competency unit, trainees will be able to :-
• Prepare plastic injection mould try-out requirements
• Set up plastic injection mould to machine
• Carry out pre-heating
• Set up machine parameters
• Produce product sample
• Inspect product sample
• Perform surface finishing process
• Check mould try out and troubleshooting
Competency Unit ID CU04 Level 03
Training
Duration
240 Hours
Credit
Hours
24
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
1. Prepare plastic
injection mould
try-out
requirements
i. Content of job
instruction
• Job description
Type of
process by
sequences
• Lead time (delivery
date)
• Company rules &
regulation
Company
policy
ii. Product drawing
• Product
i. Interpret job
instruction
ii. Interpret product
drawing
iii. Select measuring
instrument
iv. Identify type of tools
v. Select type of tools
vi. Identify plastic
injection mould
vii. Identify moulding
machine specification
viii. Identify moulding
machine and
Attitude:
i. Resourceful
in acquiring
information
and data
ii. Precise in
communicati
ng with
internal staff
iii. Meticulous in
acquiring
information
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Job instruction
interpreted
ii. Product
dimensions
identified
iii. Product
material
selected
iv. Measuring
instrument
selected
v. Type of tools
listed and
selected
59
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
dimensions
• Product material
iii. Measuring instrument
• Micrometer
• Vernier calliper
iv. Type of tools such as:
• Allen key
• Copper mallet
• Oil stone
v. Type of plastic
injection mould
vi. Moulding machine
• Machine
specification
• Machine function
• Type of auxiliary
accessories
functional
vi. Type of plastic
injection mould
identified
vii.Moulding
machine
specification
identified
viii. Moulding
machine
function
explained
2. Set up mould
on injection
moulding
machine
i. Moulding machine
• Machine tonnage
• Mould platen and
tie-bar size
• Machine and
auxiliary condition
ii. Type of clamping
devices
iii. Plastic injection mould
preparation set up
• Nozzle radius
• Nozzle length
• Locating ring size
• Resin
• Cooling system
• Hydraulic Core
System
i. Select moulding
machine and
auxiliary
ii. Select type of
clamping devices
iii. Check mould
preparation set up
iv. Set plastic injection
mould to machine
v. Comply machine
safety precaution
Attitude:
i. Alert to
electrical
supply
ii. Attentive in
handling die
components
and tools
iii. Adhere to
safe handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Related
Knowledge
16 hours
Related
skills
32 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Machine
tonnage
identified and
confirmed
ii. Moulding
machine &
auxiliary
conditions
checked and
confirmed
iii. Type of
clamping
devices
selected
iv. Mould
preparation
set up
checked and
60
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
• Ejector machine
system
Location
Size
Length
iv. Mould set up
• Mould align to
machine
• Machine nozzle
align to mould
sprue bush
• Mould clamping
v. Machine safety
precaution
Safety
Regulation &
Standard
ii. Beware of
sharp edges &
pinch point
confirmed
v. Plastic
injection
mould set to
machine
secured
vi. Machine
safety
precaution
complied in
performing
mould setup
3. Carry out pre-
heating
i. Product material
(Resin)
• Type of resin
Polypropylene
(PP)
Acrylonitrile
Butadene
Styrene (ABS)
Polyamide
(PA6GF
Nylon)
Master batch
• Resin specification
Melt
temperature
Melting point
Shrinkage
• Material
characteristic
Flow
Speed
i. Identify type of resin
ii. Identify resin
specification
iii. Identify material
(resin) characteristic
iv. Set temperature
range
v. Set pre-heat duration
vi. Carry out resin pre-
heating
vii. Carry out machine
pre-heating
viii. Carry out mould pre-
heating
Attitude:
i. Meticulous in
interpreting
drawing
ii. Alert to
electrical
supply
iii. Attentive in
handling
mould
components
and tools
iv. Adhere to
safe handling
technique
Safety:
iii. Ensure
personal
protective
equipment
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Type of resin
identified
ii. Resin
specification
identified
iii. Resin
(material)
characteristic
identified
iv. Temperature
set
v. Pre-heat
duration set
vi. Resin pre-
heating carried
out
vii. Machine pre-
heating carried
out
viii. Mould pre-
heating carried
61
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
Strength
Stiffness
ii. Pre-heating process
requirements
• Temperature range
• Duration
iii. Resin pre-heating
iv. Machine pre-heating
v. Mould pre-heating
(PPE) meet
Safety
Regulation &
Standard
out
ix. Safety
precaution
applied during
pre-heating
process
4. Set up machine
parameters
i. Clamping adjustment
• Clamping force
• Ejector stroke
• Mould opening
ii. Part weight
iii. Dosage/metering
iv. Injection speed
v. Injection pressure
vi. Cooling time
vii. Safety devices
• Sensor
• Mechanical
i. Set clamping force
ii. Set ejector stroke
iii. Set mould opening
iv. Identify Part weight
v. Set dosage /
metering
vi. Set injection speed
vii. Adjust injection
pressure
viii. Set cooling time
ix. Set safety devices
Attitude:
i. Alert to
electrical
supply
ii. Attentive in
handling
mould
components
and tools
iii. Adhere to
safe handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Clamping force
set
demonstrated
ii. Ejector stroke
set
demonstrated
iii. Mould opening
set
demonstrated
iv. Part weight
identified
v. Dosage /
metering set
vi. Injection speed
pressure set
vii. Injection
pressure
adjusted
viii. Cooling time
Set
ix. Safety devices
set
62
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
5. Produce
product sample
i. Product resin
ii. Plastic injection
mould conditions
iii. Material purging
• Material viscosity
• Discard remaining
iv. Product sample
condition /
abnormalities
• Sink mark
• Burn mark
• Flushing
• Short shot
v. Causes of product
defects
vi. Corrective actions
• Rework
Touch up
Re-grind
Re-machining
• Replace
i. Confirm product resin
ii. Check plastic injection
mould condition
iii. Measure material
temperature
iv. Check material
viscosity
v. Ensure discard
remaining
vi. Carry out material
purging
vii. Produce product
sample
viii. Check Product
abnormalities
ix. Identify type of
product defect
x. Identify type of causes
xi. Identify problem
solving
xii. Perform corrective
actions
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting
when using
measuring
instrument
iii. Alert to
electrical
supply
iv. Attentive in
handling
mould
components
and tools
v. Adhere to
safe handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges
& pinch point
Related
Knowledge
8 hours
Related
skills
24 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Product resin
checked and
confirmed
ii. Plastic
injection mould
conditions
checked and
confirmed
iii. Material
temperature
confirmed
iv. Material
viscosity
checked
v. Discard
remaining
ensured
vi. Product
sample defect
identified
vii. Type of defect
listed
viii. Problem
solving listed
and explained
ix. Corrective
actions
demonstrated
x. Safety
precaution
applied during
producing
product
sample
63
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
6. Inspect product
sample
i. Type of measuring
instrument
• Micro meter
• Vernier calliper
• Go No Go gauge
• Profile projector
ii. Product sample
• Dimension
• Profile
• Appearance
iii. Product inspection
check sheet
i. Select type of
measuring instrument
ii. Check product sample
appearance
iii. Check product sample
profile
iv. Check product sample
dimension
v. Fill up product
inspection check
sheet
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting
when using
measuring
instrument
iii. Alert to
electrical
supply
iv. Attentive in
handling
mould
components
and tools
v. Adhere to
safe handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges
Related
Knowledge
4 hours
Related
skills
8 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Type of
measuring
instrument
listed and
functional
described
ii. Product
sample
dimension
identified
iii. Product
sample profile
identified
iv. Product
sample
appearance
identified
v. Measurement
method
applied
vi. Product
inspection
check sheet
Filled up
64
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
7. Perform surface
finishing
process
i. Type of surface finish
• Polishing
• Surface finish
treatment
Texture
Etching
Chrome
plating
ii. Surface area
iii. Type of abrasive paper
and grit size
iv. Polishing kits and grit
size
v. Polishing technique
• Selection of grit
size
• Polishing direction
vi. Dispose schedule
waste
i. Identify type of surface
finish
ii. Arrange for surface
finish treatment
iii. Identify surface area to
be polished
iv. Select abrasive paper
and grit size
v. Select polishing kits
and grit size
vi. Carry out polishing
process
vii. Practice waste
disposal
Attitude:
i. Exacting when
using
measuring
instrument
ii. Alert to
electrical
supply
iii. Attentive in
handling mould
components
and tools
iv. Adhere to safe
handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges
iii. Comply with
Environmental
Management
System (EMS)
Related
Knowledge
16 hours
Related
skills
40 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Type of
surface finish
identified and
confirmed
ii. Surface finish
treatment
arranged
iii. Surface area
identified and
confirmed
iv. Abrasive
paper and grit
size selected
v. Polishing kits
and grit size
selected
vi. Polishing
process
carried out
vii. Polishing
technique
demonstrated
viii. waste
disposal
procedure are
adhered to
ix. Polishing
process in
compliance
with
Environmental
Management
System (EMS)
65
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
8. Check mould try
out and
troubleshoot
i. Plastic injection
mould set up
ii. Machine parameter
set up
iii. Product sample
iv. Product inspection
check sheet
v. Mould surface finish
vi. Mould try out check
sheet
i. Check plastic
injection mould set
up
ii. Confirm machine
parameter set up
iii. Check product
sample quality
iv. Check mould
surface finish
v. Update mould try out
check sheet
Attitude:
i. Resourceful
in acquiring
information
and data
ii. Precise in
communicati
ng with
internal staff
iii. Meticulous in
acquiring
information
Related
Knowledge
4 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Plastic
injection mould
set up checked
and clamp
secured
ii. Machine
parameter set
up confirmed
iii. Product
sample quality
checked
iv. Mould surface
finish checked
and confirmed
v. Mould try out
check sheet
updated
66
Employability Skills
Core Abilities Social Skills
01.07 Utilize database applications to locate and process information
01.08 Utilize spreadsheets applications to locate and process information
01.09 Utilize business graphic application to process information
01.10 Apply a variety of mathematical techniques
01.11 Apply thinking skills and creativity
02.09 Prepare flowcharts
02.10 Prepare reports and instructions
02.11 Convey information and ideas to people
03.09 Manage and improve performance of individuals
03.10 Provide consultation and counselling
03.11 Monitor and evaluate performance of human resources
03.12 Provide coaching/on-the job training
03.13 Develop and maintain team harmony and resolve conflicts
03.14 Facilitate and coordinate teams and ideas
03.15 Liaise to achieve identified outcomes
03.16 Identify and assess client/customer needs
03.17 Identify staff training needs and facilitate access to training
04.06 Allocate work
04.07 Negotiate acceptance and support for objectives and strategies
05.01 Implement project/work plans
05.02 Inspect and monitor work done and/or in progress
06.07 Develop and maintain networks
1. Communication skills
2. Conceptual skills
3. Interpersonal skills
4. Learning skills
5. Leadership skills
6. Multitasking and prioritising
7. Self-discipline
8. Teamwork
67
Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)
1. Job Instruction
2. Plastic injection mould
3. Moulding machine
4. Mould assembly drawing
5. Product drawing
6. Measuring instruments
7. Hand tools
8. Product material (resin)
9. Polishing kits
10. Check sheet
11. Personal Protective Equipment (PPE)
1 : 1
1 : 5
1 : 5
1 : 1
1 : 1
1 : 5
1 : 1
As required
As required
1 : 1
1 : 1
References
REFERENCES
1. Richard M. Lead (2002), Tool and Die Making Troubleshoot, Society of Manufacturing Engineers, ISBN 978-0-87263-643-9
2. Gunter Mennig (1998), Mould Making Handbook, Hanser / Gardner publication, ISBN 1-56990-261-5
3. Eric V. Buckleitner (1995), Plastics Mold Engineer Handbook, Chapman & Hall, ISBN 0-412-98951-4
4. Georg Menges/Paul Mahren (1993), How to make Injection Molds, Hanser Publishers, ISBN 3-446-16305-0
5. Donald V. Rosato/Dominick V (1995), Roasato, Injection Molding Handbook, Chapman & Hall, ISBN 0-412-99381-3
6. E. Lindner and P. Unger (1993), Injection Mold 108 Proven Designs, Hanser Publishers, ISBN 3-446-15682-8
7. Michael L. Berins (1991), Plastics Engineering Handbook, Chapman & Hall, ISBN 0-412-99181-0
68
CURRICULUM of COMPETENCY UNIT (CoCU)
Sub Sector METAL MACHINING TECHNOLOGY
Job Area MOULD & DIE MANUFACTURING
Competency Unit Title STAMPING DIE MAINTENANCE
Learning Outcome
The person who is competent in Stamping Die Maintenance shall be able to carry out preventive and corrective
maintenance exercise that ensures the stamping die is in good operational condition. Upon completion of this
competency unit, trainees will be able to :-
• Prepare stamping die maintenance requirements
• Carry out stamping die maintenance activities
• Perform stamping die assembly activities
• Perform stamping die try-out
• Inspect product sample
• Check stamping die maintenance activity
Competency Unit ID CU05 Level 03
Training
Duration
180 Hours Credit Hours 18
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
1. Prepare
stamping die
maintenance
requirements
i. Job instruction
• Assembly drawing
• Job description
Type of process
by sequences
• Lead time (delivery
date)
• Company rules &
regulation
Company policy
ii. Die maintenance
schedule
• Type of
maintenance
(corrective/
i. Interpret Job
instruction
ii. Interpret die
maintenance
schedule
iii. Identify type of Die
iv. Identify type of
stamping processes
v. Select maintenance
tools
vi. Obtain product
sample
Attitude:
i. Resourceful in
acquiring
information and
data
ii. Precise in
communicating
with internal staff
iii. Meticulous in
acquiring
information
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Assembly
drawing
interpreted
ii. Job description
explained
iii. Delivery date
identified
iv. Company rule
& regulation
complied
v. Die
maintenance
schedule
interpreted
vi. Type of die
69
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
preventive)
• Replaced parts.
• Modified part
iii. Product samples
• Product defect
• Master sample
iv. Type of Die
• Single die
• Compound die
• Progressive die
v. Types of stamping
processes such as
• Blanking
• Piercing
• Bending
vi. Type of tools and
consumables
• allen key,
• copper mallet
• shim
• abrasive paper
• oil stone
listed
vii. Type of
stamping
process
explained
viii. Type of tools
listed and
selected
ix. Product
samples
obtained
70
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
2. Carry out
stamping die
maintenance
activities
i. Defected product
sample
• Type of defect
• Type of abnormality
ii. Type of die
components such as:-
• Upper plate
• Punch plate
• Stripper plate
• Punch block
• Die block
• Lower plate
iii. Type of die standard
parts such as :-
• Guide post
• Guide bush
• Spring
• Stripper bolts
iv. Type of die component
defects such as :-
• Scratch
• Dented
• Wear and tear
v. Counter problem
techniques such as:-
• Touch up
• Regrind
• Replace
i. Identify type of
product defect
ii. Dismantle die
components
iii. Dismantle die
standard parts
iv. Identify die
components defect
v. Identify die
standard parts
defect
vi. Carry out touch up
die component
vii. Carry out regrind
die component
viii. Carry out
replacement of die
component
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting
when using
measuring
instrument
iii. Alert to
electrical
supply
iv. Attentive in
handling die
components
and tools
v. Adhere to
safe handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges &
pinch point
Related
Knowledge
16 hours
Related
skills
40 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Type of
product defect
listed
ii. Die
components
listed
iii. Die standard
parts listed
iv. Die
component
defects
identified and
listed
v. Touch up die
component
performed
vi. Regrind die
component
performed
vii. Replacement
of die
component
performed
viii. Safety
precaution
applied in
performing die
maintenance
71
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
3. Perform
stamping die
assembly
activities
i. Assembly drawing
• Drawing symbol
• Die datum
• Upper die set
• Lower die set
ii. Die assemble
technique
• Upper die set
assembly
Guide post to
top plate
Punch to punch
holder
Punch holder,
backing plate to
top plate
• Lower die set
assemble
Guide bush to
bottom plate
Die block,
backing plate to
bottom plate
iii. Die assembly method
• Perpendicular
• Flatness
iv. Die alignment
• Matching agent
• Matching surface
area
i. Interpret assembly
drawing
ii. Apply die assembly
technique
iii. Perform die
assembly
iv. Perform die
alignment
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting when
using
measuring
instrument
iii. Alert to
electrical
supply
iv. Attentive in
handling die
components
and tools
v. Adhere to safe
handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges &
pinch point
Related
Knowledge
8 hours
Related
skills
24 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Assembly
drawing
interpreted
ii. Die assembly
technique
demonstrate
iii. Die assembly
performed
iv. Matching
agent selected
v. Matching
surface area
confirmed
vi. Die alignment
performed
xii. Safety
precaution
applied in
performing die
assembly
72
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
4. Perform
stamping die
try-out
i. Stamping machine
and accessories
• Machine tonnage
• Machine and
accessories
conditions
• Type of feeders
ii. Type of clamping
devices
iii. Stamping die setting
method
iv. Die shut height
• Top dead centre
• Bottom dead
centre
v. Safety devices
• Sensor
• Mechanical safety
devices
vi. Test run
• Stamping die
condition
• Stamping machine
condition
vii. Feeder system
• Manual feeder
• Roller
• Transfer
viii. Product material
• Type of material
• Material
specification
ix. Die conditions
x. Product sample
i. Identify stamping
machine and
accessories
ii. Identify type of
clamping devices
iii. Clamp stamping die
to machine
iv. Set die shut height
v. Set safety devices
vi. Perform test run
vii. Set feeder system
viii. Select product
material
ix. Check die conditions
x. Produce product
sample
xi. Identify type of
product defect
xii. Apply
countermeasure
xiii. Apply corrective
actions
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting when
using
measuring
instrument
iii. Alert to
electrical
supply
iv. Attentive in
handling die
components
and tools
v. Adhere to safe
handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges &
pinch point
Related
Knowledge
16 hours
Related
skills
24 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Machine
tonnage
confirmed
ii. Machine and
accessories
conditions
checked and
confirmed
iii. Type of
feeders
selected
iv. Type of
clamping
devices
selected
v. Stamping die
set to machine
secured
vi. Die shut height
checked and
confirmed
vii. Safety devices
set
viii. Die conditions
checked and
confirmed
ix. Feeder system
set
x. Product
material
confirmed
xi. Product
sample
produced
xii. Type of
73
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
xi. Type of stamping fault
and countermeasure
such as:-
• Burrs
• Wrinkle
• Crack
xii. Causes of product
defects
xiii. Corrective actions
product defect
identified
xiii. Counter
measure listed
xiv. Corrective
actions applied
xv. Safety
precaution
applied in
performing die
try out
5. Inspect product
sample
i. Type and usage of
measuring instrument
• Micro meter
• Vernier calliper
• Go No Go gauge
• Profile projector
ii. Product sample
• Dimension
• Profile
• Appearance
iii. Product inspection
check sheet
i. Select type of
measuring instrument
ii. Identify product
sample dimension
iii. Identify product
sample profile
iv. Identify product
sample appearance
v. Apply measurement
method
vi. Fill up product
inspection check
sheet
Attitude:
i. Resourceful in
acquiring
information
and data
ii. Precise in
communicatin
g with internal
staff
iii. Meticulous in
acquiring
information
iv. Exacting
when using
measuring
instrument
Related
Knowledge
4 hours
Related
skills
8 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Type of
measuring
instrument
listed and
functional
described
ii. Product
sample
dimension
identified
iii. Product
sample profile
identified
iv. Product
sample
appearance
identified
v. Measurement
method
applied
vi. Product
inspection
check sheet
filled up
74
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
6. Check stamping
die
maintenance
activity
i. Type of die
maintenance
• Corrective
• preventive
ii. Assembly drawing
• Type of die
• Type of
components
iii. Product drawing
• Product
specification
iv. Product inspection
check sheet
• Product inspection
result
• Die components
condition
• Die try –out result
v. Die maintenance check
sheet
i. Confirm type
maintenance
ii. Confirm die to be
maintain
iii. Confirm die
component defects
iv. Confirm die
assembly activities
v. Confirm die try-out
vi. Confirm Product
quality
vii. Update die
maintenance check
sheet
Attitude:
i. Resourceful in
acquiring
information
and data
ii. Precise in
communicatin
g with internal
staff
iii. Meticulous in
acquiring
information
Related
Knowledge
4 hours
Related
skills
12 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Type of
maintenance
Confirmed
ii. Die to be
maintain
confirmed
iii. Die
component
defects listed
iv. Die assembly
activities
confirmed
v. Die try-out
confirmed
vi. Product
quality
assured
vii. Die
maintenance
check sheet
updated
75
Employability Skills
Core Abilities Social Skills
01.07 Utilize database applications to locate and process information
01.08 Utilize spreadsheets applications to locate and process information
01.09 Utilize business graphic application to process information
01.10 Apply a variety of mathematical techniques
01.11 Apply thinking skills and creativity
02.09 Prepare flowcharts
02.10 Prepare reports and instructions
02.11 Convey information and ideas to people
03.09 Manage and improve performance of individuals
03.10 Provide consultation and counselling
03.11 Monitor and evaluate performance of human resources
03.12 Provide coaching/on-the job training
03.13 Develop and maintain team harmony and resolve conflicts
03.14 Facilitate and coordinate teams and ideas
03.15 Liaise to achieve identified outcomes
03.16 Identify and assess client/customer needs
03.17 Identify staff training needs and facilitate access to training
04.06 Allocate work
04.07 Negotiate acceptance and support for objectives and strategies
05.01 Implement project/work plans
05.02 Inspect and monitor work done and/or in progress
06.07 Develop and maintain networks
1. Communication skills
2. Conceptual skills
3. Interpersonal skills
4. Learning skills
5. Leadership skills
6. Multitasking and prioritising
7. Self-discipline
8. Teamwork
76
Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)
1. Job Instruction
2. Assembly drawing
3. Hand tools
4. Measuring instruments
5. Matching agent
6. Stamping die components
7. Die spotting machine
8. Inspection check sheet
9. Personal Protective Equipment (PPE)
1:1
1:1
1:1
1:1
1:1
1:5
1:25
1:1
1:1
References
REFERENCES
1. David A Smith (2001), Die maintenance handbook, Society of manufacturing engineers (SME), ISBN 978-0-87263-528-9
2. Richard M. Lead (2002), Tool and Die Making Troubleshoot, Society of Manufacturing Engineers, ISBN 978-0-87263-643-9
3. Jerry Arnold (2000), Die Maker Handbook, Industrial press, Inc., ISBN 0-831-3132-2
4. James A Szumera (2003), The Metal Stamping Process, Industrial press, Inc. ISBN 0-8311-3164-0
5. Vokota Boljanovic (1987), Die design fundamentals, Industrial Press Inc., ISBN 0-8311-1172-0
6. Donald A. Peterson (1994), Progressive Dies Principles and Practicesof Design, Society of Manufacturing Engineers, ISBN 0-87263-448-5
7. David A Smith (1990), Die design Handbook, Society of manufacturing engineers (SME), ISBN 0-87263-375-6
77
CURRICULUM of COMPETENCY UNIT (CoCU)
Sub Sector METAL MACHINING TECHNOLOGY
Job Area MOULD & DIE MANUFACTURING
Competency Unit Title PLASTIC INJECTION MOULD MAINTENANCE
Learning Outcome
The person who is competent in Plastic Injection Mould Maintenance shall be able to carry out preventive and
corrective maintenance exercise that ensures the Plastic Injection Mould is in good operational condition. Upon
completion of this competency unit, trainees will be able to :-
• Prepare mould maintenance requirements
• Carry out plastic injection mould maintenance
• Perform mould assembly activities
• Perform mould try-out
• Inspect product sample
• Check mould maintenance activity
Competency Unit ID CU06 Level 03
Training
Duration
180 Hours Credit Hours 18
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
1. Prepare
mould
maintenance
requirements
i. Job instruction
• Assembly drawing
• Job description
Type of process by
sequences
• Lead time (delivery
date)
• Company rules &
regulation
Company policy
ii. Mould maintenance
schedule
• Mould history
• Type of
maintenance
(corrective/
i. Interpret job
instruction
ii. Interpret mould
maintenance
schedule
iii. Identify type of
mould
iv. Identify mould
construction
v. Identify type of
maintenance tools
vi. Select maintenance
tools
vii. Select defected
product
Attitude:
i. Resourceful in
acquiring
information
and data
ii. Precise in
communicating
with internal
staff
iii. Meticulous in
acquiring
information
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Assembly
drawing
interpreted
ii. Job
description
explained
iii. Delivery date
identified
iv. Company rule
& regulation
complied
v. Mould
maintenance
schedule
differentiate
vi. Type of mould
78
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
preventive)
• Replaced parts.
• Modified part
iii. Type of mould
• Two plate mould
• Three plate mould
iv. Mould construction
• Side core
• Stripper plate
• Slant block
v. Type of tools &
consumables
• allen key,
• copper mallet
• shim
• abrasive paper
• matching agent
• oil stone
vii. Product samples
• Defective
product
• Master sample
listed
vii. Mould
construction
explained
viii. Type of tools
listed
ix. Product defect
selected
2. Carry out plastic
injection mould
maintenance
i. Defected product
sample
• Type of defect
• Type of
abnormality
ii. Mould components
such as:
• Top plate
• Core plate
• Core insert
• Cavity plate
• Cavity insert
i. Identify type product
defect
ii. Identify type of
product abnormality
iii. Dismantle mould
components
iv. Dismantle mould
standard parts
v. Identify mould
component defects
vi. Carry out touch up
mould component
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting when
using
measuring
instrument
iii. Alert to
electrical
supply
iv. Attentive in
Related
Knowledge
16 hours
Related
skills
40 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Type of product
defect identified
and listed
ii. Type of product
abnormality
identified and
listed
iii. Mould
components
dismantled
iv. Mould standard
parts
79
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
• Spacer block
• Ejector retainer
plate
• Ejector back plate
• Bottom plate
iii. Mould standard parts
such as :-
• Locating ring
• Sprue bush
• Guide pillar
• Guide bush
• Spring
• Ejector pin
• Return pin
iv. Type of mould
component defects
such as :-
• Scratch
• Dented
• Wear and tear
v. Counter problem
techniques such as:-
• Touch up
• Regrind
• Replace
vii. Carry out regrind
mould component
viii. Carry out
replacement of
mould component
handling mould
components
and tools
v. Adhere to safe
handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges &
pinch point
dismantled
v. Mould
component
defects
checked and
listed
vi. Touch up
mould
component
performed
vii. Regrind mould
component
performed
viii. Replacement of
mould
component
performed
ix. Safety
precaution
applied in
performing
mould
maintenance
3. Perform mould
assembly
activities
i. Assembly drawing
• Drawing symbol
• Mould datum
• Mould components
ii. Mould fitting technique
• Fixed half
• Moving half
iii. Mould fitting method
• Perpendicular
i. Interpret drawing
symbols
ii. Identify mould
references (datum)
iii. Assemble moving
half
iv. Assemble fixed half
v. Check mould
perpendicular
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting
when using
measuring
instrument
iii. Alert to
Related
Knowledge
8 hours
Related
skills
24 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Assembly
drawing
interpreted
ii. Mould fitting
technique
demonstrate
iii. Mould fitting
performed
iv. Matching
80
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
• Flatness
iv. Mould matching
• Matching agent
• Matching surface
area
vi. Check mould
flatness
vii. Perform mould
matching
electrical
supply
iv. Attentive in
handling
mould
components
and tools
v. Adhere to
safe handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges
agent selected
v. Matching
surface area
confirmed
vi. Mould
matching
performed
vii. Safety
precaution
applied in
performing
mould
assembly
4. Perform mould
try-out
i. Mould set up safety
and procedure
ii. Moulding machine and
function
• Machine
specification
• Machine parameter
• Clamping devices
iii. Pre heat procedure
• Material
• Mould
• Machine
iv. Mould set-up
i. Comply to Mould set
up safety and
procedure
ii. Identify Moulding
machine and
function
iii. Perform pre heat
procedure
iv. Perform mould set-
up
v. Perform material
purging
vi. Optimised parameter
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting
when using
measuring
instrument
iii. Alert to
electrical
supply
iv. Attentive in
handling
Related
Knowledge
16 hours
Related
skills
24 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Mould set up
safety and
procedure
complied
ii. Moulding
machine
identified
iii. Moulding
machine
function
explained
iv. Pre heat
process listed
81
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
• Mould clamping
• Mould accessories
• Parameter setting
v. Material purging
• Material viscosity
• Discard remaining
vi. Product sample
• Specification
• Appearance
• Profile
vii. Type of moulding fault
and countermeasure
such as:-
• Short shot
• Sink mark
• Burn mark
• Flashing
viii. Causes of product
defects
ix. Corrective actions
• Touch up
• Re-grind
• Re-machining
vii. Produce product
sample
viii. Identify product
abnormality
ix. Apply
Countermeasure
x. Perform corrective
action
mould
components
and tools
v. Adhere to
safe handling
technique
Safety:
i. Ensure
personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of
sharp edges
& pinch point
v. Mould set-up
performed
vi. Material
purging
performed
vii. Moulding
machine
parameter
confirmed
viii. Product
sample
produced
ix. Product
abnormality
identified
x. Moulding fault
listed and
parameter
optimised
xi. Counter
measure listed
xii. Corrective
action
performed
xiii. Safety
precaution
applied in
performing
mould try out
5. Inspect
product
sample
i. Type of measuring
instrument
• Vernier calliper
• Micrometer
• Go No Go Gauge
ii. Product Drawing
i. Select type of
measuring instrument
ii. Identify Product
sample dimension
iii. Identify Product
sample profile
Attitude:
i. Resourceful in
acquiring
information
and data
ii. Precise in
Related
Knowledge
4 hours
Related
skills
Related
Knowledge
Lecture
Related skills
Practical
i. Type of
measuring
instrument
listed and
selected
ii. Product sample
82
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
• Dimension
• Profile
• Appearance
iii. Product sample
iv. Product inspection
check sheet
iv. Identify Product
sample appearance
v. Perform Product
sample inspection
vi. Fill up Product
inspection check
sheet
communicating
with internal
staff
iii. Meticulous in
acquiring
information
iv. Exacting
when using
measuring
instrument
8 hours Demonstration identified
dimension
iii. Product sample
profile identified
iv. Product sample
appearance
identified
v. Product sample
inspection
performed
vi. Product
inspection
check sheet
updated
6. Check mould
maintenance
activity
i. Type of maintenance
• Corrective
• preventive
ii. Assembly drawing
• Type of mould
• Type of mould
components
iii. Product drawing
• Product
specification
iv. Product inspection
check sheet
• Product inspection
result
• Mould components
condition
• Mould try –out
result
v. Mould maintenance
check sheet
i. Confirm type of
mould maintenance
ii. Confirm mould to be
maintain
iii. Confirm mould
component defects
iv. Confirm mould
assembly activities
v. Confirm mould try-
out
vi. Confirm product
quality
vii. Update mould
maintenance check
sheet
Attitude:
i. Resourceful in
acquiring
information
and data
ii. Precise in
communicatin
g with internal
staff
iii. Meticulous in
acquiring
information
Related
Knowledge
4 hours
Related
skills
12 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Type of
maintenance
Confirmed
ii. Mould to be
maintain
confirmed
iii. Mould
component
defects listed
iv. Mould
assembly
activities
confirmed
v. Mould try-out
confirmed
vi. Product quality
assured
vii. Mould
maintenance
check sheet
updated
83
Employability Skills
Core Abilities Social Skills
01.07 Utilize database applications to locate and process information
01.08 Utilize spreadsheets applications to locate and process information
01.09 Utilize business graphic application to process information
01.10 Apply a variety of mathematical techniques
01.11 Apply thinking skills and creativity
02.09 Prepare flowcharts
02.10 Prepare reports and instructions
02.11 Convey information and ideas to people
03.09 Manage and improve performance of individuals
03.10 Provide consultation and counselling
03.11 Monitor and evaluate performance of human resources
03.12 Provide coaching/on-the job training
03.13 Develop and maintain team harmony and resolve conflicts
03.14 Facilitate and coordinate teams and ideas
03.15 Liaise to achieve identified outcomes
03.16 Identify and assess client/customer needs
03.17 Identify staff training needs and facilitate access to training
04.06 Allocate work
04.07 Negotiate acceptance and support for objectives and strategies
05.01 Implement project/work plans
05.02 Inspect and monitor work done and/or in progress
06.07 Develop and maintain networks
1. Communication skills
2. Conceptual skills
3. Interpersonal skills
4. Learning skills
5. Leadership skills
6. Multitasking and prioritising
7. Self-discipline
8. Teamwork
84
Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)
1. Job Instruction
2. Maintenance schedule
3. Assembly drawing
4. Injection trouble shooting guidance/chart
5. Hand tools
6. Bunsen burner
7. Measuring instruments
8. Matching agent
9. Mould release agent
10. Plastic resin
11. Plastic injection mould
12. Die spotting machine
13. Plastic injection moulding machine
14. Inspection check sheet
15. Personal Protective Equipment (PPE)
1:1
1:1
1:1
1:1
1:1
1:5
1:25
1:1
As required
As required
1:5
1:25
1:25
1:1
1:1
References
REFERENCES
1. Richard M. Lead, Tool and Die Making Troubleshoot (2002), Society of Manufacturing Engineers, ISBN 978-0-87263-643-9
2. Gunter Mennig (1998), Mould Making Handbook, Hanser / Gardner publication, ISBN 1-56990-261-5
3. Eric V. Buckleitner (1995), Plastics Mold Engineer Handbook, Chapman & Hall, ISBN 0-412098951-4
4. Georg Menges/Paul Mahren (1993), How to make Injection Molds, Hanser Publishers, ISBN 3-446-16305-0
5. Donald V. Rosato/Dominick V. Roasato (1995), Injection Molding Handbook, Chapman & Hall, ISBN 0-412-99381-3
6. E. Lindner and P. Unger (1993), Injection Mold 108 Proven Designs, Hanser Publishers, ISBN 3-446-15682-8
7. Michael L. Berins (1991), Plastics Engineering Handbook, Chapman & Hall, ISBN 0-412-99181-0
85
CURRICULUM of COMPETENCY UNIT (CoCU)
Sub Sector METAL MACHINING TECHNOLOGY
Job Area MOULD & DIE MANUFACTURING
Competency Unit Title MOULD & DIE OPERATIONAL SUPERVISION
Learning Outcome
The person who is competent in mould & die supervision shall be able to supervise of group mould and die making
to carry out assembly, try-out, troubleshooting and maintenance activities in accordance with standard operation
procedure (SOP). Upon completion of this competency unit, trainees will be able to :-
• Carry out daily briefing
• Prepare work schedule
• Carry out job distribution
• Supervise work progress performance
• Conduct section meeting
• Carry out staff coaching
• Control inventory
• Prepare appraisal recommendation
Competency Unit ID CU07 Level 03
Training
Duration
180 Hours Credit Hours 18
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
1. Carry out daily
briefing
i. Job scheduling/job
order
ii. Company’s policy,
rules and
regulation
iii. Daily briefing
objective
iv. Daily briefing
agenda
v. Briefing feedback
i. Interpret Job
scheduling/job order
ii. Comply to
Company’s policy,
rules and regulation
iii. Identify daily briefing
objective
iv. Identify daily briefing
agenda
v. Execute daily
briefing
vi. Record briefing
feedback
Attitude:
Meticulous in
identifying
requirement of jobs
schedule/jobs order
Related
Knowledge
4 hours
Related
skills
8 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Job
scheduling/job
order
Interpreted
ii. Company’s
policy, rules
and regulation
complied
iii. Daily briefing
objective
listed
iv. Daily briefing
agenda listed
86
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
v. Daily briefing
conducted
vi. briefing
feedback
recorded
2. Prepare work
schedule
i. Work scheduling
format
ii. Master schedule
• Type of job
• Delivery date
iii. Type of work process
requirements
iv. Type of resources
• Manpower
• Machine
• Material
• Method
v. Company target
i. Identify schedule
format
ii. Interpret master
schedule
iii. Identify job
requirement
iv. Identify delivery date
v. Identify work process
vi. Identify Resources
availability and
capability
vii. Identify company
target
viii. Plan manpower
availability
ix. Plan machine
capacity
x. Plan material
receiving
xi. Plan mould and die
schedule
xii. Produce mould and
die schedule
xiii. Submit mould and die
schedule to superior
Attitude:
i. Resourceful in
acquiring
information and
data
ii. Precise in
communicating
with internal
staff
iii. Meticulous in
acquiring
information
Related
Knowledge
8 hours
Related
skills
24 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Schedule
format
ii. Master
schedule
interpreted
iii. Job
requirement
identified
iv. Work process
identified
v. Delivery date
identified
vi. Resources
availability
and capability
identified
vii. Company
target
identified
viii. Manpower
availability
planned
ix. Machine
capacity
planned
x. Material
receiving
87
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
planned
xi. Mould and die
planned
schedule
xii. Mould and die
schedule
produced
xiii. Mould and die
schedule
submitted to
superior
3. Carry out job
distribution
i. Job distribution form
ii. Work schedule
• Lead time
• Delivery date
iii. Job distribution
• Manpower
availability
• Machine availability
i. Identify Job
distribution form
ii. Estimate lead time
iii. Confirmed delivery
date
iv. Arrange Manpower
v. Arrange machine
Attitude:
i. Resourceful in
acquiring
information and
data
ii. Precise in
communicating
with internal staff
iii. Meticulous in
acquiring
information
Related
Knowledge
4 hours
Related
skills
8 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Job distribution
form
determined
ii. Work schedule
checked
iii. Lead time
estimated
iv. Job distribution
arranged
v. Manpower and
machine
availability
arranged
4. Supervise work
progress
performance
i. Company
organization chart
ii. Job status
iii. Recovery plan
iv. Work progress
check sheet format
i. Coordinate with
responsibility
personnel
ii. Check work status
iii. Arrange recovery
plan
iv. Update work
progress check
Attitude:
i. Resourceful in
acquiring
information and
data
ii. Precise in
communicating
with internal staff
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Authorised
personnel /
responsibility
personnel /
parties involved
coordinated
ii. Work progress
checked
88
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
sheet
v. Submit work
progress check
sheet
Meticulous in
acquiring
information
iii. Recovery plan
arranged
iv. Work progress
report produced
v. Work progress
report submitted
5. Conduct section
meeting
i. Group meeting
requirement
• Type of meeting
• Meeting objective
• Meeting frequency
• Meeting
documents
• Company’s rule
and regulation
requirement
ii. Group meeting activities
• Meeting Plan
• Meeting Agenda
• Meeting
participants
• Meeting
preparation
• Effective meeting
• Meeting minute
i. Identify group meeting
requirement
ii. Plan group meeting
activities group
iii. Carry out group
meeting
iv. Record meeting
minute
v. Review achievement
of meeting conducted
vi. Compile group
meeting documents
Attitude:
i. Observe
procedure and
condition during
meeting
Responsible and
accountable in
handling meeting
condition
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Group meeting
requirement
Identified
ii. Group meeting
activities
Planned
iii. Group meeting
Carried out
iv. Meeting minute
recorded for
further action
v. Achievement of
meeting
conducted
reviewed
vi. Group meeting
documents
Compiled
6. Carry out staff
coaching
i. Coaching objective
ii. Skills matrix chart
iii. Coaching material
iv. Coaching facilities
v. Coaching module
i. Identify coaching
objective
ii. Interpret skills matrix
chart
iii. Prepare coaching
material
iv. Prepare coaching
Attitude:
i. Responsible
and accountable
in conducting
training
ii. Resourceful in
interpret training
Related
Knowledge
8 hours
Related
skills
24 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Coaching
objective
explained
ii. Staff skills
assessed in
accordance with
skills matrix
89
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
facilities
v. Prepare coaching
module
vi. Perform internal staff
coaching
syllabus/title
Safety:
i. Adhere to safety
requirement
chart
iii. Coaching
materials
prepared
iv. Coaching
facilities
prepared
v. Staff coaching
performed
7. Control inventory i. Company rules &
regulation
• Company policy
ii. Type of item / grouping
• Raw material
• Spare parts
• Standard parts
• Cutting tools
• Hand tools
iii. Type of document
• Receiving form
• Inventory record
form
• Request form
iv. Inventory system
• Storage media
• Location
• Labelling
v. Stocktake
• Stock balance
• Stock requirements
• Stock record form
i. Comply to Company
rules & regulation
ii. Identify type of item
iii. Identify type of
document
iv. Organise inventory
system
v. Organise stocktake
vi. Update stock record
form
Attitude:
i. Resourceful in
acquiring
information and
data
ii. Precise in
communicating
with internal staff
iii. Meticulous in
acquiring
information
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Company rules
& regulation
complied
ii. Type of item
listed
iii. Type of
document
explained
iv. Items stored
v. Stock record
form updated
90
Work Activities Related Knowledge Related Skills
Attitude/Safety/
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
8. Prepare
appraisal
recommendation
i. Personnel appraisal
form format
ii. Subordinate job
description
iii. Personnel appraisal
evaluation criteria
iv. Subordinate
performance
assessment
i. Identify Personnel
appraisal form
format
ii. Identify Subordinate
job description
iii. Identify Personnel
appraisal evaluation
criteria
iv. Assess Subordinate
performance
v. Forward personnel
appraisal form to
superior
Attitude:
i. Responsible in
interpreting
appraisal criteria
Related
Knowledge
8 hours
Related
skills
12 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Personnel
appraisal form
format
Identified
ii. Subordinate
job description
Identified
iii. Personnel
appraisal
evaluation
criteria
Identified
iv. Subordinate
performance
assessed
v. Personnel
appraisal form
to superior
forwarded
91
Employability Skills
Core Abilities Social Skills
01.07 Utilize database applications to locate and process information
01.08 Utilize spreadsheets applications to locate and process information
01.09 Utilize business graphic application to process information
01.10 Apply a variety of mathematical techniques
01.11 Apply thinking skills and creativity
02.09 Prepare flowcharts
02.10 Prepare reports and instructions
02.11 Convey information and ideas to people
03.09 Manage and improve performance of individuals
03.10 Provide consultation and counselling
03.11 Monitor and evaluate performance of human resources
03.12 Provide coaching/on-the job training
03.13 Develop and maintain team harmony and resolve conflicts
03.14 Facilitate and coordinate teams and ideas
03.15 Liaise to achieve identified outcomes
03.16 Identify and assess client/customer needs
03.17 Identify staff training needs and facilitate access to training
04.06 Allocate work
04.07 Negotiate acceptance and support for objectives and strategies
05.01 Implement project/work plans
05.02 Inspect and monitor work done and/or in progress
06.07 Develop and maintain networks
1. Communication skills
2. Conceptual skills
3. Interpersonal skills
4. Learning skills
5. Leadership skills
6. Multitasking and prioritising
7. Self-discipline
8. Teamwork
92
Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)
1. Meeting schedule
2. Minutes of meeting form
3. Computer with software
4. Printer
5. Jobs list
6. Attendant sheet
1:1
1:1
1:1
1:25
1:1
1:25
References
REFERENCES
1. Lihui Wang (2007), Process Planning and Schedulling for Distributed Manufacturing, Springer, ISBN: 978-1-84-628751-0
2. L.N. Lopez De Lacalle (2007), Machine Tools for High Performance Machining, Springer, ISBN:978-1-848-00379-8
3. Alan Dalton (1998), Safety, Health and Environmental Hazards at the Workplace, Cengage Learning, ISBN:978-0-30-433291-5
4. Dan Hopwood, Steve Thompson(2006), Workplace safety a guide for small and midsized companies, John Wiley & Sons Inc., ISBN:978-0-7821-
3604-3
93
CURRICULUM OF COMPETENCY UNIT (CoCU)
Sub Sector METAL MACHINING TECHNOLOGY
Job Area MOULD & DIE MANUFACTURING
Competency Unit Title CNC MILLING MACHINE OPERATION
Learning Outcome
The person who is competent in this CU shall be able to provide excellent CNC Milling Machine Operation to ensure
the product requirement accepted in accordance to drawing specification. Upon completion of this competency unit,
trainees will be able to :-
• Interpret detail drawing
• Select CNC milling machine
• Setup work piece
• Retrieve CNC program
• Setup cutting tool
• Execute CNC milling machine operation
• Inspect finished product
• Submit finished product with recorded data to superior
Competency Unit ID CU08 Level 03
Training
Duration
180 Hours
Credit
Hours
18
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
1. Interpret detail
drawing
i. Detail Drawing
ii. Drawing symbols
iii. Dimensions
iv. Tolerances
v. Drawing projection
vi. Type of machining
process
i. Obtain detail drawing
i. Identify Drawing
symbols
ii. Identify Dimensions
and Tolerances
iii. Determine Drawing
projection
iv. Identify Type of
machining process
Attitude:
i. Resourceful in
interpreting
drawing
ii. Observe
cleanliness
during handling
drawing
document
Related
Knowledge
2 hours
Related
skills
4 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Drawing
symbols
Identified
ii. Dimensions
and
Tolerances
Identified
iii. Drawing
projection
Determined
iv. Type of
machining
process
Identified
94
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
2. Select CNC
milling
machine
i. Types of CNC milling
machine
ii. CNC milling machine
specification
iii. type of CNC milling
machine accessories
iv. CNC milling machine
and accessories to be
used
i. Identify types of
CNC milling
machine
ii. Identify CNC milling
machine
specification
iii. Identify type of
CNC milling
machine
accessories
iv. Confirm CNC
milling machine and
accessories to be
used
Safety:
1. Adhere to safety
requirement
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Types of
CNC milling
machine
identified
ii. CNC milling
machine
specification
Identified
iii. Types of
accessories
identified
iv. CNC milling
machine and
accessories
to be used
confirmed
3. Setup work piece i. work holding device
ii. work piece orientation
iii. work piece alignment
• Flatness
• Squareness /
parallelism
iv. Work piece ready to be
machine
i. Identify work holding
device
ii. Confirm workpiece
orientation
iii. Carryout workpiece
alignment
iv. Confirm workpiece
ready to be machine
Attitude:
i. Careful when
handling hand
tools
Related
Knowledge
4 hours
Related
skills
8 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
i. Work holding
device
Identified
ii. Workpiece
orientation
confirmed
iii. Workpiece
alignment
carried out
iv. Workpiece
ready to be
machine
Confirmed
95
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
4. Retrieve CNC
program
i. Program number
ii. Types of machine
controller
iii. Machine language
iv. CNC program
editing
i. Indentify program
number
ii. Identify types of
machine controller
iii. Identify machine
language
iv. Check CNC
program
v. Carry out CNC
program editing
Attitude:
i. Responsible
and quick
response in
receiving
instruction
Safety:
i. Adhere to safety
requirement
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
&
Observation
i. CNC program
number
identified
ii. Types of
machine
controller
Identified
iii. Machine
language
Identified
iv. CNC program
checked
v. CNC program
editing carried
out
5. Setup cutting
tool
i. Number of tool
ii. Tool magazine
iii. Tool register
iv. Type of tool holder
v. Tool parameter setting
vi. Reference point
(datum)
vii. Checking instruments
such as:
• Edge finder
• probe
• tool setter
viii. Mount cutting tool
i. Identify number of
tool
ii. Identify tool magazine
iii. Confirm tool register
iv. Confirm type of tool
holder
v. Perform tool
parameter setting
vi. Set reference point
(datum)
vii. Apply checking
instruments such as:
• Edge finder
• Probe
• Tool setter
viii. Fix cutting tool secure
Attitude:
i. Careful when
handling cutting
tools
Safety:
i. Ensure personal
protective
equipment (PPE)
meet Safety
Regulation &
Standard
ii. Beware of sharp
edges
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
&
Observation
i. Number of
tool identified
ii. Tool
magazine
identified
iii. Tool register
confirmed
iv. Type of tool
holder
confirmed
v. Tool
parameter
setting
performed
vi. Reference
point (datum)
confirmed
96
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
vii. Checking
instruments
such as
applied
viii. Cutting tool fix
secured
6. Execute CNC
milling machine
operation
v. CNC milling Program
vi. CNC milling Machine
parameter
• Spindle speed (RPM)
• Tool offset
• Feed rate
vii. CNC milling process
• Drilling
• Reaming
• tapping
• counter bore/ sunk/
chamfering
• Boring
• Face milling
• Side milling
• Slotting
• Pocketing
• 2D profile
• 3D profile
viii. Product specification
ix. In-process CNC milling
operation checking
i. Confirm CNC milling
program
ii. Confirm CNC milling
Machine parameter
iii. Perform CNC milling
process
• Drilling
• Reaming
• tapping
• counter bore/
sunk/ chamfering
• Boring
• Face milling
• Side milling
• Slotting
• Pocketing
• 2D profile
• 3D profile
iv. Identify product
specification
v. In-process milling
operation checking
Related
Knowledge
18 hours
Related
skills
64 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
&
Observation
i. CNC milling
program
confirmed
ii. CNC milling
Machine
parameter
confirmed
iii. CNC milling
process
Performed
iv. product
specification
Identified
v. In-process
milling
operation
checked
97
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
7. Inspect
finished
product
i. Product dimension
ii. Surface finish
iii. Product appearance
iv. Measuring equipment
v. Company’s organization
chart.
vi. Product inspection
check sheet
i. Check product
dimension
ii. Check surface finish
iii. Check product
appearance
iv. utilize Measuring
equipment
v. Identify responsible
personnel
vi. Update Product
inspection check
sheet
vii. Forward product
with recorded data
to superior
Attitude:
i. Resourceful in
interpreting
drawing
ii. Observe
cleanliness
during handling
drawing
document
Related
Knowledge
2 hours
Related
skills
6 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
&
Observation
i. Product
dimension
Checked
ii. Surface finish
Checked
iii. Product
appearance
Checked
iv. Measuring
equipment
utilized
v. Responsible
personnel
Identified
vi. Product
inspection
check sheet
update
vii. Product with
recording data
to superior
forwarded
98
Employability Skills
Core Abilities Social Skills
01.07 Utilize database applications to locate and process information
01.08 Utilize spreadsheets applications to locate and process information
01.09 Utilize business graphic application to process information
01.10 Apply a variety of mathematical techniques
01.11 Apply thinking skills and creativity
02.09 Prepare flowcharts
02.10 Prepare reports and instructions
02.11 Convey information and ideas to people
03.09 Manage and improve performance of individuals
03.10 Provide consultation and counselling
03.11 Monitor and evaluate performance of human resources
03.12 Provide coaching/on-the job training
03.13 Develop and maintain team harmony and resolve conflicts
03.14 Facilitate and coordinate teams and ideas
03.15 Liaise to achieve identified outcomes
03.16 Identify and assess client/customer needs
03.17 Identify staff training needs and facilitate access to training
04.06 Allocate work
04.07 Negotiate acceptance and support for objectives and strategies
05.01 Implement project/work plans
05.02 Inspect and monitor work done and/or in progress
06.07 Develop and maintain networks
1. Communication skills
2. Conceptual skills
3. Interpersonal skills
4. Learning skills
5. Leadership skills
6. Multitasking and prioritizing
7. Self-discipline
8. Teamwork
99
Tools, Equipment and Materials (TEM)
ITEMS RATIO (TEM : Trainees)
1. Measuring instruments
2. Instrument cabinet
3. Instrument accessories
4. Instrument charts and posters
5. Technical drawing
6. Workpiece
7. Check sheet
8. Flipchart
9. Surface table
10. Personal Protective Equipment (PPE)
11. CNC Milling machine
12. Milling tool
13. Tool box
14. Hand tool
1:10
1:25
1:25
1:25
1:1
1:1
1:1
1:5
1:5
1:1
1:5
1:5
1:1
1:25
REFERENCES
1. W. Chapman (1972), Workshop Technology Part 2, Fourth Edition, Butterworth-Heinemann, ISBN: 978-0-71-313272-4
2. Karl Moltrecht (1981), Machine Shop Practice, Industrial Press, Inc., ISBN: 978-0-83-111126-7
3. David L. Goetsch, John Nelson (2004), Technical Drawing, Cengage Learning, ISBN: 978-1-40-185760-8
4. Peter Smid(2003), CNC Programming Handbook, Industrial Press, Inc., ISBN: 978-0-83-11358-6
5. Peter Smid (2010), CNC Setup and Operation Milling-Turning, Industrial Press, Inc., ISBN: 978-0-83-113350-4
6. Ibrahim Zeid (1991), CAD/CAM Theory and Practice, McGraw-Hill, ISBN: 0-07-112901-4
100
CURRICULUM OF COMPETENCY UNIT (CoCU)
Sub Sector METAL MACHINING TECHNOLOGY
Job Area MOULD & DIE MANUFACTURING
Competency Unit Title CNC ELECTRICAL DISCHARGE MACHINE (EDM) DIE SINKING OPERATION
Learning Outcome
The person who is competent in this CU shall be able to provide excellent CNC ELECTRICAL DISCHARGE
MACHINE (EDM) Die Sinking Operation to ensure the product requirement accepted in accordance to drawing
specification. Upon completion of this competency unit, trainees will be able to :-
• Interpret detail drawing.
• Select CNC EDM Die Sinking machine
• Set up EDM electrode
• Set up work piece.
• Generate CNC Program Die Sinking
• Execute CNC EDM Die Sinking operation.
• Inspect finished product.
• Submit finished product with recording data to superior
Competency Unit ID CU09 Level 3
Training
Duration
150 Hours
Credit
Hours
15
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
1. Interpret detail
drawing
i. Detail Drawing
ii. Drawing symbols
iii. Dimensions
iv. Tolerances
v. Drawing projection
vi. Type of EDM process
i. Obtain detail
drawing
ii. Identify Drawing
symbols
iii. Identify Dimensions
and Tolerances
iv. Determine Drawing
projection
v. Identify Type of
EDM process
Attitude:
i. Resourceful in
interpreting
drawing
ii. Observe
cleanliness
during handling
drawing
document
Related
Knowledge
2 hours
Related
skills
4 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
&
Observation
i. Detail drawing
obtained
ii. Drawing
symbols
identified
iii. Dimensions
and
tolerances
identified
iv. Drawing
projection
determined
v. Type of EDM
101
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
process
identified
2. Select CNC
EDM Die
Sinking
machine
i. Type of machine
controller
ii. Types of EDM die
sinking machine
iii. Types of accessories
• Tool and work
holding devices
• Dielectric fluid
i. Identify type of
machine controller
ii. Identify types of
EDM die sinking
machine
iii. Identify type of
accessories
iv. Identify Dielectric
fluid
v. Decide CNC EDM
die sinking machine
and specification to
be used
Safety:
i. Adhere to safety
requirement
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
&
Observation
i. Type of
machine
controller
identified
ii. Types of EDM
die sinking
machine
identified.
iii. Types of
accessories
identified
iv. Dielectric fluid
v. CNC EDM die
sinking
machine and
specification
to be used
decided
3. Set up EDM
electrode
i. EDM electrodes
ii. EDM electrode holder
iii. Type of electrode
material
iv. Spark gap
v. EDM electrode fixing
vi. techniques
vii. Number of electrode
viii. Orientation of
electrode
ix. Alignment electrode
i. Select EDM
electrodes
ii. Select EDM electrode
holder
iii. Identify type of
electrode material
iv. identify spark gap
v. Identify EDM
electrode fixing
techniques
vi. Determine number of
electrode
Attitude:
i. Careful when
handling
electrode
Safety:
i. Ensure personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
Related
Knowledge
4 hours
Related
skills
8 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
&
Observation
i. EDM
electrodes
selected
ii. EDM
electrode
holder
selected
iii. Type of
electrode
material
identified
iv. Spark gap
102
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
x. Flatness of electrode
xi. Reference point
(datum) of electrode
vii. Decide orientation of
electrode
viii. Check alignment
electrode
ix. Check flatness of
electrode
x. Decide reference
point (datum) of
electrode
ii. Beware of sharp
edges
identified
v. EDM
electrode
fixing
techniques
identified
vi. number of
electrode
determined
vii. Orientation of
electrode
decided
viii. Alignment
electrode
checked
ix. Flatness of
electrode
checked
x. Reference
point (datum)
of electrode
decided
4. Set up work
piece.
i. Type of material
ii. Size of material
iii. Shape of material
iv. Clamping device
v. Work pieces orientation
vi. Hand tools
vii. Alignment work piece
viii. Flatness of work piece
i. Identify type of
material
ii. Identify size of
material
iii. Identify shape of
material
iv. Identify Clamping
device
Attitude:
i. Careful when
handling hand
tools
Safety:
i. Ensure personal
protective
equipment
(PPE) meet
Related
Knowledge
4 hours
Related
skills
8 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
&
Observation
i. Type of
material
identified
ii. Size of
material
identified
iii. Shape of
material
103
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
ix. Datum of work piece v. Decide work
pieces orientation
vi. Identify hand tools
vii. Check alignment
work piece
viii. Check flatness of
work piece
ix. Decide datum of
work piece
Safety
Regulation &
Standard
ii. Beware of sharp
edges
identified
iv. Clamping
device
identified
v. Work pieces
orientation
decided
vi. Hand tools
identified
vii. Alignment
work piece
checked
viii. Flatness of
work piece
checked
ix. Datum of
work piece
decided
5. Generate CNC
Program Die
Sinking
i. Types of machine
controller
ii. Machine language
iii. CNC EDM die
sinking Programming
• Simulation
• dry run
i. Identify types of
machine controller
ii. Identify machine
language
iii. Create CNC EDM
die sinking
Program
iv. Check CNC die
sinking program:
v. Confirm program
number
vi. Store CNC
program
Attitude:
i. Responsible
and quick
response in
receiving
instruction
Safety:
i. Adhere to safety
requirement
Related
Knowledge
8 hours
Related
skills
16 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
&
Observation
i. Types of
machine
controller
Identified
ii. Machine
language
Identified
iii. CNC EDM die
sinking
Program
created
iv. CNC die
sinking
104
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
program
checked
v. Program
number
Confirmed
vi. CNC program
Stored
6. Execute CNC
EDM Die
Sinking
operation
i. Programming code
ii. Reference point
iii. CNC EDM die sinking
iv. Surface finish
v. Product specification
vi. Safety precaution
i. Confirm
programming number
ii. Confirm reference
point/ datum
iii. Perform CNC EDM
die sinking
iv. Check surface finish
v. Identify product
specification
Attitude:
i. Meticulous in
interpreting
drawing
ii. Exacting when
using
measuring
instrument
iii. Alert to
electrical supply
iv. Attentive in
handling
workpiece and
tools
Safety:
i. Ensure personal
protective
equipment
(PPE) meet
Safety
Regulation &
Standard
ii. Beware of sharp
edges
Related
Knowledge
16 hours
Related
skills
48 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
& Individual
project
i. Programming
code
confirmed
ii. Reference
point
confirmed
iii. CNC EDM die
sinking
performed
iv. Surface finish
checked
v. Product
specification
identified
vi. Safety
precaution
applied
105
Work Activities Related Knowledge Related Skills
Attitude / Safety /
Environmental
Training
Hours
Delivery
Mode
Assessment
Criteria
7. Inspect
finished
product.
i. Product dimension
ii. Surface finish
iii. Perpendicular
iv. Product appearance
v. Check sheet
vi. Measuring equipment
vii. Company’s organization
chart.
viii. Product inspection
check sheet
i. Identify product
dimension
ii. Check surface
finish
iii. Check
perpendicular
iv. Check product
appearance
v. Fill up check sheet
vi. Utilize measuring
equipment
vii. Identify
responsible
personnel
viii. Update Product
inspection check
sheet
ix. Forward product
with recording
data to
responsible
personnel
Attitude:
i. Resourceful in
interpreting
drawing
ii. Observe
cleanliness
during handling
drawing
document
Related
Knowledge
2 hours
Related
skills
6 hours
Related
Knowledge
Lecture
Related skills
Practical
Demonstration
&
Individual
project
i. Product
dimension
identified
ii. surface finish
checked
iii. Perpendicular
checked
iv. Product
appearance
checked
v. Check sheet
filled
vi. Measuring
equipment
utilized
vii. Responsible
personnel
identified
viii. Product
inspection
check sheet
updated
ix. Product with
recording data
to superior
forwarded
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013
Co cu mould and die -lulus-24julai2013

More Related Content

Similar to Co cu mould and die -lulus-24julai2013

The ROI of Improved Injection Molding Process Flow
The ROI of Improved Injection Molding Process FlowThe ROI of Improved Injection Molding Process Flow
The ROI of Improved Injection Molding Process Flow
Kaysun Corporation
 
resume
resumeresume
CV2015 Linkedin
CV2015 LinkedinCV2015 Linkedin
CV2015 Linkedin
Michael Andresen
 
The ROI of Improved Project Flow: How Injection Molders Impact Outcomes
The ROI of Improved Project Flow: How Injection Molders Impact OutcomesThe ROI of Improved Project Flow: How Injection Molders Impact Outcomes
The ROI of Improved Project Flow: How Injection Molders Impact Outcomes
Kaysun Corporation
 
UNIT 1 PPT.pptx
UNIT 1 PPT.pptxUNIT 1 PPT.pptx
UNIT 1 PPT.pptx
Sengolrajan
 
Practical Assessment_Full set of stairs with handrail.pdf
Practical Assessment_Full set of stairs with handrail.pdfPractical Assessment_Full set of stairs with handrail.pdf
Practical Assessment_Full set of stairs with handrail.pdf
Canberra Institute of technology
 
Biw fixture
Biw fixtureBiw fixture
Biw fixture
Jayesh Sarode
 
L1.01.01.02
L1.01.01.02L1.01.01.02
L1.01.01.02
Azahar Abdullah
 
Mahesha HG 3.3 year experience in Mechanical Designing
Mahesha HG 3.3 year experience in Mechanical DesigningMahesha HG 3.3 year experience in Mechanical Designing
Mahesha HG 3.3 year experience in Mechanical Designing
mahesh mahesh hg
 
K to 12 TLE Curriculum Guide for Tile Setting
K to 12 TLE Curriculum Guide for Tile SettingK to 12 TLE Curriculum Guide for Tile Setting
K to 12 TLE Curriculum Guide for Tile Setting
Dr. Joy Kenneth Sala Biasong
 
1 a. Introduction design of machine element
1 a. Introduction   design of machine element1 a. Introduction   design of machine element
1 a. Introduction design of machine element
Dr.R. SELVAM
 
Workshop theory and_practice
Workshop theory and_practiceWorkshop theory and_practice
Workshop theory and_practice
physics101
 
Cbc shielded metal arc welding nc ii
Cbc   shielded metal arc welding nc iiCbc   shielded metal arc welding nc ii
Cbc shielded metal arc welding nc ii
Lennard Charles
 
Importance of standards
Importance of standardsImportance of standards
Importance of standards
Gulfam Hussain
 
ESD, BIS, IPC A610 Hzssasdads a sda fa fa fa fa fa f fa (1).pptx
ESD, BIS, IPC A610 Hzssasdads a sda fa fa fa fa fa f fa (1).pptxESD, BIS, IPC A610 Hzssasdads a sda fa fa fa fa fa f fa (1).pptx
ESD, BIS, IPC A610 Hzssasdads a sda fa fa fa fa fa f fa (1).pptx
sonukumar170894
 
Specification writing
Specification writingSpecification writing
Specification writing
BSRIA
 
Practical assessment 3 - Install horizontal and vertical sheet panels
Practical assessment 3 - Install horizontal and vertical sheet panels Practical assessment 3 - Install horizontal and vertical sheet panels
Practical assessment 3 - Install horizontal and vertical sheet panels
Canberra Institute of technology
 
What’s Standard? Industry Application versus University Education of Engineer...
What’s Standard? Industry Application versus University Education of Engineer...What’s Standard? Industry Application versus University Education of Engineer...
What’s Standard? Industry Application versus University Education of Engineer...
Chelsea Leachman
 
Product Design Process
Product Design ProcessProduct Design Process
Product Design Process
Istiaque Reza
 
Computer hardware servicing ncii
Computer hardware servicing nciiComputer hardware servicing ncii
Computer hardware servicing ncii
Marsha Superio
 

Similar to Co cu mould and die -lulus-24julai2013 (20)

The ROI of Improved Injection Molding Process Flow
The ROI of Improved Injection Molding Process FlowThe ROI of Improved Injection Molding Process Flow
The ROI of Improved Injection Molding Process Flow
 
resume
resumeresume
resume
 
CV2015 Linkedin
CV2015 LinkedinCV2015 Linkedin
CV2015 Linkedin
 
The ROI of Improved Project Flow: How Injection Molders Impact Outcomes
The ROI of Improved Project Flow: How Injection Molders Impact OutcomesThe ROI of Improved Project Flow: How Injection Molders Impact Outcomes
The ROI of Improved Project Flow: How Injection Molders Impact Outcomes
 
UNIT 1 PPT.pptx
UNIT 1 PPT.pptxUNIT 1 PPT.pptx
UNIT 1 PPT.pptx
 
Practical Assessment_Full set of stairs with handrail.pdf
Practical Assessment_Full set of stairs with handrail.pdfPractical Assessment_Full set of stairs with handrail.pdf
Practical Assessment_Full set of stairs with handrail.pdf
 
Biw fixture
Biw fixtureBiw fixture
Biw fixture
 
L1.01.01.02
L1.01.01.02L1.01.01.02
L1.01.01.02
 
Mahesha HG 3.3 year experience in Mechanical Designing
Mahesha HG 3.3 year experience in Mechanical DesigningMahesha HG 3.3 year experience in Mechanical Designing
Mahesha HG 3.3 year experience in Mechanical Designing
 
K to 12 TLE Curriculum Guide for Tile Setting
K to 12 TLE Curriculum Guide for Tile SettingK to 12 TLE Curriculum Guide for Tile Setting
K to 12 TLE Curriculum Guide for Tile Setting
 
1 a. Introduction design of machine element
1 a. Introduction   design of machine element1 a. Introduction   design of machine element
1 a. Introduction design of machine element
 
Workshop theory and_practice
Workshop theory and_practiceWorkshop theory and_practice
Workshop theory and_practice
 
Cbc shielded metal arc welding nc ii
Cbc   shielded metal arc welding nc iiCbc   shielded metal arc welding nc ii
Cbc shielded metal arc welding nc ii
 
Importance of standards
Importance of standardsImportance of standards
Importance of standards
 
ESD, BIS, IPC A610 Hzssasdads a sda fa fa fa fa fa f fa (1).pptx
ESD, BIS, IPC A610 Hzssasdads a sda fa fa fa fa fa f fa (1).pptxESD, BIS, IPC A610 Hzssasdads a sda fa fa fa fa fa f fa (1).pptx
ESD, BIS, IPC A610 Hzssasdads a sda fa fa fa fa fa f fa (1).pptx
 
Specification writing
Specification writingSpecification writing
Specification writing
 
Practical assessment 3 - Install horizontal and vertical sheet panels
Practical assessment 3 - Install horizontal and vertical sheet panels Practical assessment 3 - Install horizontal and vertical sheet panels
Practical assessment 3 - Install horizontal and vertical sheet panels
 
What’s Standard? Industry Application versus University Education of Engineer...
What’s Standard? Industry Application versus University Education of Engineer...What’s Standard? Industry Application versus University Education of Engineer...
What’s Standard? Industry Application versus University Education of Engineer...
 
Product Design Process
Product Design ProcessProduct Design Process
Product Design Process
 
Computer hardware servicing ncii
Computer hardware servicing nciiComputer hardware servicing ncii
Computer hardware servicing ncii
 

Recently uploaded

Modified O-RAN 5G Edge Reference Architecture using RNN
Modified O-RAN 5G Edge Reference Architecture using RNNModified O-RAN 5G Edge Reference Architecture using RNN
Modified O-RAN 5G Edge Reference Architecture using RNN
ijwmn
 
Agricultural Profitability through Resilience: Smallholder Farmers' Strategie...
Agricultural Profitability through Resilience: Smallholder Farmers' Strategie...Agricultural Profitability through Resilience: Smallholder Farmers' Strategie...
Agricultural Profitability through Resilience: Smallholder Farmers' Strategie...
IJAEMSJORNAL
 
ECONOMIC FEASIBILITY AND ENVIRONMENTAL IMPLICATIONS OF PERMEABLE PAVEMENT IN ...
ECONOMIC FEASIBILITY AND ENVIRONMENTAL IMPLICATIONS OF PERMEABLE PAVEMENT IN ...ECONOMIC FEASIBILITY AND ENVIRONMENTAL IMPLICATIONS OF PERMEABLE PAVEMENT IN ...
ECONOMIC FEASIBILITY AND ENVIRONMENTAL IMPLICATIONS OF PERMEABLE PAVEMENT IN ...
Fady M. A Hassouna
 
Chapter 1 Introduction to Software Engineering and Process Models.pdf
Chapter 1 Introduction to Software Engineering and Process Models.pdfChapter 1 Introduction to Software Engineering and Process Models.pdf
Chapter 1 Introduction to Software Engineering and Process Models.pdf
MeghaGupta952452
 
EAAP2023 : Durabilité et services écosystémiques de l'élevage ovin de montagne
EAAP2023 : Durabilité et services écosystémiques de l'élevage ovin de montagneEAAP2023 : Durabilité et services écosystémiques de l'élevage ovin de montagne
EAAP2023 : Durabilité et services écosystémiques de l'élevage ovin de montagne
idelewebmestre
 
Kerong Gas Gas Recovery System Catalogue.pdf
Kerong Gas Gas Recovery System Catalogue.pdfKerong Gas Gas Recovery System Catalogue.pdf
Kerong Gas Gas Recovery System Catalogue.pdf
Nicky Xiong熊妮
 
Human_assault project using jetson nano new
Human_assault project using jetson nano newHuman_assault project using jetson nano new
Human_assault project using jetson nano new
frostflash010
 
Red Hat Enterprise Linux Administration 9.0 RH134 pdf
Red Hat Enterprise Linux Administration 9.0 RH134 pdfRed Hat Enterprise Linux Administration 9.0 RH134 pdf
Red Hat Enterprise Linux Administration 9.0 RH134 pdf
mdfkobir
 
Fix Production Bugs Quickly - The Power of Structured Logging in Ruby on Rail...
Fix Production Bugs Quickly - The Power of Structured Logging in Ruby on Rail...Fix Production Bugs Quickly - The Power of Structured Logging in Ruby on Rail...
Fix Production Bugs Quickly - The Power of Structured Logging in Ruby on Rail...
John Gallagher
 
If we're running two pumps, why aren't we getting twice as much flow? v.17
If we're running two pumps, why aren't we getting twice as much flow? v.17If we're running two pumps, why aren't we getting twice as much flow? v.17
If we're running two pumps, why aren't we getting twice as much flow? v.17
Brian Gongol
 
System Analysis and Design in a changing world 5th edition
System Analysis and Design in a changing world 5th editionSystem Analysis and Design in a changing world 5th edition
System Analysis and Design in a changing world 5th edition
mnassar75g
 
Generative AI and Large Language Models (LLMs)
Generative AI and Large Language Models (LLMs)Generative AI and Large Language Models (LLMs)
Generative AI and Large Language Models (LLMs)
rkpv2002
 
carpentry-11-module-1.docx 1 identifying tools
carpentry-11-module-1.docx 1 identifying toolscarpentry-11-module-1.docx 1 identifying tools
carpentry-11-module-1.docx 1 identifying tools
ChristopherAltizen2
 
NOVEC 1230 Fire Suppression System Presentation
NOVEC 1230 Fire Suppression System PresentationNOVEC 1230 Fire Suppression System Presentation
NOVEC 1230 Fire Suppression System Presentation
miniruwan1
 
DPWH - DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS
DPWH - DEPARTMENT OF PUBLIC WORKS AND HIGHWAYSDPWH - DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS
DPWH - DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS
RyanMacayan
 
Ebara corporation introduction. looking ahead, going beyond expectation
Ebara corporation introduction. looking ahead, going beyond expectationEbara corporation introduction. looking ahead, going beyond expectation
Ebara corporation introduction. looking ahead, going beyond expectation
nanjay2
 
Indian Railway Signalling concepts and basics.pdf
Indian Railway Signalling concepts and basics.pdfIndian Railway Signalling concepts and basics.pdf
Indian Railway Signalling concepts and basics.pdf
princeshah76
 
charting the development of the autonomous train
charting the development of the autonomous traincharting the development of the autonomous train
charting the development of the autonomous train
huseindihon
 
Machine Learning- Perceptron_Backpropogation_Module 3.pdf
Machine Learning- Perceptron_Backpropogation_Module 3.pdfMachine Learning- Perceptron_Backpropogation_Module 3.pdf
Machine Learning- Perceptron_Backpropogation_Module 3.pdf
Dr. Shivashankar
 
OME754 – INDUSTRIAL SAFETY - unit notes.pptx
OME754 – INDUSTRIAL SAFETY - unit notes.pptxOME754 – INDUSTRIAL SAFETY - unit notes.pptx
OME754 – INDUSTRIAL SAFETY - unit notes.pptx
shanmugamram247
 

Recently uploaded (20)

Modified O-RAN 5G Edge Reference Architecture using RNN
Modified O-RAN 5G Edge Reference Architecture using RNNModified O-RAN 5G Edge Reference Architecture using RNN
Modified O-RAN 5G Edge Reference Architecture using RNN
 
Agricultural Profitability through Resilience: Smallholder Farmers' Strategie...
Agricultural Profitability through Resilience: Smallholder Farmers' Strategie...Agricultural Profitability through Resilience: Smallholder Farmers' Strategie...
Agricultural Profitability through Resilience: Smallholder Farmers' Strategie...
 
ECONOMIC FEASIBILITY AND ENVIRONMENTAL IMPLICATIONS OF PERMEABLE PAVEMENT IN ...
ECONOMIC FEASIBILITY AND ENVIRONMENTAL IMPLICATIONS OF PERMEABLE PAVEMENT IN ...ECONOMIC FEASIBILITY AND ENVIRONMENTAL IMPLICATIONS OF PERMEABLE PAVEMENT IN ...
ECONOMIC FEASIBILITY AND ENVIRONMENTAL IMPLICATIONS OF PERMEABLE PAVEMENT IN ...
 
Chapter 1 Introduction to Software Engineering and Process Models.pdf
Chapter 1 Introduction to Software Engineering and Process Models.pdfChapter 1 Introduction to Software Engineering and Process Models.pdf
Chapter 1 Introduction to Software Engineering and Process Models.pdf
 
EAAP2023 : Durabilité et services écosystémiques de l'élevage ovin de montagne
EAAP2023 : Durabilité et services écosystémiques de l'élevage ovin de montagneEAAP2023 : Durabilité et services écosystémiques de l'élevage ovin de montagne
EAAP2023 : Durabilité et services écosystémiques de l'élevage ovin de montagne
 
Kerong Gas Gas Recovery System Catalogue.pdf
Kerong Gas Gas Recovery System Catalogue.pdfKerong Gas Gas Recovery System Catalogue.pdf
Kerong Gas Gas Recovery System Catalogue.pdf
 
Human_assault project using jetson nano new
Human_assault project using jetson nano newHuman_assault project using jetson nano new
Human_assault project using jetson nano new
 
Red Hat Enterprise Linux Administration 9.0 RH134 pdf
Red Hat Enterprise Linux Administration 9.0 RH134 pdfRed Hat Enterprise Linux Administration 9.0 RH134 pdf
Red Hat Enterprise Linux Administration 9.0 RH134 pdf
 
Fix Production Bugs Quickly - The Power of Structured Logging in Ruby on Rail...
Fix Production Bugs Quickly - The Power of Structured Logging in Ruby on Rail...Fix Production Bugs Quickly - The Power of Structured Logging in Ruby on Rail...
Fix Production Bugs Quickly - The Power of Structured Logging in Ruby on Rail...
 
If we're running two pumps, why aren't we getting twice as much flow? v.17
If we're running two pumps, why aren't we getting twice as much flow? v.17If we're running two pumps, why aren't we getting twice as much flow? v.17
If we're running two pumps, why aren't we getting twice as much flow? v.17
 
System Analysis and Design in a changing world 5th edition
System Analysis and Design in a changing world 5th editionSystem Analysis and Design in a changing world 5th edition
System Analysis and Design in a changing world 5th edition
 
Generative AI and Large Language Models (LLMs)
Generative AI and Large Language Models (LLMs)Generative AI and Large Language Models (LLMs)
Generative AI and Large Language Models (LLMs)
 
carpentry-11-module-1.docx 1 identifying tools
carpentry-11-module-1.docx 1 identifying toolscarpentry-11-module-1.docx 1 identifying tools
carpentry-11-module-1.docx 1 identifying tools
 
NOVEC 1230 Fire Suppression System Presentation
NOVEC 1230 Fire Suppression System PresentationNOVEC 1230 Fire Suppression System Presentation
NOVEC 1230 Fire Suppression System Presentation
 
DPWH - DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS
DPWH - DEPARTMENT OF PUBLIC WORKS AND HIGHWAYSDPWH - DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS
DPWH - DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS
 
Ebara corporation introduction. looking ahead, going beyond expectation
Ebara corporation introduction. looking ahead, going beyond expectationEbara corporation introduction. looking ahead, going beyond expectation
Ebara corporation introduction. looking ahead, going beyond expectation
 
Indian Railway Signalling concepts and basics.pdf
Indian Railway Signalling concepts and basics.pdfIndian Railway Signalling concepts and basics.pdf
Indian Railway Signalling concepts and basics.pdf
 
charting the development of the autonomous train
charting the development of the autonomous traincharting the development of the autonomous train
charting the development of the autonomous train
 
Machine Learning- Perceptron_Backpropogation_Module 3.pdf
Machine Learning- Perceptron_Backpropogation_Module 3.pdfMachine Learning- Perceptron_Backpropogation_Module 3.pdf
Machine Learning- Perceptron_Backpropogation_Module 3.pdf
 
OME754 – INDUSTRIAL SAFETY - unit notes.pptx
OME754 – INDUSTRIAL SAFETY - unit notes.pptxOME754 – INDUSTRIAL SAFETY - unit notes.pptx
OME754 – INDUSTRIAL SAFETY - unit notes.pptx
 

Co cu mould and die -lulus-24julai2013

  • 1. 36 CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector METAL MACHINING TECHNOLOGY Job Area MOULD & DIE MANUFACTURING Competency Unit Title STAMPING DIE ASSEMBLING Learning Outcome The person who is competent in stamping die assembling shall be able to assemble stamping die components based on assembly drawing to produce a complete and functional stamping die for the mass production of high quality and standardised products. Upon completion of this competency unit, trainees will be able to :- • Prepare die assembly requirements • Perform die assembling • Perform die alignment • Check die assembling Competency Unit ID CU01 Level 03 Training Duration 180 hours Credit Hours 18 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 1. Prepare die assembly requirements i. Content of job instruction • Job description Type of process by sequences • Lead time (delivery date) • Company rules & regulation Company policy ii. Die assembly drawing • Stamping die concept • Types of die i. Interpret job instruction ii. Interpret die assembly drawing iii. Select measuring instrument iv. Select die assembly tools Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff iii. Meticulous in acquiring information iv. Meticulous in interpreting drawing Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Job description interpreted ii. Delivery date identified iii. Company rules & regulation complied iv. Die concepts explained v. Die components name and quantity listed vi. Fitting tolerance, surface finish and drawing
  • 2. 37 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria Components names and quantity • Fitting tolerance • Surface finish • Drawing symbols iii. Measuring instrument iv. Type of tools • Allen key • Copper mallet symbols identified and explained vii. Measuring instrument functionality explained viii.Measuring instrument selected ix. Type of tools identified, listed and selected 2. Perform die assembling i. Types of die • Single die • Compound die • Progressive die • Hot stamping die ii. Types of stamping processes such as • Blanking • Piercing • Bending iii. Die components • Components name • Components function • Components material • Components dimension i. Select types of die ii. Select types of stamping processes iii. Identify type of die components iv. Check components dimension v. Identify types of die component material vi. Identify die references (datum) vii. Apply die fitting technique by sequence viii. Assemble upper die components ix. Assemble lower die components Attitude: i. Exacting when using measuring instrument ii. Alert to electrical supply iii. Attentive in handling die components and tools iv. Adhere to safe handling technique Safety: i. Ensure personal Related Knowledge 28 hours Related skills 56 hours Related Knowledge Lecture Related skills Practical Demonstration i. Types of dies selected ii. Types of stamping processes explained iii. Type of die components and standard parts listed iv. Type of die components and standard parts functions explained v. Die components material listed vi. Components dimension checked and
  • 3. 38 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria iv. Type of standard parts and functions such as :- • Guide post • Guide bush • Spring • Stripper bolts • Dowel pin v. Type of die component materials such as: • SKD11/XW42 • SKS3/DF2 • SKD61 vi. Die references (datum) • Refer from drawing • Refer from die components • Mark components vii. Die fitting technique • Sliding fit • Tight fit viii. Upper die assembly • Guide bush to top plate • Punch to punch holder • Punch holder, backing plate to top plate ix. Lower die assembly • Guide post to protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point confirmed vii. Die references (datum) checked and marked viii. Die fitting technique applied accordance with fitting requirements. ix. Upper die components assembled in accordance with assembly drawing x. Lower die components assembled in accordance with assembly drawing xi. Safety precaution applied in performing die assembling
  • 4. 39 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria bottom plate • Die block, backing plate to bottom plate 3. Perform die alignment i. Die clearance • Die calculation ii. Type of gauges/ matching agent • Filler gauge • Shim • Blue matching • Die light iii. Die align method • Forming area Matching agents application Matching force application • Clearance area Guide post align to guide bush Filler gauge to check Punch and die clearance application iv. Transfer hole location v. Safety precaution on die alignment i. Identify die clearance ii. Identify gauges/ material agents iii. Select gauges/material agent iv. Apply die alignment method v. Align upper and lower die vi. Drill and ream dowel hole Attitude: i. Exacting when using measuring instrument ii. Alert to electrical supply iii. Attentive in handling die components and tools iv. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point Related Knowledge 16 hours Related skills 40 hours Related Knowledge Lecture Related skills Practical Demonstration i. Die clearance identified and confirmed ii. Type of gauges / matching agents selected iii.Die alignment method applied iv.Upper and lower die set align demonstrated and confirmed. v. Dowel pin assembled vi.Safety precaution applied in performing die alignment
  • 5. 40 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 4. Check die assembling for verification i. Die assembly drawing • Type of stamping die • Die operation ii. Die set assembly iii. Die alignment process iv. Die assembly check sheet i. Interpret die assembly drawing ii. Check die set assembly iii. Check die alignment iv. Update die assembly check sheet Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff iii. Meticulous in acquiring information Related Knowledge 4 hours Related skills 12 hours Related Knowledge Lecture Related skills Practical Demonstration i. Die assembly drawing interpreted ii. Die components tighten confirmed iii. Die alignment confirmed iv. Die assembly check sheet updated
  • 6. 41 Employability Skills Core Abilities Social Skills 01.07 Utilize database applications to locate and process information 01.08 Utilize spreadsheets applications to locate and process information 01.09 Utilize business graphic application to process information 01.10 Apply a variety of mathematical techniques 01.11 Apply thinking skills and creativity 02.09 Prepare flowcharts 02.10 Prepare reports and instructions 02.11 Convey information and ideas to people 03.09 Manage and improve performance of individuals 03.10 Provide consultation and counselling 03.11 Monitor and evaluate performance of human resources 03.12 Provide coaching/on-the job training 03.13 Develop and maintain team harmony and resolve conflicts 03.14 Facilitate and coordinate teams and ideas 03.15 Liaise to achieve identified outcomes 03.16 Identify and assess client/customer needs 03.17 Identify staff training needs and facilitate access to training 04.06 Allocate work 04.07 Negotiate acceptance and support for objectives and strategies 05.01 Implement project/work plans 05.02 Inspect and monitor work done and/or in progress 06.07 Develop and maintain networks 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 4. Learning skills 5. Leadership skills 6. Multitasking and prioritising 7. Self-discipline 8. Teamwork
  • 7. 42 Tools, Equipment and Materials (TEM) ITEMS RATIO (TEM : Trainees) 1. Job Instruction 2. Assembly drawing 3. Hand tools 4. Measuring instruments 5. Matching agent 6. Stamping die components 7. Die spotting machine 8. Inspection check sheet 9. Personal Protective Equipment (PPE) 1:1 1:1 1:1 1:1 1:1 1:5 1:25 1:1 1:1 References REFERENCES 1. Jerry Arnold (2000), Die Maker Handbook, Industrial Press, Inc., ISBN 0-831-3132-2 2. James A. Szumera (2003), The Metal Stamping Process, Industrial Press, Inc. ISBN 0-8311-3164-0 3. Vokota Boljanovic (1987), Die design fundamentals, Industrial Press Inc., ISBN 0-8311-1172-0 4. Donald A. Peterson (1994), Progressive Dies Principles and Practices of Design, Society of Manufacturing Engineers, ISBN 0-87263-448-5 5. Vukota Boljanovic (2004), Sheet Metal Forming Processes and Die Design, Industrial Press Inc., ISBN 0-8311-3182-9 6. David A Smith (1990), Die design Handbook, Society of manufacturing engineers (SME), ISBN 0-87263-375-6
  • 8. 43 CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector METAL MACHINING TECHNOLOGY Job Area MOULD & DIE MANUFACTURING Competency Unit Title PLASTIC INJECTION MOULD ASSEMBLING Learning Outcome The person who is competent in plastic injection mould assembling shall be able to assemble plastic injection mould components based on assembly drawing to produce a complete and functional mould for the mass production of high quality and standardised products. Upon completion of this competency unit, trainees will be able to :- • Prepare plastic injection mould assembly requirements • Perform mould assembling • Perform mould matching • Check mould assembling Competency Unit ID CU02 Level 03 Training Duration 180 Hours Credit Hours 18 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 1. Prepare plastic injection mould assembly requirements i. Job instruction • Job description Type of process by sequences • Lead time (delivery date) • Company rules & regulation Company policy ii. Mould assembly drawing • Mould concepts • Types of plastic injection moulds • Part names and quantity i. Interpret Job instruction ii. Interpret Mould assembly drawing iii. Select measuring instruments iv. Select type of tools Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Attentive in handling mould components and tools iv. Adhere to safe handling technique Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Type of job description interpreted ii. Delivery date identified iii. Company rules & regulation complied iv. Mould concepts explained v. Mould components name and quantity listed vi. Fitting tolerance, surface finish and drawing symbols
  • 9. 44 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria • Fitting tolerance • Surface finish • Drawing symbols iii. Measuring instruments iv. Type of tools and function • Allen key • Copper mallet • Oil Stone Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges identified vii. Measuring instrument identified and selected viii.Type of tools identified, listed and selected 2. Perform mould assembling i. Types of plastic injection moulds and function • Two-plate mould With side core without side core • Three-plate mould With side core without side core • Hot runner system ii. Mould components and functions • Top plate • Core plate • Core insert • Cavity plate • Cavity insert • Spacer block • Ejector retainer plate • Ejector back plate i. Identify type mould and function ii. Identify element of mould and function iii. Identify type of mould standard parts and functions iv. Identify type of mould components material v. Check mould references (datum) vi. Assemble moving half vii. Assemble fixed half viii. Identify types of cooling system ix. Fix ejector system x. Fix feed system xi. Check mould perpendicular xii. Check mould levelling xiii. Apply Safety precaution Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in handling mould components and tools v. Adhere to safe handling technique Related Knowledge 28 hours Related skills 56 hours Related Knowledge Lecture Related skills Practical Demonstration i. Types of plastic injection moulds explained ii. Type of mould components and standard parts listed iii. Type of mould components and standard parts functions explained and differentiated iv. Mould components material listed v. Components dimension confirmed vi. Mould references (datum) confirmed
  • 10. 45 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria • Bottom plate iii. Type of standard parts and functions such as :- • Locating ring • Sprue bush • Guide pillar • Guide bush • Spring • Ejector pin • Return pin iv. Type of mould components material such as: • Stavax • 718 • Rmax v. Mould references (datum) • Refer from drawing • Refer from components • Mark component vi. Mould fitting technique • Moving half Core insert Core plate Ejector plate Ejector pin Return pin Support plate Spacer block Bottom plate • Fixed half Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point vii. Mould fitting technique demonstrated viii. Moving half assembled ix. Fixed half assembled x. Types of cooling system identified xi. Ejector system fixed xii. Feed system fixed xiii. Mould perpendicular checked and confirmed xiv. Mould Level checked and confirmed xv. Safety precaution applied in performing mould assembly
  • 11. 46 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria Cavity insert Cavity plate Top plate Sprue bush Locating ring vii. Types of cooling system • Direct • Buffle • Spiral viii. Types of injector system • Pin • Stripper • Slant block ix. Feed system • Sprue • Runner • Gate x. Mould fitting method • Perpendicular • Flatness xi. Safety precaution on mould assembling 3. Perform mould matching i. Mould matching area ii. Type of gauges/ matching agent such as:- • Filler gauge • Shim • Blue matching • Lead • Modelling clay • Wax i. Identify mould matching area ii. Identify type of gauges/ matching agent iii. Select gauges/ matching agent iv. Identify mould parting line v. Identify Wall thickness Attitude: i. Exacting when using measuring instrument ii. Alert to electrical supply iii. Attentive in handling Related Knowledge 16 hours Related skills 40 hours Related Knowledge Lecture Related skills Practical Demonstration i. Mould matching area checked and confirmed ii. Type of gauges/ matching agent listed and selected iii. Mould parting
  • 12. 47 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria iii. Mould matching method • Parting line • Wall thickness iv. Matching process • Matching agents • Die spot force • Surface contact area v. Safety precaution on mould matching vi. Apply matching agent vii. Apply matching force viii. Check match area transferred mould components and tools iv. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point line identified and confirmed iv. Wall thickness identified v. Matching agent applied vi. Matching force applied vii. Matching area transfer, checked and confirmed viii. Safety precaution applied in performing mould matching 4. Check mould assembling i. Mould assembly drawing • Type of mould • Mould operation ii. Mould assembly set iii. Mould matching process iv. Mould assembly check sheet i. Interpret mould assembly drawing ii. Check mould set assembly iii. Check mould matching iv. Mould assembly check sheet Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff iii. Meticulous in acquiring information Related Knowledge 4 hours Related skills 12 hours Related Knowledge Lecture Related skills Practical Demonstration i. Mould assembly drawing interpreted ii. Mould components tighten confirmed iii. Mould matching checked and confirmed iv. Mould assembly check sheet updated
  • 13. 48 Employability Skills Core Abilities Social Skills 01.07 Utilize database applications to locate and process information 01.08 Utilize spreadsheets applications to locate and process information 01.09 Utilize business graphic application to process information 01.10 Apply a variety of mathematical techniques 01.11 Apply thinking skills and creativity 02.09 Prepare flowcharts 02.10 Prepare reports and instructions 02.11 Convey information and ideas to people 03.09 Manage and improve performance of individuals 03.10 Provide consultation and counselling 03.11 Monitor and evaluate performance of human resources 03.12 Provide coaching/on-the job training 03.13 Develop and maintain team harmony and resolve conflicts 03.14 Facilitate and coordinate teams and ideas 03.15 Liaise to achieve identified outcomes 03.16 Identify and assess client/customer needs 03.17 Identify staff training needs and facilitate access to training 04.06 Allocate work 04.07 Negotiate acceptance and support for objectives and strategies 05.01 Implement project/work plans 05.02 Inspect and monitor work done and/or in progress 06.07 Develop and maintain networks 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 4. Learning skills 5. Leadership skills 6. Multitasking and prioritising 7. Self-discipline 8. Teamwork
  • 14. 49 Tools, Equipment and Materials (TEM) ITEMS RATIO (TEM : Trainees) 1. Job Instruction 2. Assembly drawing 3. Hand tools 4. Measuring instruments 5. Matching agent 6. Mould components 7. Die spotting machine 8. Inspection check sheet 9. Lifting equipment 10. Personal Protective Equipment (PPE) 1:1 1:1 1:1 1:1 1:1 1:5 1:25 1:1 1:25 1:1 References REFERENCES 1. Gunter Mennig (1998), Mould Making Handbook, Hanser / Gardner publication, ISBN 1-56990-261-5 2. Eric V. Buckleitner (1995), Plastics Mold Engineering Handbook, Chapman & Hall, ISBN 0-412-98951-4 3. Georg Menges/Paul Mahren (1993), How to make Injection Molds, Hanser Publishers, ISBN 3-446-16305-0 4. Donald V. Rosato/Dominick V. Roasato (1995), Injection Molding Handbook, Chapman & Hall, ISBN 0-412-99381-3 5. E. Lindner and P. Unger (1993), Injection Mold 108 Proven Designs, Hanser Publishers, ISBN 3-446-15682-8 6. Michael L. Berins (1991), Plastics Engineering Handbook, Chapman & Hall, ISBN 0-412-99181-0
  • 15. 50 CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector METAL MACHINING TECHNOLOGY Job Area MOULD & DIE MANUFACTURING Competency Unit Title STAMPING DIE TRY-OUT & TROUBLESHOOT Learning Outcome The person who is competent in stamping die try-out & troubleshoot shall be able to setup the stamping die to machine to ensure the stamping die is functional in accordance with design requirements and to produce samples that meet product specifications. Upon completion of this competency unit, trainees will be able to :- • Prepare stamping die try-out requirements • Set up stamping die to machine • Set up machine parameters • Produce product sample • Inspect product sample • Check die try out and troubleshooting Competency Unit ID CU03 Level 03 Training Duration 160 Hours Credit Hours 16 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 1. Prepare stamping die try-out requirements i. Content of job instruction • Job description Type of process by sequences • Lead time (delivery date) • Company rules & regulation Company policy ii. Product drawing • Product dimensions • Product material iii. Measuring instruments i. Interpret job instruction ii. Interpret product drawing iii. Select measuring instruments iv. Select type of tools v. Identify stamping die vi. Identify stamping machine specification vii. Identify stamping machine and Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff iii. Meticulous in acquiring information iv. Meticulous in interpreting drawing Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Job instruction interpreted ii. Product dimensions identified iii. Product material selected iv. Measuring instrument selected v. Type of tools listed and selected vi. Type of stamping die identified and selected vii. Stamping machine
  • 16. 51 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria • Micrometer • Vernier calliper • Pin gauges iv. Type of tools such as: • Allen key • Copper mallet • Oil stone v. Type of stamping die vi. Stamping machine & accessories • Machine specification • Machine function • Type of accessories accessories functional specification identified and selected viii. Stamping machine function explained 2. Set up stamping die on stamping machine i. Stamping machine and accessories • Machine tonnage • Machine Shut- height • Machine and accessories conditions • Type of feeders ii. Type of clamping devices iii. Stamping die setting method • With shank • Without shank • Clamping technique iv. Machine safety precaution i. Check stamping machine and accessories conditions ii. Select stamping machine and accessories iii. Select type of feeders iv. Select type of clamping devices v. Set stamping die on machine Attitude: i. Exacting when using measuring instrument ii. Alert to electrical supply iii. Attentive in handling die components and tools iv. Adhere to safe handling technique Safety: i. Ensure personal protective Related Knowledge 16 hours Related skills 32 hours Related Knowledge Lecture Related skills Practical Demonstration i. Machine & accessories conditions confirmed ii. Stamping machine tonnage and shut- height selected and confirmed iii. Type of feeders selected iv. Type of clamping devices selected v. Stamping die clamp to machine secured vi. Machine safety precaution complied in performing die setup
  • 17. 52 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point 3. Set up machine parameters i. Die shut height • Top dead centre • Bottom dead centre ii. Machine pressure • Air pressure inlet • Machine tonnage • Cushion pressure iii. Test run • Stamping die condition • Stamping machine condition iv. Feeder system • Manual feeder • Roller • Transfer v. Safety devices • Sensor • Mechanical safety devices i. Set die shut height ii. Set machine pressure iii. Perform test run iv. Check stamping die functionality v. Confirm machine condition vi. Set feeder system vii. Set safety devices Attitude: i. Resourceful in acquiring information and data ii. Alert to electrical supply iii. Attentive in handling die and tools iv. Adhere to safe handling technique Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Top dead centre identified ii. Bottom dead centre confirmed iii. Air pressure inlet adjusted and confirmed iv. Machine tonnage set v. Cushion pressure set and confirmed vi. Stamping die functionality checked and confirmed vii. Stamping machine condition confirmed viii. Feeder system set ix. Safety devices set
  • 18. 53 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 4. Produce product sample i. Product material • Type of material • Material specification ii. Product Sample • Product appearance • Product profile iii. Type of product defect • Burrs • Wrinkle • Crack iv. Causes of product defects v. Corrective actions • Rework Touch up Re-grind Re-machining • Replace i. Select strip material ii. Produce product sample iii. Check product abnormalities iv. Identify type of product defect v. Identify type of causes vi. Identify problem solving vii. Perform corrective actions Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in handling die components and tools v. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point Related Knowledge 8 hours Related skills 24 hours Related Knowledge Lecture Related skills Practical Demonstration i. Product material selected ii. Product sample produced iii. Type of product abnormality checked, identified and listed iv. Type of causes listed v. Problem solving listed and explained vi. Corrective actions applied vii. Safety precaution applied during producing product sample
  • 19. 54 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 5. Inspect product sample i. Product Drawing • Product dimension • Product profile • Product specification ii. Type of measuring instrument • Micro meter • Vernier calliper • Go No Go gauge • Profile projector iii. Product sample • Dimension • Profile • Appearance iv. Product inspection check sheet i. Interpret product drawing ii. Select type of measuring instrument iii. Check product sample dimension iv. Check product sample profile v. Check product sample appearance vi. Fill up product inspection check sheet Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in handling mould components and tools v. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges Related Knowledge 4 hours Related skills 8 hours Related Knowledge Lecture Related skills Practical Demonstration i. Product drawing interpreted ii. Type of measuring instrument listed and functional described iii. Product sample dimension checked and confirmed iv. Product sample profile checked and confirmed v. Product sample appearance checked and confirmed vi. Measurement method applied vii. Product inspection check sheet Filled up
  • 20. 55 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 6. Check die try out & troubleshoot i. Stamping Die set up ii. Machine parameter set up iii. Product quality • Product sample • Product check sheet iv. Die try out check sheet i. Check stamping die set up ii. Confirmed machine parameter set up iii. Check product quality iv. Update die try out check sheet Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff iii. Meticulous in acquiring information Related Knowledge 4 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Stamping Die set up checked and clamp secured ii. Machine parameter set up confirmed iii. Product quality checked and confirmed iv. Die try out check sheet updated
  • 21. 56 Employability Skills Core Abilities Social Skills 01.07 Utilize database applications to locate and process information 01.08 Utilize spreadsheets applications to locate and process information 01.09 Utilize business graphic application to process information 01.10 Apply a variety of mathematical techniques 01.11 Apply thinking skills and creativity 02.09 Prepare flowcharts 02.10 Prepare reports and instructions 02.11 Convey information and ideas to people 03.09 Manage and improve performance of individuals 03.10 Provide consultation and counselling 03.11 Monitor and evaluate performance of human resources 03.12 Provide coaching/on-the job training 03.13 Develop and maintain team harmony and resolve conflicts 03.14 Facilitate and coordinate teams and ideas 03.15 Liaise to achieve identified outcomes 03.16 Identify and assess client/customer needs 03.17 Identify staff training needs and facilitate access to training 04.06 Allocate work 04.07 Negotiate acceptance and support for objectives and strategies 05.01 Implement project/work plans 05.02 Inspect and monitor work done and/or in progress 06.07 Develop and maintain networks 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 4. Learning skills 5. Leadership skills 6. Multitasking and prioritising 7. Self-discipline 8. Teamwork
  • 22. 57 Tools, Equipment and Materials (TEM) ITEMS RATIO (TEM : Trainees) 1. Job Instruction 2. Assembly drawing 3. Hand tools 4. Measuring instruments 5. Matching agent 6. Stamping die components 7. Die spotting machine 8. Inspection check sheet 9. Personal Protective Equipment (PPE) 1:1 1:1 1:1 1:1 1:1 1:5 1:25 1:1 1:1 References REFERENCES 1. Jerry Arnold (2000), Die Maker Handbook, Industrial press, Inc., ISBN 0-831-3132-2 2. James A Szumera (2003), The Metal Stamping Process, Industrial press, Inc. ISBN 0-8311-3164-0 3. Richard M. Lead (2002), Tool and Die Making Troubleshoot, Society of Manufacturing Engineers, ISBN 978-0-87263-643-9 4. Vokota Boljanovic (1987), Die design fundamentals, Industrial Press Inc., ISBN 0-8311-1172-0 5. Donald A. Peterson (1994), Progressive Dies Principles and Practices of Design, Society of Manufacturing Engineers, ISBN 0-87263-448-5 6. Vukota Boljanovic (2004), Sheet Metal Forming Processes and Die Design, Industrial Press Inc., ISBN 0-8311-3182-9 7. David A Smith (1990), Die design Handbook, Society of manufacturing engineers (SME), ISBN 0-87263-375-6
  • 23. 58 CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector METAL MACHINING TECHNOLOGY Job Area MOULD & DIE MANUFACTURING Competency Unit Title PLASTIC INJECTION MOULD TRY-OUT & TROUBLESHOOT Learning Outcome The person who is competent in Plastic Injection Mould Try-Out & Troubleshoot shall be able to setup injection moulding machine to ensure the mould is functional in accordance with design requirements and to produce samples that meet product specifications. Upon completion of this competency unit, trainees will be able to :- • Prepare plastic injection mould try-out requirements • Set up plastic injection mould to machine • Carry out pre-heating • Set up machine parameters • Produce product sample • Inspect product sample • Perform surface finishing process • Check mould try out and troubleshooting Competency Unit ID CU04 Level 03 Training Duration 240 Hours Credit Hours 24 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 1. Prepare plastic injection mould try-out requirements i. Content of job instruction • Job description Type of process by sequences • Lead time (delivery date) • Company rules & regulation Company policy ii. Product drawing • Product i. Interpret job instruction ii. Interpret product drawing iii. Select measuring instrument iv. Identify type of tools v. Select type of tools vi. Identify plastic injection mould vii. Identify moulding machine specification viii. Identify moulding machine and Attitude: i. Resourceful in acquiring information and data ii. Precise in communicati ng with internal staff iii. Meticulous in acquiring information Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Job instruction interpreted ii. Product dimensions identified iii. Product material selected iv. Measuring instrument selected v. Type of tools listed and selected
  • 24. 59 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria dimensions • Product material iii. Measuring instrument • Micrometer • Vernier calliper iv. Type of tools such as: • Allen key • Copper mallet • Oil stone v. Type of plastic injection mould vi. Moulding machine • Machine specification • Machine function • Type of auxiliary accessories functional vi. Type of plastic injection mould identified vii.Moulding machine specification identified viii. Moulding machine function explained 2. Set up mould on injection moulding machine i. Moulding machine • Machine tonnage • Mould platen and tie-bar size • Machine and auxiliary condition ii. Type of clamping devices iii. Plastic injection mould preparation set up • Nozzle radius • Nozzle length • Locating ring size • Resin • Cooling system • Hydraulic Core System i. Select moulding machine and auxiliary ii. Select type of clamping devices iii. Check mould preparation set up iv. Set plastic injection mould to machine v. Comply machine safety precaution Attitude: i. Alert to electrical supply ii. Attentive in handling die components and tools iii. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Related Knowledge 16 hours Related skills 32 hours Related Knowledge Lecture Related skills Practical Demonstration i. Machine tonnage identified and confirmed ii. Moulding machine & auxiliary conditions checked and confirmed iii. Type of clamping devices selected iv. Mould preparation set up checked and
  • 25. 60 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria • Ejector machine system Location Size Length iv. Mould set up • Mould align to machine • Machine nozzle align to mould sprue bush • Mould clamping v. Machine safety precaution Safety Regulation & Standard ii. Beware of sharp edges & pinch point confirmed v. Plastic injection mould set to machine secured vi. Machine safety precaution complied in performing mould setup 3. Carry out pre- heating i. Product material (Resin) • Type of resin Polypropylene (PP) Acrylonitrile Butadene Styrene (ABS) Polyamide (PA6GF Nylon) Master batch • Resin specification Melt temperature Melting point Shrinkage • Material characteristic Flow Speed i. Identify type of resin ii. Identify resin specification iii. Identify material (resin) characteristic iv. Set temperature range v. Set pre-heat duration vi. Carry out resin pre- heating vii. Carry out machine pre-heating viii. Carry out mould pre- heating Attitude: i. Meticulous in interpreting drawing ii. Alert to electrical supply iii. Attentive in handling mould components and tools iv. Adhere to safe handling technique Safety: iii. Ensure personal protective equipment Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Type of resin identified ii. Resin specification identified iii. Resin (material) characteristic identified iv. Temperature set v. Pre-heat duration set vi. Resin pre- heating carried out vii. Machine pre- heating carried out viii. Mould pre- heating carried
  • 26. 61 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria Strength Stiffness ii. Pre-heating process requirements • Temperature range • Duration iii. Resin pre-heating iv. Machine pre-heating v. Mould pre-heating (PPE) meet Safety Regulation & Standard out ix. Safety precaution applied during pre-heating process 4. Set up machine parameters i. Clamping adjustment • Clamping force • Ejector stroke • Mould opening ii. Part weight iii. Dosage/metering iv. Injection speed v. Injection pressure vi. Cooling time vii. Safety devices • Sensor • Mechanical i. Set clamping force ii. Set ejector stroke iii. Set mould opening iv. Identify Part weight v. Set dosage / metering vi. Set injection speed vii. Adjust injection pressure viii. Set cooling time ix. Set safety devices Attitude: i. Alert to electrical supply ii. Attentive in handling mould components and tools iii. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Clamping force set demonstrated ii. Ejector stroke set demonstrated iii. Mould opening set demonstrated iv. Part weight identified v. Dosage / metering set vi. Injection speed pressure set vii. Injection pressure adjusted viii. Cooling time Set ix. Safety devices set
  • 27. 62 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 5. Produce product sample i. Product resin ii. Plastic injection mould conditions iii. Material purging • Material viscosity • Discard remaining iv. Product sample condition / abnormalities • Sink mark • Burn mark • Flushing • Short shot v. Causes of product defects vi. Corrective actions • Rework Touch up Re-grind Re-machining • Replace i. Confirm product resin ii. Check plastic injection mould condition iii. Measure material temperature iv. Check material viscosity v. Ensure discard remaining vi. Carry out material purging vii. Produce product sample viii. Check Product abnormalities ix. Identify type of product defect x. Identify type of causes xi. Identify problem solving xii. Perform corrective actions Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in handling mould components and tools v. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point Related Knowledge 8 hours Related skills 24 hours Related Knowledge Lecture Related skills Practical Demonstration i. Product resin checked and confirmed ii. Plastic injection mould conditions checked and confirmed iii. Material temperature confirmed iv. Material viscosity checked v. Discard remaining ensured vi. Product sample defect identified vii. Type of defect listed viii. Problem solving listed and explained ix. Corrective actions demonstrated x. Safety precaution applied during producing product sample
  • 28. 63 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 6. Inspect product sample i. Type of measuring instrument • Micro meter • Vernier calliper • Go No Go gauge • Profile projector ii. Product sample • Dimension • Profile • Appearance iii. Product inspection check sheet i. Select type of measuring instrument ii. Check product sample appearance iii. Check product sample profile iv. Check product sample dimension v. Fill up product inspection check sheet Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in handling mould components and tools v. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges Related Knowledge 4 hours Related skills 8 hours Related Knowledge Lecture Related skills Practical Demonstration i. Type of measuring instrument listed and functional described ii. Product sample dimension identified iii. Product sample profile identified iv. Product sample appearance identified v. Measurement method applied vi. Product inspection check sheet Filled up
  • 29. 64 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 7. Perform surface finishing process i. Type of surface finish • Polishing • Surface finish treatment Texture Etching Chrome plating ii. Surface area iii. Type of abrasive paper and grit size iv. Polishing kits and grit size v. Polishing technique • Selection of grit size • Polishing direction vi. Dispose schedule waste i. Identify type of surface finish ii. Arrange for surface finish treatment iii. Identify surface area to be polished iv. Select abrasive paper and grit size v. Select polishing kits and grit size vi. Carry out polishing process vii. Practice waste disposal Attitude: i. Exacting when using measuring instrument ii. Alert to electrical supply iii. Attentive in handling mould components and tools iv. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges iii. Comply with Environmental Management System (EMS) Related Knowledge 16 hours Related skills 40 hours Related Knowledge Lecture Related skills Practical Demonstration i. Type of surface finish identified and confirmed ii. Surface finish treatment arranged iii. Surface area identified and confirmed iv. Abrasive paper and grit size selected v. Polishing kits and grit size selected vi. Polishing process carried out vii. Polishing technique demonstrated viii. waste disposal procedure are adhered to ix. Polishing process in compliance with Environmental Management System (EMS)
  • 30. 65 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 8. Check mould try out and troubleshoot i. Plastic injection mould set up ii. Machine parameter set up iii. Product sample iv. Product inspection check sheet v. Mould surface finish vi. Mould try out check sheet i. Check plastic injection mould set up ii. Confirm machine parameter set up iii. Check product sample quality iv. Check mould surface finish v. Update mould try out check sheet Attitude: i. Resourceful in acquiring information and data ii. Precise in communicati ng with internal staff iii. Meticulous in acquiring information Related Knowledge 4 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Plastic injection mould set up checked and clamp secured ii. Machine parameter set up confirmed iii. Product sample quality checked iv. Mould surface finish checked and confirmed v. Mould try out check sheet updated
  • 31. 66 Employability Skills Core Abilities Social Skills 01.07 Utilize database applications to locate and process information 01.08 Utilize spreadsheets applications to locate and process information 01.09 Utilize business graphic application to process information 01.10 Apply a variety of mathematical techniques 01.11 Apply thinking skills and creativity 02.09 Prepare flowcharts 02.10 Prepare reports and instructions 02.11 Convey information and ideas to people 03.09 Manage and improve performance of individuals 03.10 Provide consultation and counselling 03.11 Monitor and evaluate performance of human resources 03.12 Provide coaching/on-the job training 03.13 Develop and maintain team harmony and resolve conflicts 03.14 Facilitate and coordinate teams and ideas 03.15 Liaise to achieve identified outcomes 03.16 Identify and assess client/customer needs 03.17 Identify staff training needs and facilitate access to training 04.06 Allocate work 04.07 Negotiate acceptance and support for objectives and strategies 05.01 Implement project/work plans 05.02 Inspect and monitor work done and/or in progress 06.07 Develop and maintain networks 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 4. Learning skills 5. Leadership skills 6. Multitasking and prioritising 7. Self-discipline 8. Teamwork
  • 32. 67 Tools, Equipment and Materials (TEM) ITEMS RATIO (TEM : Trainees) 1. Job Instruction 2. Plastic injection mould 3. Moulding machine 4. Mould assembly drawing 5. Product drawing 6. Measuring instruments 7. Hand tools 8. Product material (resin) 9. Polishing kits 10. Check sheet 11. Personal Protective Equipment (PPE) 1 : 1 1 : 5 1 : 5 1 : 1 1 : 1 1 : 5 1 : 1 As required As required 1 : 1 1 : 1 References REFERENCES 1. Richard M. Lead (2002), Tool and Die Making Troubleshoot, Society of Manufacturing Engineers, ISBN 978-0-87263-643-9 2. Gunter Mennig (1998), Mould Making Handbook, Hanser / Gardner publication, ISBN 1-56990-261-5 3. Eric V. Buckleitner (1995), Plastics Mold Engineer Handbook, Chapman & Hall, ISBN 0-412-98951-4 4. Georg Menges/Paul Mahren (1993), How to make Injection Molds, Hanser Publishers, ISBN 3-446-16305-0 5. Donald V. Rosato/Dominick V (1995), Roasato, Injection Molding Handbook, Chapman & Hall, ISBN 0-412-99381-3 6. E. Lindner and P. Unger (1993), Injection Mold 108 Proven Designs, Hanser Publishers, ISBN 3-446-15682-8 7. Michael L. Berins (1991), Plastics Engineering Handbook, Chapman & Hall, ISBN 0-412-99181-0
  • 33. 68 CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector METAL MACHINING TECHNOLOGY Job Area MOULD & DIE MANUFACTURING Competency Unit Title STAMPING DIE MAINTENANCE Learning Outcome The person who is competent in Stamping Die Maintenance shall be able to carry out preventive and corrective maintenance exercise that ensures the stamping die is in good operational condition. Upon completion of this competency unit, trainees will be able to :- • Prepare stamping die maintenance requirements • Carry out stamping die maintenance activities • Perform stamping die assembly activities • Perform stamping die try-out • Inspect product sample • Check stamping die maintenance activity Competency Unit ID CU05 Level 03 Training Duration 180 Hours Credit Hours 18 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 1. Prepare stamping die maintenance requirements i. Job instruction • Assembly drawing • Job description Type of process by sequences • Lead time (delivery date) • Company rules & regulation Company policy ii. Die maintenance schedule • Type of maintenance (corrective/ i. Interpret Job instruction ii. Interpret die maintenance schedule iii. Identify type of Die iv. Identify type of stamping processes v. Select maintenance tools vi. Obtain product sample Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff iii. Meticulous in acquiring information Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Assembly drawing interpreted ii. Job description explained iii. Delivery date identified iv. Company rule & regulation complied v. Die maintenance schedule interpreted vi. Type of die
  • 34. 69 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria preventive) • Replaced parts. • Modified part iii. Product samples • Product defect • Master sample iv. Type of Die • Single die • Compound die • Progressive die v. Types of stamping processes such as • Blanking • Piercing • Bending vi. Type of tools and consumables • allen key, • copper mallet • shim • abrasive paper • oil stone listed vii. Type of stamping process explained viii. Type of tools listed and selected ix. Product samples obtained
  • 35. 70 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 2. Carry out stamping die maintenance activities i. Defected product sample • Type of defect • Type of abnormality ii. Type of die components such as:- • Upper plate • Punch plate • Stripper plate • Punch block • Die block • Lower plate iii. Type of die standard parts such as :- • Guide post • Guide bush • Spring • Stripper bolts iv. Type of die component defects such as :- • Scratch • Dented • Wear and tear v. Counter problem techniques such as:- • Touch up • Regrind • Replace i. Identify type of product defect ii. Dismantle die components iii. Dismantle die standard parts iv. Identify die components defect v. Identify die standard parts defect vi. Carry out touch up die component vii. Carry out regrind die component viii. Carry out replacement of die component Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in handling die components and tools v. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point Related Knowledge 16 hours Related skills 40 hours Related Knowledge Lecture Related skills Practical Demonstration i. Type of product defect listed ii. Die components listed iii. Die standard parts listed iv. Die component defects identified and listed v. Touch up die component performed vi. Regrind die component performed vii. Replacement of die component performed viii. Safety precaution applied in performing die maintenance
  • 36. 71 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 3. Perform stamping die assembly activities i. Assembly drawing • Drawing symbol • Die datum • Upper die set • Lower die set ii. Die assemble technique • Upper die set assembly Guide post to top plate Punch to punch holder Punch holder, backing plate to top plate • Lower die set assemble Guide bush to bottom plate Die block, backing plate to bottom plate iii. Die assembly method • Perpendicular • Flatness iv. Die alignment • Matching agent • Matching surface area i. Interpret assembly drawing ii. Apply die assembly technique iii. Perform die assembly iv. Perform die alignment Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in handling die components and tools v. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point Related Knowledge 8 hours Related skills 24 hours Related Knowledge Lecture Related skills Practical Demonstration i. Assembly drawing interpreted ii. Die assembly technique demonstrate iii. Die assembly performed iv. Matching agent selected v. Matching surface area confirmed vi. Die alignment performed xii. Safety precaution applied in performing die assembly
  • 37. 72 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 4. Perform stamping die try-out i. Stamping machine and accessories • Machine tonnage • Machine and accessories conditions • Type of feeders ii. Type of clamping devices iii. Stamping die setting method iv. Die shut height • Top dead centre • Bottom dead centre v. Safety devices • Sensor • Mechanical safety devices vi. Test run • Stamping die condition • Stamping machine condition vii. Feeder system • Manual feeder • Roller • Transfer viii. Product material • Type of material • Material specification ix. Die conditions x. Product sample i. Identify stamping machine and accessories ii. Identify type of clamping devices iii. Clamp stamping die to machine iv. Set die shut height v. Set safety devices vi. Perform test run vii. Set feeder system viii. Select product material ix. Check die conditions x. Produce product sample xi. Identify type of product defect xii. Apply countermeasure xiii. Apply corrective actions Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in handling die components and tools v. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point Related Knowledge 16 hours Related skills 24 hours Related Knowledge Lecture Related skills Practical Demonstration i. Machine tonnage confirmed ii. Machine and accessories conditions checked and confirmed iii. Type of feeders selected iv. Type of clamping devices selected v. Stamping die set to machine secured vi. Die shut height checked and confirmed vii. Safety devices set viii. Die conditions checked and confirmed ix. Feeder system set x. Product material confirmed xi. Product sample produced xii. Type of
  • 38. 73 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria xi. Type of stamping fault and countermeasure such as:- • Burrs • Wrinkle • Crack xii. Causes of product defects xiii. Corrective actions product defect identified xiii. Counter measure listed xiv. Corrective actions applied xv. Safety precaution applied in performing die try out 5. Inspect product sample i. Type and usage of measuring instrument • Micro meter • Vernier calliper • Go No Go gauge • Profile projector ii. Product sample • Dimension • Profile • Appearance iii. Product inspection check sheet i. Select type of measuring instrument ii. Identify product sample dimension iii. Identify product sample profile iv. Identify product sample appearance v. Apply measurement method vi. Fill up product inspection check sheet Attitude: i. Resourceful in acquiring information and data ii. Precise in communicatin g with internal staff iii. Meticulous in acquiring information iv. Exacting when using measuring instrument Related Knowledge 4 hours Related skills 8 hours Related Knowledge Lecture Related skills Practical Demonstration i. Type of measuring instrument listed and functional described ii. Product sample dimension identified iii. Product sample profile identified iv. Product sample appearance identified v. Measurement method applied vi. Product inspection check sheet filled up
  • 39. 74 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 6. Check stamping die maintenance activity i. Type of die maintenance • Corrective • preventive ii. Assembly drawing • Type of die • Type of components iii. Product drawing • Product specification iv. Product inspection check sheet • Product inspection result • Die components condition • Die try –out result v. Die maintenance check sheet i. Confirm type maintenance ii. Confirm die to be maintain iii. Confirm die component defects iv. Confirm die assembly activities v. Confirm die try-out vi. Confirm Product quality vii. Update die maintenance check sheet Attitude: i. Resourceful in acquiring information and data ii. Precise in communicatin g with internal staff iii. Meticulous in acquiring information Related Knowledge 4 hours Related skills 12 hours Related Knowledge Lecture Related skills Practical Demonstration i. Type of maintenance Confirmed ii. Die to be maintain confirmed iii. Die component defects listed iv. Die assembly activities confirmed v. Die try-out confirmed vi. Product quality assured vii. Die maintenance check sheet updated
  • 40. 75 Employability Skills Core Abilities Social Skills 01.07 Utilize database applications to locate and process information 01.08 Utilize spreadsheets applications to locate and process information 01.09 Utilize business graphic application to process information 01.10 Apply a variety of mathematical techniques 01.11 Apply thinking skills and creativity 02.09 Prepare flowcharts 02.10 Prepare reports and instructions 02.11 Convey information and ideas to people 03.09 Manage and improve performance of individuals 03.10 Provide consultation and counselling 03.11 Monitor and evaluate performance of human resources 03.12 Provide coaching/on-the job training 03.13 Develop and maintain team harmony and resolve conflicts 03.14 Facilitate and coordinate teams and ideas 03.15 Liaise to achieve identified outcomes 03.16 Identify and assess client/customer needs 03.17 Identify staff training needs and facilitate access to training 04.06 Allocate work 04.07 Negotiate acceptance and support for objectives and strategies 05.01 Implement project/work plans 05.02 Inspect and monitor work done and/or in progress 06.07 Develop and maintain networks 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 4. Learning skills 5. Leadership skills 6. Multitasking and prioritising 7. Self-discipline 8. Teamwork
  • 41. 76 Tools, Equipment and Materials (TEM) ITEMS RATIO (TEM : Trainees) 1. Job Instruction 2. Assembly drawing 3. Hand tools 4. Measuring instruments 5. Matching agent 6. Stamping die components 7. Die spotting machine 8. Inspection check sheet 9. Personal Protective Equipment (PPE) 1:1 1:1 1:1 1:1 1:1 1:5 1:25 1:1 1:1 References REFERENCES 1. David A Smith (2001), Die maintenance handbook, Society of manufacturing engineers (SME), ISBN 978-0-87263-528-9 2. Richard M. Lead (2002), Tool and Die Making Troubleshoot, Society of Manufacturing Engineers, ISBN 978-0-87263-643-9 3. Jerry Arnold (2000), Die Maker Handbook, Industrial press, Inc., ISBN 0-831-3132-2 4. James A Szumera (2003), The Metal Stamping Process, Industrial press, Inc. ISBN 0-8311-3164-0 5. Vokota Boljanovic (1987), Die design fundamentals, Industrial Press Inc., ISBN 0-8311-1172-0 6. Donald A. Peterson (1994), Progressive Dies Principles and Practicesof Design, Society of Manufacturing Engineers, ISBN 0-87263-448-5 7. David A Smith (1990), Die design Handbook, Society of manufacturing engineers (SME), ISBN 0-87263-375-6
  • 42. 77 CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector METAL MACHINING TECHNOLOGY Job Area MOULD & DIE MANUFACTURING Competency Unit Title PLASTIC INJECTION MOULD MAINTENANCE Learning Outcome The person who is competent in Plastic Injection Mould Maintenance shall be able to carry out preventive and corrective maintenance exercise that ensures the Plastic Injection Mould is in good operational condition. Upon completion of this competency unit, trainees will be able to :- • Prepare mould maintenance requirements • Carry out plastic injection mould maintenance • Perform mould assembly activities • Perform mould try-out • Inspect product sample • Check mould maintenance activity Competency Unit ID CU06 Level 03 Training Duration 180 Hours Credit Hours 18 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 1. Prepare mould maintenance requirements i. Job instruction • Assembly drawing • Job description Type of process by sequences • Lead time (delivery date) • Company rules & regulation Company policy ii. Mould maintenance schedule • Mould history • Type of maintenance (corrective/ i. Interpret job instruction ii. Interpret mould maintenance schedule iii. Identify type of mould iv. Identify mould construction v. Identify type of maintenance tools vi. Select maintenance tools vii. Select defected product Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff iii. Meticulous in acquiring information Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Assembly drawing interpreted ii. Job description explained iii. Delivery date identified iv. Company rule & regulation complied v. Mould maintenance schedule differentiate vi. Type of mould
  • 43. 78 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria preventive) • Replaced parts. • Modified part iii. Type of mould • Two plate mould • Three plate mould iv. Mould construction • Side core • Stripper plate • Slant block v. Type of tools & consumables • allen key, • copper mallet • shim • abrasive paper • matching agent • oil stone vii. Product samples • Defective product • Master sample listed vii. Mould construction explained viii. Type of tools listed ix. Product defect selected 2. Carry out plastic injection mould maintenance i. Defected product sample • Type of defect • Type of abnormality ii. Mould components such as: • Top plate • Core plate • Core insert • Cavity plate • Cavity insert i. Identify type product defect ii. Identify type of product abnormality iii. Dismantle mould components iv. Dismantle mould standard parts v. Identify mould component defects vi. Carry out touch up mould component Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in Related Knowledge 16 hours Related skills 40 hours Related Knowledge Lecture Related skills Practical Demonstration i. Type of product defect identified and listed ii. Type of product abnormality identified and listed iii. Mould components dismantled iv. Mould standard parts
  • 44. 79 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria • Spacer block • Ejector retainer plate • Ejector back plate • Bottom plate iii. Mould standard parts such as :- • Locating ring • Sprue bush • Guide pillar • Guide bush • Spring • Ejector pin • Return pin iv. Type of mould component defects such as :- • Scratch • Dented • Wear and tear v. Counter problem techniques such as:- • Touch up • Regrind • Replace vii. Carry out regrind mould component viii. Carry out replacement of mould component handling mould components and tools v. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point dismantled v. Mould component defects checked and listed vi. Touch up mould component performed vii. Regrind mould component performed viii. Replacement of mould component performed ix. Safety precaution applied in performing mould maintenance 3. Perform mould assembly activities i. Assembly drawing • Drawing symbol • Mould datum • Mould components ii. Mould fitting technique • Fixed half • Moving half iii. Mould fitting method • Perpendicular i. Interpret drawing symbols ii. Identify mould references (datum) iii. Assemble moving half iv. Assemble fixed half v. Check mould perpendicular Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to Related Knowledge 8 hours Related skills 24 hours Related Knowledge Lecture Related skills Practical Demonstration i. Assembly drawing interpreted ii. Mould fitting technique demonstrate iii. Mould fitting performed iv. Matching
  • 45. 80 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria • Flatness iv. Mould matching • Matching agent • Matching surface area vi. Check mould flatness vii. Perform mould matching electrical supply iv. Attentive in handling mould components and tools v. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges agent selected v. Matching surface area confirmed vi. Mould matching performed vii. Safety precaution applied in performing mould assembly 4. Perform mould try-out i. Mould set up safety and procedure ii. Moulding machine and function • Machine specification • Machine parameter • Clamping devices iii. Pre heat procedure • Material • Mould • Machine iv. Mould set-up i. Comply to Mould set up safety and procedure ii. Identify Moulding machine and function iii. Perform pre heat procedure iv. Perform mould set- up v. Perform material purging vi. Optimised parameter Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in handling Related Knowledge 16 hours Related skills 24 hours Related Knowledge Lecture Related skills Practical Demonstration i. Mould set up safety and procedure complied ii. Moulding machine identified iii. Moulding machine function explained iv. Pre heat process listed
  • 46. 81 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria • Mould clamping • Mould accessories • Parameter setting v. Material purging • Material viscosity • Discard remaining vi. Product sample • Specification • Appearance • Profile vii. Type of moulding fault and countermeasure such as:- • Short shot • Sink mark • Burn mark • Flashing viii. Causes of product defects ix. Corrective actions • Touch up • Re-grind • Re-machining vii. Produce product sample viii. Identify product abnormality ix. Apply Countermeasure x. Perform corrective action mould components and tools v. Adhere to safe handling technique Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges & pinch point v. Mould set-up performed vi. Material purging performed vii. Moulding machine parameter confirmed viii. Product sample produced ix. Product abnormality identified x. Moulding fault listed and parameter optimised xi. Counter measure listed xii. Corrective action performed xiii. Safety precaution applied in performing mould try out 5. Inspect product sample i. Type of measuring instrument • Vernier calliper • Micrometer • Go No Go Gauge ii. Product Drawing i. Select type of measuring instrument ii. Identify Product sample dimension iii. Identify Product sample profile Attitude: i. Resourceful in acquiring information and data ii. Precise in Related Knowledge 4 hours Related skills Related Knowledge Lecture Related skills Practical i. Type of measuring instrument listed and selected ii. Product sample
  • 47. 82 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria • Dimension • Profile • Appearance iii. Product sample iv. Product inspection check sheet iv. Identify Product sample appearance v. Perform Product sample inspection vi. Fill up Product inspection check sheet communicating with internal staff iii. Meticulous in acquiring information iv. Exacting when using measuring instrument 8 hours Demonstration identified dimension iii. Product sample profile identified iv. Product sample appearance identified v. Product sample inspection performed vi. Product inspection check sheet updated 6. Check mould maintenance activity i. Type of maintenance • Corrective • preventive ii. Assembly drawing • Type of mould • Type of mould components iii. Product drawing • Product specification iv. Product inspection check sheet • Product inspection result • Mould components condition • Mould try –out result v. Mould maintenance check sheet i. Confirm type of mould maintenance ii. Confirm mould to be maintain iii. Confirm mould component defects iv. Confirm mould assembly activities v. Confirm mould try- out vi. Confirm product quality vii. Update mould maintenance check sheet Attitude: i. Resourceful in acquiring information and data ii. Precise in communicatin g with internal staff iii. Meticulous in acquiring information Related Knowledge 4 hours Related skills 12 hours Related Knowledge Lecture Related skills Practical Demonstration i. Type of maintenance Confirmed ii. Mould to be maintain confirmed iii. Mould component defects listed iv. Mould assembly activities confirmed v. Mould try-out confirmed vi. Product quality assured vii. Mould maintenance check sheet updated
  • 48. 83 Employability Skills Core Abilities Social Skills 01.07 Utilize database applications to locate and process information 01.08 Utilize spreadsheets applications to locate and process information 01.09 Utilize business graphic application to process information 01.10 Apply a variety of mathematical techniques 01.11 Apply thinking skills and creativity 02.09 Prepare flowcharts 02.10 Prepare reports and instructions 02.11 Convey information and ideas to people 03.09 Manage and improve performance of individuals 03.10 Provide consultation and counselling 03.11 Monitor and evaluate performance of human resources 03.12 Provide coaching/on-the job training 03.13 Develop and maintain team harmony and resolve conflicts 03.14 Facilitate and coordinate teams and ideas 03.15 Liaise to achieve identified outcomes 03.16 Identify and assess client/customer needs 03.17 Identify staff training needs and facilitate access to training 04.06 Allocate work 04.07 Negotiate acceptance and support for objectives and strategies 05.01 Implement project/work plans 05.02 Inspect and monitor work done and/or in progress 06.07 Develop and maintain networks 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 4. Learning skills 5. Leadership skills 6. Multitasking and prioritising 7. Self-discipline 8. Teamwork
  • 49. 84 Tools, Equipment and Materials (TEM) ITEMS RATIO (TEM : Trainees) 1. Job Instruction 2. Maintenance schedule 3. Assembly drawing 4. Injection trouble shooting guidance/chart 5. Hand tools 6. Bunsen burner 7. Measuring instruments 8. Matching agent 9. Mould release agent 10. Plastic resin 11. Plastic injection mould 12. Die spotting machine 13. Plastic injection moulding machine 14. Inspection check sheet 15. Personal Protective Equipment (PPE) 1:1 1:1 1:1 1:1 1:1 1:5 1:25 1:1 As required As required 1:5 1:25 1:25 1:1 1:1 References REFERENCES 1. Richard M. Lead, Tool and Die Making Troubleshoot (2002), Society of Manufacturing Engineers, ISBN 978-0-87263-643-9 2. Gunter Mennig (1998), Mould Making Handbook, Hanser / Gardner publication, ISBN 1-56990-261-5 3. Eric V. Buckleitner (1995), Plastics Mold Engineer Handbook, Chapman & Hall, ISBN 0-412098951-4 4. Georg Menges/Paul Mahren (1993), How to make Injection Molds, Hanser Publishers, ISBN 3-446-16305-0 5. Donald V. Rosato/Dominick V. Roasato (1995), Injection Molding Handbook, Chapman & Hall, ISBN 0-412-99381-3 6. E. Lindner and P. Unger (1993), Injection Mold 108 Proven Designs, Hanser Publishers, ISBN 3-446-15682-8 7. Michael L. Berins (1991), Plastics Engineering Handbook, Chapman & Hall, ISBN 0-412-99181-0
  • 50. 85 CURRICULUM of COMPETENCY UNIT (CoCU) Sub Sector METAL MACHINING TECHNOLOGY Job Area MOULD & DIE MANUFACTURING Competency Unit Title MOULD & DIE OPERATIONAL SUPERVISION Learning Outcome The person who is competent in mould & die supervision shall be able to supervise of group mould and die making to carry out assembly, try-out, troubleshooting and maintenance activities in accordance with standard operation procedure (SOP). Upon completion of this competency unit, trainees will be able to :- • Carry out daily briefing • Prepare work schedule • Carry out job distribution • Supervise work progress performance • Conduct section meeting • Carry out staff coaching • Control inventory • Prepare appraisal recommendation Competency Unit ID CU07 Level 03 Training Duration 180 Hours Credit Hours 18 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 1. Carry out daily briefing i. Job scheduling/job order ii. Company’s policy, rules and regulation iii. Daily briefing objective iv. Daily briefing agenda v. Briefing feedback i. Interpret Job scheduling/job order ii. Comply to Company’s policy, rules and regulation iii. Identify daily briefing objective iv. Identify daily briefing agenda v. Execute daily briefing vi. Record briefing feedback Attitude: Meticulous in identifying requirement of jobs schedule/jobs order Related Knowledge 4 hours Related skills 8 hours Related Knowledge Lecture Related skills Practical Demonstration i. Job scheduling/job order Interpreted ii. Company’s policy, rules and regulation complied iii. Daily briefing objective listed iv. Daily briefing agenda listed
  • 51. 86 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria v. Daily briefing conducted vi. briefing feedback recorded 2. Prepare work schedule i. Work scheduling format ii. Master schedule • Type of job • Delivery date iii. Type of work process requirements iv. Type of resources • Manpower • Machine • Material • Method v. Company target i. Identify schedule format ii. Interpret master schedule iii. Identify job requirement iv. Identify delivery date v. Identify work process vi. Identify Resources availability and capability vii. Identify company target viii. Plan manpower availability ix. Plan machine capacity x. Plan material receiving xi. Plan mould and die schedule xii. Produce mould and die schedule xiii. Submit mould and die schedule to superior Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff iii. Meticulous in acquiring information Related Knowledge 8 hours Related skills 24 hours Related Knowledge Lecture Related skills Practical Demonstration i. Schedule format ii. Master schedule interpreted iii. Job requirement identified iv. Work process identified v. Delivery date identified vi. Resources availability and capability identified vii. Company target identified viii. Manpower availability planned ix. Machine capacity planned x. Material receiving
  • 52. 87 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria planned xi. Mould and die planned schedule xii. Mould and die schedule produced xiii. Mould and die schedule submitted to superior 3. Carry out job distribution i. Job distribution form ii. Work schedule • Lead time • Delivery date iii. Job distribution • Manpower availability • Machine availability i. Identify Job distribution form ii. Estimate lead time iii. Confirmed delivery date iv. Arrange Manpower v. Arrange machine Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff iii. Meticulous in acquiring information Related Knowledge 4 hours Related skills 8 hours Related Knowledge Lecture Related skills Practical Demonstration i. Job distribution form determined ii. Work schedule checked iii. Lead time estimated iv. Job distribution arranged v. Manpower and machine availability arranged 4. Supervise work progress performance i. Company organization chart ii. Job status iii. Recovery plan iv. Work progress check sheet format i. Coordinate with responsibility personnel ii. Check work status iii. Arrange recovery plan iv. Update work progress check Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Authorised personnel / responsibility personnel / parties involved coordinated ii. Work progress checked
  • 53. 88 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria sheet v. Submit work progress check sheet Meticulous in acquiring information iii. Recovery plan arranged iv. Work progress report produced v. Work progress report submitted 5. Conduct section meeting i. Group meeting requirement • Type of meeting • Meeting objective • Meeting frequency • Meeting documents • Company’s rule and regulation requirement ii. Group meeting activities • Meeting Plan • Meeting Agenda • Meeting participants • Meeting preparation • Effective meeting • Meeting minute i. Identify group meeting requirement ii. Plan group meeting activities group iii. Carry out group meeting iv. Record meeting minute v. Review achievement of meeting conducted vi. Compile group meeting documents Attitude: i. Observe procedure and condition during meeting Responsible and accountable in handling meeting condition Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Group meeting requirement Identified ii. Group meeting activities Planned iii. Group meeting Carried out iv. Meeting minute recorded for further action v. Achievement of meeting conducted reviewed vi. Group meeting documents Compiled 6. Carry out staff coaching i. Coaching objective ii. Skills matrix chart iii. Coaching material iv. Coaching facilities v. Coaching module i. Identify coaching objective ii. Interpret skills matrix chart iii. Prepare coaching material iv. Prepare coaching Attitude: i. Responsible and accountable in conducting training ii. Resourceful in interpret training Related Knowledge 8 hours Related skills 24 hours Related Knowledge Lecture Related skills Practical Demonstration i. Coaching objective explained ii. Staff skills assessed in accordance with skills matrix
  • 54. 89 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria facilities v. Prepare coaching module vi. Perform internal staff coaching syllabus/title Safety: i. Adhere to safety requirement chart iii. Coaching materials prepared iv. Coaching facilities prepared v. Staff coaching performed 7. Control inventory i. Company rules & regulation • Company policy ii. Type of item / grouping • Raw material • Spare parts • Standard parts • Cutting tools • Hand tools iii. Type of document • Receiving form • Inventory record form • Request form iv. Inventory system • Storage media • Location • Labelling v. Stocktake • Stock balance • Stock requirements • Stock record form i. Comply to Company rules & regulation ii. Identify type of item iii. Identify type of document iv. Organise inventory system v. Organise stocktake vi. Update stock record form Attitude: i. Resourceful in acquiring information and data ii. Precise in communicating with internal staff iii. Meticulous in acquiring information Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Company rules & regulation complied ii. Type of item listed iii. Type of document explained iv. Items stored v. Stock record form updated
  • 55. 90 Work Activities Related Knowledge Related Skills Attitude/Safety/ Environmental Training Hours Delivery Mode Assessment Criteria 8. Prepare appraisal recommendation i. Personnel appraisal form format ii. Subordinate job description iii. Personnel appraisal evaluation criteria iv. Subordinate performance assessment i. Identify Personnel appraisal form format ii. Identify Subordinate job description iii. Identify Personnel appraisal evaluation criteria iv. Assess Subordinate performance v. Forward personnel appraisal form to superior Attitude: i. Responsible in interpreting appraisal criteria Related Knowledge 8 hours Related skills 12 hours Related Knowledge Lecture Related skills Practical Demonstration i. Personnel appraisal form format Identified ii. Subordinate job description Identified iii. Personnel appraisal evaluation criteria Identified iv. Subordinate performance assessed v. Personnel appraisal form to superior forwarded
  • 56. 91 Employability Skills Core Abilities Social Skills 01.07 Utilize database applications to locate and process information 01.08 Utilize spreadsheets applications to locate and process information 01.09 Utilize business graphic application to process information 01.10 Apply a variety of mathematical techniques 01.11 Apply thinking skills and creativity 02.09 Prepare flowcharts 02.10 Prepare reports and instructions 02.11 Convey information and ideas to people 03.09 Manage and improve performance of individuals 03.10 Provide consultation and counselling 03.11 Monitor and evaluate performance of human resources 03.12 Provide coaching/on-the job training 03.13 Develop and maintain team harmony and resolve conflicts 03.14 Facilitate and coordinate teams and ideas 03.15 Liaise to achieve identified outcomes 03.16 Identify and assess client/customer needs 03.17 Identify staff training needs and facilitate access to training 04.06 Allocate work 04.07 Negotiate acceptance and support for objectives and strategies 05.01 Implement project/work plans 05.02 Inspect and monitor work done and/or in progress 06.07 Develop and maintain networks 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 4. Learning skills 5. Leadership skills 6. Multitasking and prioritising 7. Self-discipline 8. Teamwork
  • 57. 92 Tools, Equipment and Materials (TEM) ITEMS RATIO (TEM : Trainees) 1. Meeting schedule 2. Minutes of meeting form 3. Computer with software 4. Printer 5. Jobs list 6. Attendant sheet 1:1 1:1 1:1 1:25 1:1 1:25 References REFERENCES 1. Lihui Wang (2007), Process Planning and Schedulling for Distributed Manufacturing, Springer, ISBN: 978-1-84-628751-0 2. L.N. Lopez De Lacalle (2007), Machine Tools for High Performance Machining, Springer, ISBN:978-1-848-00379-8 3. Alan Dalton (1998), Safety, Health and Environmental Hazards at the Workplace, Cengage Learning, ISBN:978-0-30-433291-5 4. Dan Hopwood, Steve Thompson(2006), Workplace safety a guide for small and midsized companies, John Wiley & Sons Inc., ISBN:978-0-7821- 3604-3
  • 58. 93 CURRICULUM OF COMPETENCY UNIT (CoCU) Sub Sector METAL MACHINING TECHNOLOGY Job Area MOULD & DIE MANUFACTURING Competency Unit Title CNC MILLING MACHINE OPERATION Learning Outcome The person who is competent in this CU shall be able to provide excellent CNC Milling Machine Operation to ensure the product requirement accepted in accordance to drawing specification. Upon completion of this competency unit, trainees will be able to :- • Interpret detail drawing • Select CNC milling machine • Setup work piece • Retrieve CNC program • Setup cutting tool • Execute CNC milling machine operation • Inspect finished product • Submit finished product with recorded data to superior Competency Unit ID CU08 Level 03 Training Duration 180 Hours Credit Hours 18 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria 1. Interpret detail drawing i. Detail Drawing ii. Drawing symbols iii. Dimensions iv. Tolerances v. Drawing projection vi. Type of machining process i. Obtain detail drawing i. Identify Drawing symbols ii. Identify Dimensions and Tolerances iii. Determine Drawing projection iv. Identify Type of machining process Attitude: i. Resourceful in interpreting drawing ii. Observe cleanliness during handling drawing document Related Knowledge 2 hours Related skills 4 hours Related Knowledge Lecture Related skills Practical Demonstration i. Drawing symbols Identified ii. Dimensions and Tolerances Identified iii. Drawing projection Determined iv. Type of machining process Identified
  • 59. 94 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria 2. Select CNC milling machine i. Types of CNC milling machine ii. CNC milling machine specification iii. type of CNC milling machine accessories iv. CNC milling machine and accessories to be used i. Identify types of CNC milling machine ii. Identify CNC milling machine specification iii. Identify type of CNC milling machine accessories iv. Confirm CNC milling machine and accessories to be used Safety: 1. Adhere to safety requirement Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration i. Types of CNC milling machine identified ii. CNC milling machine specification Identified iii. Types of accessories identified iv. CNC milling machine and accessories to be used confirmed 3. Setup work piece i. work holding device ii. work piece orientation iii. work piece alignment • Flatness • Squareness / parallelism iv. Work piece ready to be machine i. Identify work holding device ii. Confirm workpiece orientation iii. Carryout workpiece alignment iv. Confirm workpiece ready to be machine Attitude: i. Careful when handling hand tools Related Knowledge 4 hours Related skills 8 hours Related Knowledge Lecture Related skills Practical Demonstration i. Work holding device Identified ii. Workpiece orientation confirmed iii. Workpiece alignment carried out iv. Workpiece ready to be machine Confirmed
  • 60. 95 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria 4. Retrieve CNC program i. Program number ii. Types of machine controller iii. Machine language iv. CNC program editing i. Indentify program number ii. Identify types of machine controller iii. Identify machine language iv. Check CNC program v. Carry out CNC program editing Attitude: i. Responsible and quick response in receiving instruction Safety: i. Adhere to safety requirement Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration & Observation i. CNC program number identified ii. Types of machine controller Identified iii. Machine language Identified iv. CNC program checked v. CNC program editing carried out 5. Setup cutting tool i. Number of tool ii. Tool magazine iii. Tool register iv. Type of tool holder v. Tool parameter setting vi. Reference point (datum) vii. Checking instruments such as: • Edge finder • probe • tool setter viii. Mount cutting tool i. Identify number of tool ii. Identify tool magazine iii. Confirm tool register iv. Confirm type of tool holder v. Perform tool parameter setting vi. Set reference point (datum) vii. Apply checking instruments such as: • Edge finder • Probe • Tool setter viii. Fix cutting tool secure Attitude: i. Careful when handling cutting tools Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration & Observation i. Number of tool identified ii. Tool magazine identified iii. Tool register confirmed iv. Type of tool holder confirmed v. Tool parameter setting performed vi. Reference point (datum) confirmed
  • 61. 96 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria vii. Checking instruments such as applied viii. Cutting tool fix secured 6. Execute CNC milling machine operation v. CNC milling Program vi. CNC milling Machine parameter • Spindle speed (RPM) • Tool offset • Feed rate vii. CNC milling process • Drilling • Reaming • tapping • counter bore/ sunk/ chamfering • Boring • Face milling • Side milling • Slotting • Pocketing • 2D profile • 3D profile viii. Product specification ix. In-process CNC milling operation checking i. Confirm CNC milling program ii. Confirm CNC milling Machine parameter iii. Perform CNC milling process • Drilling • Reaming • tapping • counter bore/ sunk/ chamfering • Boring • Face milling • Side milling • Slotting • Pocketing • 2D profile • 3D profile iv. Identify product specification v. In-process milling operation checking Related Knowledge 18 hours Related skills 64 hours Related Knowledge Lecture Related skills Practical Demonstration & Observation i. CNC milling program confirmed ii. CNC milling Machine parameter confirmed iii. CNC milling process Performed iv. product specification Identified v. In-process milling operation checked
  • 62. 97 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria 7. Inspect finished product i. Product dimension ii. Surface finish iii. Product appearance iv. Measuring equipment v. Company’s organization chart. vi. Product inspection check sheet i. Check product dimension ii. Check surface finish iii. Check product appearance iv. utilize Measuring equipment v. Identify responsible personnel vi. Update Product inspection check sheet vii. Forward product with recorded data to superior Attitude: i. Resourceful in interpreting drawing ii. Observe cleanliness during handling drawing document Related Knowledge 2 hours Related skills 6 hours Related Knowledge Lecture Related skills Practical Demonstration & Observation i. Product dimension Checked ii. Surface finish Checked iii. Product appearance Checked iv. Measuring equipment utilized v. Responsible personnel Identified vi. Product inspection check sheet update vii. Product with recording data to superior forwarded
  • 63. 98 Employability Skills Core Abilities Social Skills 01.07 Utilize database applications to locate and process information 01.08 Utilize spreadsheets applications to locate and process information 01.09 Utilize business graphic application to process information 01.10 Apply a variety of mathematical techniques 01.11 Apply thinking skills and creativity 02.09 Prepare flowcharts 02.10 Prepare reports and instructions 02.11 Convey information and ideas to people 03.09 Manage and improve performance of individuals 03.10 Provide consultation and counselling 03.11 Monitor and evaluate performance of human resources 03.12 Provide coaching/on-the job training 03.13 Develop and maintain team harmony and resolve conflicts 03.14 Facilitate and coordinate teams and ideas 03.15 Liaise to achieve identified outcomes 03.16 Identify and assess client/customer needs 03.17 Identify staff training needs and facilitate access to training 04.06 Allocate work 04.07 Negotiate acceptance and support for objectives and strategies 05.01 Implement project/work plans 05.02 Inspect and monitor work done and/or in progress 06.07 Develop and maintain networks 1. Communication skills 2. Conceptual skills 3. Interpersonal skills 4. Learning skills 5. Leadership skills 6. Multitasking and prioritizing 7. Self-discipline 8. Teamwork
  • 64. 99 Tools, Equipment and Materials (TEM) ITEMS RATIO (TEM : Trainees) 1. Measuring instruments 2. Instrument cabinet 3. Instrument accessories 4. Instrument charts and posters 5. Technical drawing 6. Workpiece 7. Check sheet 8. Flipchart 9. Surface table 10. Personal Protective Equipment (PPE) 11. CNC Milling machine 12. Milling tool 13. Tool box 14. Hand tool 1:10 1:25 1:25 1:25 1:1 1:1 1:1 1:5 1:5 1:1 1:5 1:5 1:1 1:25 REFERENCES 1. W. Chapman (1972), Workshop Technology Part 2, Fourth Edition, Butterworth-Heinemann, ISBN: 978-0-71-313272-4 2. Karl Moltrecht (1981), Machine Shop Practice, Industrial Press, Inc., ISBN: 978-0-83-111126-7 3. David L. Goetsch, John Nelson (2004), Technical Drawing, Cengage Learning, ISBN: 978-1-40-185760-8 4. Peter Smid(2003), CNC Programming Handbook, Industrial Press, Inc., ISBN: 978-0-83-11358-6 5. Peter Smid (2010), CNC Setup and Operation Milling-Turning, Industrial Press, Inc., ISBN: 978-0-83-113350-4 6. Ibrahim Zeid (1991), CAD/CAM Theory and Practice, McGraw-Hill, ISBN: 0-07-112901-4
  • 65. 100 CURRICULUM OF COMPETENCY UNIT (CoCU) Sub Sector METAL MACHINING TECHNOLOGY Job Area MOULD & DIE MANUFACTURING Competency Unit Title CNC ELECTRICAL DISCHARGE MACHINE (EDM) DIE SINKING OPERATION Learning Outcome The person who is competent in this CU shall be able to provide excellent CNC ELECTRICAL DISCHARGE MACHINE (EDM) Die Sinking Operation to ensure the product requirement accepted in accordance to drawing specification. Upon completion of this competency unit, trainees will be able to :- • Interpret detail drawing. • Select CNC EDM Die Sinking machine • Set up EDM electrode • Set up work piece. • Generate CNC Program Die Sinking • Execute CNC EDM Die Sinking operation. • Inspect finished product. • Submit finished product with recording data to superior Competency Unit ID CU09 Level 3 Training Duration 150 Hours Credit Hours 15 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria 1. Interpret detail drawing i. Detail Drawing ii. Drawing symbols iii. Dimensions iv. Tolerances v. Drawing projection vi. Type of EDM process i. Obtain detail drawing ii. Identify Drawing symbols iii. Identify Dimensions and Tolerances iv. Determine Drawing projection v. Identify Type of EDM process Attitude: i. Resourceful in interpreting drawing ii. Observe cleanliness during handling drawing document Related Knowledge 2 hours Related skills 4 hours Related Knowledge Lecture Related skills Practical Demonstration & Observation i. Detail drawing obtained ii. Drawing symbols identified iii. Dimensions and tolerances identified iv. Drawing projection determined v. Type of EDM
  • 66. 101 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria process identified 2. Select CNC EDM Die Sinking machine i. Type of machine controller ii. Types of EDM die sinking machine iii. Types of accessories • Tool and work holding devices • Dielectric fluid i. Identify type of machine controller ii. Identify types of EDM die sinking machine iii. Identify type of accessories iv. Identify Dielectric fluid v. Decide CNC EDM die sinking machine and specification to be used Safety: i. Adhere to safety requirement Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration & Observation i. Type of machine controller identified ii. Types of EDM die sinking machine identified. iii. Types of accessories identified iv. Dielectric fluid v. CNC EDM die sinking machine and specification to be used decided 3. Set up EDM electrode i. EDM electrodes ii. EDM electrode holder iii. Type of electrode material iv. Spark gap v. EDM electrode fixing vi. techniques vii. Number of electrode viii. Orientation of electrode ix. Alignment electrode i. Select EDM electrodes ii. Select EDM electrode holder iii. Identify type of electrode material iv. identify spark gap v. Identify EDM electrode fixing techniques vi. Determine number of electrode Attitude: i. Careful when handling electrode Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard Related Knowledge 4 hours Related skills 8 hours Related Knowledge Lecture Related skills Practical Demonstration & Observation i. EDM electrodes selected ii. EDM electrode holder selected iii. Type of electrode material identified iv. Spark gap
  • 67. 102 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria x. Flatness of electrode xi. Reference point (datum) of electrode vii. Decide orientation of electrode viii. Check alignment electrode ix. Check flatness of electrode x. Decide reference point (datum) of electrode ii. Beware of sharp edges identified v. EDM electrode fixing techniques identified vi. number of electrode determined vii. Orientation of electrode decided viii. Alignment electrode checked ix. Flatness of electrode checked x. Reference point (datum) of electrode decided 4. Set up work piece. i. Type of material ii. Size of material iii. Shape of material iv. Clamping device v. Work pieces orientation vi. Hand tools vii. Alignment work piece viii. Flatness of work piece i. Identify type of material ii. Identify size of material iii. Identify shape of material iv. Identify Clamping device Attitude: i. Careful when handling hand tools Safety: i. Ensure personal protective equipment (PPE) meet Related Knowledge 4 hours Related skills 8 hours Related Knowledge Lecture Related skills Practical Demonstration & Observation i. Type of material identified ii. Size of material identified iii. Shape of material
  • 68. 103 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria ix. Datum of work piece v. Decide work pieces orientation vi. Identify hand tools vii. Check alignment work piece viii. Check flatness of work piece ix. Decide datum of work piece Safety Regulation & Standard ii. Beware of sharp edges identified iv. Clamping device identified v. Work pieces orientation decided vi. Hand tools identified vii. Alignment work piece checked viii. Flatness of work piece checked ix. Datum of work piece decided 5. Generate CNC Program Die Sinking i. Types of machine controller ii. Machine language iii. CNC EDM die sinking Programming • Simulation • dry run i. Identify types of machine controller ii. Identify machine language iii. Create CNC EDM die sinking Program iv. Check CNC die sinking program: v. Confirm program number vi. Store CNC program Attitude: i. Responsible and quick response in receiving instruction Safety: i. Adhere to safety requirement Related Knowledge 8 hours Related skills 16 hours Related Knowledge Lecture Related skills Practical Demonstration & Observation i. Types of machine controller Identified ii. Machine language Identified iii. CNC EDM die sinking Program created iv. CNC die sinking
  • 69. 104 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria program checked v. Program number Confirmed vi. CNC program Stored 6. Execute CNC EDM Die Sinking operation i. Programming code ii. Reference point iii. CNC EDM die sinking iv. Surface finish v. Product specification vi. Safety precaution i. Confirm programming number ii. Confirm reference point/ datum iii. Perform CNC EDM die sinking iv. Check surface finish v. Identify product specification Attitude: i. Meticulous in interpreting drawing ii. Exacting when using measuring instrument iii. Alert to electrical supply iv. Attentive in handling workpiece and tools Safety: i. Ensure personal protective equipment (PPE) meet Safety Regulation & Standard ii. Beware of sharp edges Related Knowledge 16 hours Related skills 48 hours Related Knowledge Lecture Related skills Practical Demonstration & Individual project i. Programming code confirmed ii. Reference point confirmed iii. CNC EDM die sinking performed iv. Surface finish checked v. Product specification identified vi. Safety precaution applied
  • 70. 105 Work Activities Related Knowledge Related Skills Attitude / Safety / Environmental Training Hours Delivery Mode Assessment Criteria 7. Inspect finished product. i. Product dimension ii. Surface finish iii. Perpendicular iv. Product appearance v. Check sheet vi. Measuring equipment vii. Company’s organization chart. viii. Product inspection check sheet i. Identify product dimension ii. Check surface finish iii. Check perpendicular iv. Check product appearance v. Fill up check sheet vi. Utilize measuring equipment vii. Identify responsible personnel viii. Update Product inspection check sheet ix. Forward product with recording data to responsible personnel Attitude: i. Resourceful in interpreting drawing ii. Observe cleanliness during handling drawing document Related Knowledge 2 hours Related skills 6 hours Related Knowledge Lecture Related skills Practical Demonstration & Individual project i. Product dimension identified ii. surface finish checked iii. Perpendicular checked iv. Product appearance checked v. Check sheet filled vi. Measuring equipment utilized vii. Responsible personnel identified viii. Product inspection check sheet updated ix. Product with recording data to superior forwarded