FOCUSED TRAINING MODULES

HOW TO USE OUR FOCUSED TRAINING MODULES

STEP 1 Review the Lesson Content

Preview the video training lesson for the module to determine which employees at your
facility could benefit from this training. Focus on the following criteria:

· Who would benefit directly from learning this topic?

· Who should know about the concepts covered in this module?

STEP 2 Complete the Training Plan

List all the employees identified in STEP 1 in your TRAINING PLAN for the module. We
recommend that you identify your employees by job description (such as all the technicians or
operators) and use this to track their progress throughout the training initiative.

STEP 3 Have Your Employees Watch the Video Training Lesson

Have each employee on your training plan sit down and watch the video training lesson. We
suggest that you train from the top down: This will help you get everyone on the same page.

STEP 4 Carry out the On-The-Job Training

Identify a few knowledgeable employees who can take the others out to the plant floor and
cover the ON-THE-JOB TRAINING SHEET. Be sure to complete this step within a week of
completing STEP 3.

STEP 5 Quiz Your Employees

Have each employee on your training plan take the TRAINING QUIZ. To pass the test, your
employees must answer at least 3 out of the 4 questions correctly. If they fail the quiz, have
them repeat STEP 3 and STEP 4 before giving them another opportunity to pass the quiz.

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FOCUSED TRAINING MODULE #11
Water Line Set-Up

TRAINING PLAN

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FOCUSED TRAINING MODULE #11
Water Line Set-Up

ON-THE-JOB TRAINING SHEET

Training Facilitator:

Training Participant:

Training Date:

Training Location: In front of a machine during a mold change with a mold change
SOP (Standard Operating Procedure). Have a mold installed
and water lines disconnected before starting.

Discuss the mold change SOP – paying strict attention to the water line set-up portion.

Explain to the employee that the injection mold should be closed when connecting the water lines to
help protect the mold cavity from getting wet, scratched or otherwise damaged.

Demonstrate how to check the water line fittings for damage or looseness.

Discuss the water treatment methods used at your facility: Cover how it’s managed, its toxicity, and
how to properly handle a water spill to prevent any health hazards.

Before connecting the water lines, discuss the water flow in and out of the mold – as well as any
manifold configuration. Explain the color coding used to ensure that in and out water lines are not
confused.

Once the water lines are connected, have the employee slowly turn on the water. At each increment,
ask them to check the connectors and lines for leaks.

Explain that the lines should be re-checked after a few minutes as a leak may be slow. You may also
need to dry-cycle the mold; many molds do not leak regularly, but can leak when full tonnage is
applied to the mold. This leaking may show up around different mold features such as core blocks
and mold plates.

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FOCUSED TRAINING MODULE #11
Water Line Set-Up

TRAINING QUIZ

Facilitator Name:

Participant Name:

Date:

Question #1:
When connecting the water lines, the mold should be? (circle one)
A. Open with full daylight
B. Closed without tonnage applied
C. Closed under full tonnage
D. Any of the above are acceptable

Question #2:
You should turn on the water supply quickly to help identify leaks sooner. (circle one)
True or False

Question #3:
Which is not an appropriate procedure before connecting water lines? (circle one)
A. Inspect the water fittings
B. Examine the condition of the hoses
C. Turning off the hydraulic pump
D. Place machine in manual mode
E. All of the above are appropriate procedures

Question #4:
Explain how the in and out water lines are differentiated at your facility.
(write your answer in the space below)

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FOCUSED TRAINING MODULE #11
Water Line Set-Up

TRAINING QUIZ ANSWERS

Passing Score: 3 of the 4 questions must be answered correctly

Question #1:
When connecting the water lines, the mold should be? (circle one)
A. Open with full daylight
B. Closed without tonnage applied
C. Closed under full tonnage
D. Any of the above are acceptable
Explain to the employee that the injection mold should be closed when connecting the water lines to
help protect the mold cavity from being scratched, wet, or damaged.

Question #2:
You should turn on the water supply quickly to help identify leaks sooner. (circle one)
True or False
Once the water lines are connected, slowly turn on the water. At each increment, check the connectors
and lines for leaks.

Question #3:
Which is not an appropriate procedure before connecting water lines? (circle one)
A. Inspect the water fittings
B. Examine the condition of the hoses
C. Turning off the hydraulic pump
D. Place machine in manual mode
E. All of the above are appropriate procedures
Each of the above helps protect the employee from injury as well as protect the mold from damage.

Question #4:
Explain how the in and out water lines are differentiated at your facility.
This is a plant-specific question requiring your input.

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