Government of Pakistan

National Vocational and Technical Training Commission

Prime Minister’s Hunarmand Pakistan Program

"Skills for All"

Course Contents / Lesson Plan

Course Title: Plastic Injection Molding Machine Operator
Duration: 6 Months

Revised Edition
Trainer Name

Course Title Plastic Injection Molding Machine Operator

Objectives and Employable skills and hands-on practice for Plastic Injection Molding
Expectations Machine Operator

This course offers a broad, cross-disciplinary learning experience for students

looking to pursue career as a Plastic Injection Molding Machine Operator. The
needs for superior technology have increased in keeping with the demands for
a wide variety of performances such as high productivity, high quality, as well
as labor and cost savings. This course will provide participants with an
integrated approach to learn about the various aspects of being a Plastic
Injection Molding Machine Operator and allied technologies.

Main Expectations:
In short, the course under reference should be delivered by professional
instructors in such a robust hands-on manner that the trainees are comfortably
able to employ their skills for earning money (through wage/self-employment)
at its conclusion.
This course thus clearly goes beyond the domain of the traditional training
practices in vogue and underscores an expectation that a market-centric
approach will be adopted as the main driving force while delivering it. The
instructors should therefore be experienced enough to be able to identify the
training needs for the possible market roles available out there. Moreover, they
should also know the strengths and weaknesses of each trainee to prepare
them for such market roles during/after the training.

i. Specially designed practical tasks to be performed by the trainees have

been included in the Annexure-I to this document. The record of all
tasks performed individually or in groups must be preserved by the
management of the training Institute clearly labeling name, trade,
session, etc so that these are ready to be physically inspected/verified
through monitoring visits from time to time. The weekly distribution of
tasks has also been indicated in the weekly lesson plan given in this
document.
ii. To materialize the main expectations, a special module on Job Search
& Entrepreneurial Skills has been included in the latter part of this
course (5th & 6th month) through which, the trainees will be made aware
of the Job search techniques in the local as well as international job
markets (Gulf countries). Awareness around the visa process and
immigration laws of the most favored labor destination countries also
form a part of this module. Moreover, the trainees would also be
encouraged to venture into self-employment and exposed to the main
requirements in this regard. It is also expected that a sense of civic
duties/roles and responsibilities will also be inculcated in the trainees to
make them responsible citizens of the country.

iii. A module on Work Place Ethics has also been included to highlight the
importance of good and positive behavior in the workplace in the line
2 | Plastic Injection Moulding Machine Operator
 with the best practices elsewhere in the world. An outline of such
qualities has been given in the Appendix to this document. Its
importance should be conveyed in a format that is attractive and
interesting for the trainees such as through PPT slides +short video
documentaries. Needless to say that if the training provider puts his
heart and soul into these otherwise non-technical components, the
image of the Pakistani workforce would undergo a positive
transformation in the local as well as international job markets.
To maintain interest and motivation of the trainees throughout the course,
modern techniques such as:
• Motivational Lectures
• Success Stories
• Case Studies
These techniques would be employed as an additional training tool wherever
possible (these are explained in the subsequent section on Training
Methodology).
Lastly, evaluation of the competencies acquired by the trainees will be done
objectively at various stages of the training and a proper record of the same
will be maintained. Suffice to say that for such evaluations, practical tasks
would be designed by the training providers to gauge the problem-solving
abilities of the trainees.

(i) Motivational Lectures

The proposed methodology for the training under reference employs
motivation as a tool. Hence besides the purely technical content, a trainer is
required to include elements of motivation in his/her lecture. To inspire the
trainees to utilize the training opportunity to the full and strive towards
professional excellence. Motivational lectures may also include general topics
such as the importance of moral values and civic role & responsibilities as a
Pakistani. A motivational lecture should be delivered with enough zeal to
produce a deep impact on the trainees. It may comprise of the following:

 Clear Purpose to convey the message to trainees effectively.

 Personal Story to quote as an example to follow.
 Trainees Fit so that the situation is actionable by trainees and not
represent a just idealism.
 Ending Points to persuade the trainees on changing themselves.

A good motivational lecture should help drive creativity, curiosity, and spark
the desire needed for trainees to want to learn more.
The impact of a successful motivational strategy is amongst others commonly
visible in increased class participation ratios. It increases the trainees’
willingness to be engaged on the practical tasks for a longer time without
boredom and loss of interest because they can see in their mind's eye where
their hard work would take them in short (1-3 years); medium (3 -10 years) and
long term (more than 10 years).

As this tool is expected that the training providers would make arrangements
for regular well planned motivational lectures as part of a coordinated strategy
interspersed throughout the training period as suggested in the weekly lesson
plans in this document.

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 Course-related motivational lectures online link is available in Annexure-II.

(ii) Success Stories

Another effective way of motivating the trainees is using Success Stories. Its
inclusion in the weekly lesson plan at regular intervals has been recommended
till the end of the training.
A success story may be disseminated orally, through a presentation, or using
a video/documentary of someone that has risen to fortune, acclaim, or brilliant
achievement. A success story shows how a person achieved his goal through
hard work, dedication, and devotion. An inspiring success story contains
compelling and significant facts articulated clearly and easily comprehendible
words. Moreover, it is helpful if it is assumed that the reader/listener knows
nothing of what is being revealed. The optimum impact is created when the
story is revealed in the form of:-
 Directly in person (At least 2-3 cases must be arranged by the training
institute)
 Through an audio/ videotaped message (2-3 high-quality videos must
be arranged by the training institute)
It is expected that the training provider would collect relevant high-quality
success stories for inclusion in the training as suggested in the weekly lesson
plan given in this document.
Suggestive structure and sequence of a sample success story and its various
shapes can be seen in Annexure III.

(iii) Case Studies

Where a situation allows, case studies can also be presented to the trainees to
widen their understanding of the real-life specific problem/situation and to
explore the solutions.
In simple terms, the case study method of teaching uses a real-life case
example/a typical case to demonstrate a phenomenon in action and explain
theoretical as well as practical aspects of the knowledge related to the same. It
is an effective way to help the trainees comprehend in depth both the
theoretical and practical aspects of the complex phenomenon in depth with
ease. Case teaching can also stimulate the trainees to participate in
discussions and thereby boost their confidence. It also makes the classroom
atmosphere interesting thus maintaining the trainee interest in training till the
end of the course.
Depending on suitability to the trade, the weekly lesson plan in this document
may suggest case studies be presented to the trainees. The trainer may adopt
a PowerPoint presentation or video format for such case studies whichever is
deemed suitable but only those cases must be selected that are relevant and
of a learning value.
The Trainees should be required and supervised to carefully analyze the
cases.
For this purpose, they must be encouraged to inquire and collect specific
information/data, actively participate in the discussions, and intended solutions
to the problem/situation.

Case studies can be implemented in the following ways: -

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 i. A good quality trade-specific documentary (At least 2-3
documentaries must be arranged by the training institute)

ii. Health & Safety case studies (2 cases regarding safety and
industrial accidents must be arranged by the training institute)

iii. Field visits (At least one visit to a trade-specific major industry/ site
must be arranged by the training institute)
Entry-level of
trainees Intermediate

Learning By the end of this course, students will be able to:

Outcomes of the  Be able to recognize the dangers and observe relevant safety
course precautions while performing / supervising hot work.
 Understand the differences and working principles of various Injection
moulding equipment on board.
 Troubleshoot injection moulding machine.
 Troubleshoot for moulding faults and analyse for causes and provide
remedies
 Basic operation of hydraulic and pneumatic systems
 Classify different mould fitting adjustment
 Operation & control of PLC operated IMM
 Test various properties & identify plastic using 7 QC tools
Course The total duration of the course: 6 months (26 Weeks)
Execution Plan Class hours: 4 hours per day
Theory: 20%
Practical: 80%
Weekly hours: 20 hours per week
Total contact hours: 520 hours
Companies 1. Techpro Industries Private Limited, Taxila
offering jobs in 2. Lucky Plastic Industries Pvt Ltd, Lahore
the respective 3. Engi Plastic Industries Lahore
trade 4. HI TECH Plastics Engineering
5. Borche Injection Molding Machinery Pakistan
6. PolyPlast Custom Moulders PCM
7. Sakura Group Of Companies
8. Innovative Manufacturing Industries
Job Can join industry as Technician and will progress further as Senior
Opportunities Technician, Supervisor and can rise up to the level of Manager.
Can become Entrepreneur in the related field.
Can join Apprenticeship programs in different types of industries
No of Students 25
Learning Place Classroom / Lab
Instructional 1. Injection molding theory and practice by I Rubin.
Resources 2. Plastics material and processes by Schwartz and Goodman.
3. A Guide to Injection Molding of plastics by Bolur.
4. Plastic engineering Handbook by Jeol Frados.
5. Injection molding machine by Johannaber.
6. Injection molding machine by Wheelen

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 MODULES

Scheduled Module Title Learning Units Remarks

Weeks

Week 1 Understand the  Motivational Lecture (For further detail

basic Engineering please see Page No: 3& 4)
practice and  Job market Home
Introduction  Course Applications Assignment
 Institute/work ethics
 Identify and describe personal  Task 1
protective equipment (PPE) related to  Task 2
the Injection Moulding Machine  Task 3
 Identify and describe body, foot,
and hand protective gear. Details may
 Identify and describe ear, eye, be seen at
face, and head protective gear. Annexure-I
 Identify and describe Injection Moulding
Machine safety practices related to
specific hazards or environments.
Week 2 Measuring,  Success stories ( For further detail
Cutting and please see Page No: 3& 4)
finishing tools
Students are introduced to:
 Importance of trade.
 Importance of safety & Rules.  Task 4
 Classes of fire extinguishers.
 Introduction about occupational health Details may
hazards followed in plastic industries be seen at
 Linear measuring Tools (steal rule) Annexure-I
 Hand Tools
 Marking Tools
 Punching Tools
 Sawing Tools
 Files
 Description Types grades & cut
Week 3 Drilling, Tapping,  Motivational Lecture( For further detail
Dieing please see Page No: 3& 4)
Students are introduced to:  Task 5
 Drilling machine and its types
 Drilling machines its parts and functions Details may
 Types of drill be seen at
 Operation Done of Drilling machine Annexure-I
 Tool’s used in internal threading Tap
&Tap wrench
 Tools used in external threading Die&
Diestock
 Introduction to precision measuring
instruments
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  Vernier caliper
 Micrometer
 Height gauge
 Bevel protector
 Least count calculation and it’s
measurements
 Locking devices.
Week 4 Basic electrical  Success stories ( For further detail
Earthings please see Page No: 3& 4)
 Task 6
Students are introduced to learn:
 Definition of Electrical Quantities and its Details may
Units be seen at
 Ohm’s law Annexure-I
 Types of circuits and its connections
 Types of Fuses Monthly
 Types of Earthing Test
 Wire & cable
 Electric Symbol’s
Week 5 Plastic materials  Motivational Lecture( For further detail
and properties please see Page No: 3& 4)
Students are introduced to:
 Introduction of plastic  Task 7
 Group of plastic
 Properties and used of Details may
 Thermoplastic materials be seen at
 PE *PP * PVC * PMMA * SAN* PC* Annexure-I
Nylon * PET.
 Properties and Uses of Thermosetting
materials *PF* UF* MF* EPOXY*
Polyester resin (SMC/DMC)
 Identification of plastic.
Week 6 Injection  Success stories ( For further detail
moulding items please see Page No: 3& 4)
and defects
Students are introduced to:
 Different processing techniques
 Classification of Injection moulding
machine  Task 8
 Hand injection moulding machine parts
and function Details may
 Injection moulding cycle be seen at
 Moulds used in hand injection moulding Annexure-I
 machine and its terms
 Faults, causes and its remedies in hand
injection moulding process. Basic
knowledge of mould
 Core
 Cavity
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  Cooling channel
 Ejection system
 Runner
 Gate
Week 7 Automatic  Motivational Lecture( For further detail
injection please see Page No: 3& 4)
moulding machine
Students are introduced to:
 Auto injection moulding machine its
parts and functions
 Screw type injection moulding machine
 Plunger type injection moulding  Task 9
machine
 Co-injection Details may
 Different type of clamping system be seen at
Annexure-I
 Auto injection moulding machine mould
its parts and function
 Two plate mould &three plate mould.
Hot Runner mould
 Processing defects causes and
Remedies –(product )
 Trouble shooting of injection molding
machine.
Week 8 Automatic  Success stories ( For further detail
injection please see Page No: 3& 4)
moulding machine
and Students are introduced to:
 Advantage of Microprocessor and PLC  Task 10
Microprocessor
control and PLC  Electrical injection moulding machines.
 Basic principles and feature of thermo Details may
set injection moulding process be seen at
Annexure-I
 Comparison between conventional
injection moulding machine and PLC &
microprocessor control injection
moulding machine.
Week 9 Preventive  Motivational Lecture( For further detail
maintenance of please see Page No: 3& 4)
injection
moulding machine Students are introduced to:
 Task 11
 Importance of preventive maintenance
 Schedule wise preventive maintenance Details may
of injection moulding machine
be seen at
 Introduction about hydraulic system.
Annexure-I
 Pascal’s law.
 Different hydraulic component and it
function.
 Hydraulic symbol’s of component.

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Week 10 Compression  Success stories ( For further detail
moulded items please see Page No: 3& 4)
and defects
Students are introduced to:
 Processing techniques used for thermo  Task 12
set materials
 Introducing about compression Details may
moulding process be seen at
 Machinery used for compression Annexure-I
moulding process.
 Hand compression moulding machine
parts and function
 Faults causes and remedies of product.

Week 11 Semi- auto  Motivational Lecture (For further detail

compression please see Page No: 3& 4)
moulding machine
Students are introduced to:
 Introduction about semi-auto
compression moulding machine.  Task 13
 Semi-auto compression moulding
machine parts and function. Details may
 Heating system used for mould. be seen at
 Different types of compression mould Annexure-I
 Faults, causes, remedies of processing
 Trouble shooting of compression
moulding machine
 Introduction about transfer moulding
process
Week 12 Blow moulding  Success stories ( For further detail
items and finished please see Page No: 3& 4)
product  Task 14
inspection Students are introduced to:
 Introduction to blow moulding process. Details may
 List the blow moulding techniques. be seen at
 Explain parts and functions of hand Annexure-I
blow moulding machine.
 Faults, causes & Remedies of hand
blow moulding.
Week 13 Midterm

Week 14 Pneumatic  Success stories ( For further detail  Home

circuits please see Page No: 3& 4) Assignment

Students are introduced to:  Task 15

 Introduction about pneumatic system.
 Different pneumatic component and its Details may
function. be seen at
 Pneumatics symbols of component. Annexure-I

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Week 15 Set and operate  Motivational Lecture (For further detail
the blown film please see Page No: 3& 4)
plant
Students are introduced to:
 Auto blow moulding machine parts and
functions.
 cycle of Auto blow moulding process.
 Different types of blow moulds and its
nomenclature.
 Stretch blow moulding process.
 Other blow moulding techniques.
(Extrusion stretch blow (injection stretch  Task 16
blow extrusion blow, intermittent blow,
injection blow). Details may
 Faults, causes remedies of blow be seen at
moulding. Annexure-I
 Preventive maintenance of low
moulding machine.
 Required PPE
 Introduction to extrusion process.
 Materials used for extrusion.
 Latest extrusion techniques – (multilayer
co-extruder, corrugated pipes.)
 Extrusion machine its description use
different parts & function.
 Blown film extrusion.
 Fault, causes Remedies of Blown film.
Week 16 Operate the pipe  Success stories ( For further detail
plant and produce please see Page No: 3& 4) ● Task 17
good quality pipe
Students are introduced to:
 PVC compounding and its chemical Details may
ingredients be seen at
 Pipe plant extrusion its units and Annexure-I
function
 Fault, causes, Remedies of pipe.
Week 17 Operate the  Motivational Lecture (For further detail
reprocessing please see Page No: 3& 4)
plant and produce
Students are introduced to: ● Task 18
reprocessed
granules ● Reprocessing of plastic.
 Scrap grinder parts & function & its Details may
specification. be seen at
Annexure-I
 Identification code Number for different
plastics and its use.
 Description about extrusion dies & its
parts.

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Week 18 Thermoforming  Success stories (For further detail
machine and please see Page No: 3& 4)  Task 19
defects
Students are introduced to: Details may
 Introduction thermoforming process. be seen at
 Thermoforming cycle. Annexure-I
 Materials for thermoforming.
 Mould materials.  Monthly
 Heating systems. Test

Week 19 Predrying process  Motivational Lecture (For further detail

using different please see Page No: 3& 4)
materials
Students are introduced to:
 Importance of pre-drying.  Task 20
 Various pre-drying equipments.
 Pre-drying temperature and time for Details may
various materials. be seen at
 Safety observed while operating pre- Annexure-I
drying equipment
Week 20 Machining  Success stories ( For further detail  Task 21
operations please see Page No: 3& 4)
on plastic Details may
sheets/blocks Students are introduced to: be seen at
 Methods of joining & assembly Annexure-I
 Buffing & sanding.
 Methods of machining of plastics.
 Decoration of plastics.
Week 21 Employable ● Guidelines to the Trainees for selection
Project/ of students employable project like final
Assignment year project (FYP) Monthly Test
(6 weeks) ● Assign Independent project to each
i.e. 21-26 besides Trainee
regular classes. ● A project-based on trainee’s aptitude
OR and acquired skills.
On the job ● Designed by keeping in view the
training ( 2 weeks) emerging trends in the local market as
well as across the globe.
● The project idea may be based on
Entrepreneur.
● Leading to successful employment.
● The duration of the project will be 6
weeks
 Final viva/assessment will be conducted
on project assignments.
 At the end of the session, the project will
be presented in a skills competition
 The skill competition will be conducted
on zonal, regional, and National levels.

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  The project will be presented in front of
Industrialists for commercialization
 The best business idea will be placed in
the NAVTTC business incubation center
for commercialization.
OR
On the job training for 2 weeks:
 Aims to provide 2 weeks of industrial
training to the Trainees as part of the
overall training program
 Ideal for the manufacturing trades
 As an alternative to the projects that
involve expensive equipment
 Focuses on increasing Trainee’s
motivation, productivity, efficiency, and
quick learning approach.
Week 22 Capstone Project Students are provided with details
regarding a capstone project that they
are required to complete to showcase
their learning. The project should ideally
consist of the following deliverables:
1. Design brief/description outlining their
project
2. Research collected during the project
3. Rough sketches, either hand-drawn or
digitally created that showcase their
design process
4. Professionally presented a main body of
artwork at the end of the course

Notes for the Trainer/Teacher:

 Each student must receive a
separate/independent project based on
their strengths and interests. This will
reinforce their motivation and determine
their aptitude towards specific design
fields.
 Each project should be designed
keeping future design trends as well as
current market demands in mind
 The duration for the completion of the
project is 4 weeks

It’s important to reiterate the value of

these projects as each student will later
be able to showcase their creative effort
in the real world market, giving them
leverage over others for better
employment.

Ideas for projects may be generated via

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 different sites such as:
https://1000projects.org/
https://www.freestudentprojects.com/
Week 23 Introduction to  Motivational Lecture( For further detail
Freelancing please see Page No: 3& 4)
Students are introduced to:
 the concept of freelancing
 how to become freelance and create a
sustainable income
 pros and cons of freelancing
 the ethical and professional way of
becoming a productive freelancer
 resources available for freelancing in
the field of design
 how to join freelancing sites
 the process of creating a freelancing
profile
Week 24 Professional  Success stories ( For further detail
practice please see Page No: 3& 4)
methods& legal
side of design Students are introduced to:
 the standards that define the
expectations of a professional welder
 the principles of integrity that
demonstrate respect for the profession,
for colleagues, for clients, for audiences
or consumers, and society as a whole
 the perspectives of the said profession
i.e. understanding the profession, the
meanings of environmental
responsibility, copyright, and ethics
 what legalities are involved in
professional projects
 how to build strong professional
proposals
 copyrights, copyright infringement,
plagiarism, crediting creators,
purchasing online products,
downloading ‘free’ content
 the do’s and don’ts of how to price their
time, effort, and creativity
Week 25 Preparing your  Motivational Lecture( For further detail
portfolio please see Page No: 3& 4)
Students are introduced to:
 the concept of design portfolios
 the concept of present design
work/projects in a professional manner Final
 websites that provide free portfolio Assessment
hosting such as Behance and Dribble
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  creating a portfolio
 how to select work for presenting in your
portfolio
Week 26 Entrepreneurship  Success stories ( For further detail
and Final please see Page No: 3& 4)
Assessment in  Job Market Searching
project  Self-employment
 Introduction
 Fundamentals of Business
Development
 Entrepreneurship
 Startup Funding
 Business Incubation and Acceleration
 Business Value Statement
 Business Model Canvas
 Sales and Marketing Strategies
 How to Reach Customers and Engage
 Stakeholders Power Grid
 RACI Model, SWOT Analysis, PEST
Analysis
 SMART Objectives
 OKRs
 Cost Management (OPEX, CAPEX,
ROCE, etc.)
 Final Assessment

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 Annexure-I:

Tasks For Certificate in Plastic Injection Moulding Machine Operator

Task Task Description Week

No.
1. Find the career path  Prepare a career path related to your course
and also highlight the emerging trends in the
local as well as international market
2. Work Ethics  Generate a report on Institute work ethics and Week 1
professionalism related to your course
3. Identify hazards in  Prepare a report of at least 10 safety practices
workshop and Plastic Injection Molding Machine related
hazards.
4. Check and perform  Identification to safety equipment & their use etc.
measuring, marking,  General safety precautions while working in PPO
Hack sawing, filling section.
by using various  Methods of Housekeeping.
measuring, marking,  Use fire fighting equipments.
cutting and finishing  Importance of trade training.
tools following safety  Perform marking practice straight lines. Week-2
precautions  Perform hack sawing.
 Fit hacksaw blade to frame.
 Use different types of hacksaws frames.
 Perform filling practice - (straights, cross a draw).
 Check flatness.
 Check right angle.
 Check overall dimensions with vernier calliper.
 Check overall dimensions with vernier height
gauge
5. Check and perform Drilling Practice
drilling, tapping,  Identify of different parts of drilling machine.
dieing by using  Fit the tool on drilling machine
different related tools  Set the job on machine table with machine vice.
 Perform drilled hole.
 Perform blind hole.
 Perform counter sunked hole. Week 3
 Perform counter boring hole.
 Perform spot facing with drilling machine.
 Inspect hole diameters with the help of vernier
caliper.
Tapping practice
 Illustrate tapping tools (Tap set and Tap wrench).
 Perform tapping practice with Tap set.
Dieing practice
 Illustrate dieing Tools (Die & Diestock).
 Perform dieing practice with Die.
 Inspect outside diameters with the help of outside
micrometer.
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 6. Test and Perform  Perform circuits (close open short).
basic electrical  Verify Ohm’s law.
earthings with the  Perform series circuits.
accessories fittings  Perform parallel circuits.
on board  Perform compound circuits. Week 4
 Do earthing & test
 Fix the accessories one electric board.
7. Identify different  Identify plastic (Thermoplastic / Thermoset)
plastic materials and  Perform Tensile Testing.
test the properties of Week 5
 Perform Compression Test.
material by using  Perform Shear test.
various test  Perform Hardness Test.
apparatus  Perform Melting point Test.
 Perform Impact Test.
 Perform Cup flow Testing.
 Perform Water absorption Testing.
 Perform Haze, gloss testing.
 Perform Dart impact Testing.
8. Identify, set and  Identify different parts of Hand injection moulding
produce good quality machine.
of injection moulding Week 6
 Perform Mould setting.
items and check the  Loading
defects  Perform mould
 Loading mould cooling connection
 Purging of screw and bearing
 Pre-drying requirement
 Set Temperature.
 Perform IRO.
 Perform TRO - Single cavity mould.
 Perform TRO- Double cavity mould.
 Do preventive maintenance of Hand injection
moulding machine.
9. Automatic injection  Identify of different parts of Automatic injection
moulding machine moulding machine (parts & function).
 Perform Mould setting.
 Read and set the pressure gauges. Week 7
 Read and set temperature.
 Perform IRO- (start-up, cycle and shutdown
procedure).
 Perform TRO- single cavity / double cavity mould.
 Inspect quality (visuals).
 Do preventive maintenance of auto injection
moulding machine.
10. Identify, set, maintain  Identify and list out of microprocessor control
and produce good process parameters.
quality of injection  Read and study of process parameters.
moulding items by  Perform mould setting.
using automatic  Mould loading
injection moulding  Cooling / MTC
machine with the  Hot runner system Week 8
application of  Ejection
Microprocessor
16 | Plastic Injection Moulding Machine Operator
 control and PLC  Perform Injection unit setting.
 Perform different pressure setting.
 Set the temperature.
 Perform IRO.
 Set the shot weight.
 Perform TRO.
 Shoot out troubles of processing.
 Perform mould unloading
 Perform mould loading.
 Housekeeping of mould.
 Trouble shooting of machine.
11. Preventive  Do over all cleaning.
maintenance of  Do PM of electrical accessories.
injection moulding Week 9
 Do PM of hydraulic accessories
machine  Identify hydraulic component.
 Make hydraulic circuits using single acting
cylinder, flow control valve, pressure control valve
and pump.
 Make hydraulic circuits using double acting
cylinder, flow control, pressure control valve
pump.
12. Produce good quality  Identify of different part of the hand compression
of compression moulding machine.
moulded items and Week 10
 Set the temperature on hand compression
check the defects by moulding machine.
using compression  Perform mould setting.
moulding machine  Perform TRO - hand compression.
 Do preventive maintenance of hand compression.
13. Semi- auto  Identify of different part of semi- auto
compression compression moulding machine.
moulding machine Week 11
 Illustrate hydraulic system of compression
moulding machine.
 Load the mould & set.
 Set the temperature.
 Perform IRO.
 Perform TRO.
 Do preventive maintenance of compression
moulding machine.
14. Identify and produce  Identify different parts of hand blow moulding
good quality of blow machine.
moulding items and  Set the temperature.
inspect the finished  Operate the hand blow moulding machine (IRO). Week 12
product  Perform hand blow moulding machine (TRO).
 Perform mould unloading.
 Load the mould and set
 Do preventive maintenance of hand blow
moulding machine.
Mid term Week 13

17 | Plastic Injection Moulding Machine Operator

 15. Perform simple  Identify pneumatic components.
pneumatic circuits  Perform pneumatic circuit using pneumatic
Week 14
components (use single acting cylinder)
 Perform pneumatic circuits using pneumatic
components (use double acting cylinder)

16. Identify different  Identify of different parts of the Auto blow molding
parts, set and operate machine.
the blown film plant  Load the mould and set.
 Set the temperature.
 Perform IRO – auto blow.
 Set the parison.
 Set the parison wall thickness.
 Perform TRO – auto blows.
 Unload mould.
 Do preventive maintenance of auto blow
moulding.
 Clean and inspect air compressor. Week 15
 Recognize the extruder.
 Identify of different parts of the control panels
 Set the processing temperature.
 Change the screw PVC to PE.
 Clean the breaker plate and change screen
packs.
 Load the Blown film Die.
 Connect the heaters of Blown film Die.
 Adjust the screw speed Nip rollers & winding
rollers.
 Perform TRO – (Blown film).
Operate the pipe  Unload blown film die.
plant and produce  Load pipe die.
good quality pipe  Set the pipe plant. Week 16
17.
 Change the screw (PE to PVC).
 Set the temperature for pipe processing.
 Perform TRO – (pipe).
Operate the  Load the reprocessing die on extruder.
reprocessing plant  Prepare raw material for reprocessing.
and produce Week 17
 Illustrate the scrap grinder.
18. reprocessed granules
 Grind the scrap.
 Set the processing temperature for reprocessing.
 Perform TRO – (reprocessing of plastic).
Install and Operate  Demonstrate the thermoforming machine.
thermoforming  Set the mould.
machine and identify  Set the parameters of the thermoforming
cycle of machine. (heat timer temperature, cooling system
19. thermoforming etc). Week 18
Produce good quality  Perform IRO – thermoforming machine.
of thermoforming
product and check
the defects
20. Identify and Perform  Illustrate pre-drying equipments. Week 19

18 | Plastic Injection Moulding Machine Operator

 predrying process  Set the temperature.
using different  Load the material in tray.
materials  Set the parameters and pre-dry the material.
 Perform over all maintenance of pre-drying
equipment.
Carry out different  Illustrate the fabricating methods.
machining operations  Cut the acrylic sheet using acrylic cutter.
Week 20
21. on plastic  Drill the acrylic sheet HDPE Block using hand drill
sheets/blocks machine.
 Perform screwing the acrylic sheet.
Build your CV Download professional CV template from any good Week
site (https://www.coolfreecv.com or relevant)
21-26
 Add Personal Information
22.
 Add Educational details
 Add Experience/Portfolio
 Add contact details/profile links
Create an account Create an account by following these steps: Week
profile on Fiverr (at Step 1: Personal Info
21-26
least two gigs) and Step 2: Professional Info
23.
Up-work Step 3: Linked Accounts
Step 4: Account Security

How to search and  Browse the following website and create an Week
apply for jobs in at account on each website 21-26
least two labor  Bayt.com – The Middle East Leading Job
marketplace Site
countries (KSA,  Monster Gulf – The International Job
UAE, etc.)
Portal
 Gulf Talent – Jobs in Dubai and the
Middle East
 Find the handy ‘search’ option at the top of your
homepage to search for the jobs that best suit
your skills.
 Select the job type from the first ‘Job Type’
drop-down menu, next, select the location from
24. the second drop-down menu.
 Enter any keywords you want to use to find
suitable job vacancies.
 On the results page you can search for part-
time jobs only, full-time jobs only, employers
only, or agencies only. Tick the boxes as
appropriate to your search.
 Search for jobs by:
 Company
 Category
 Location
 All jobs
 Agency

19 | Plastic Injection Moulding Machine Operator

 Annexure-II:

Plastic Injection Moulding Machine Operator

What is freelancing and how you can make money online - BBCURDU

https://www.youtube.com/watch?v=9jCJN3Ff0kA

What Is the Role of Good Manners in the Workplace? By Qasim Ali Shah | In Urdu

https://www.youtube.com/watch?v=Qi6Xn7yKIlQ

Hisham Sarwar Motivational Story | Pakistani Freelancer

https://www.youtube.com/watch?v=CHm_BH7xAXk

21 Yr Old Pakistani Fiverr Millionaire | 25-35 Lakhs a Month Income | Interview

https://www.youtube.com/watch?v=9WrmYYhr7S0

Success Story of a 23 Year - Old SEO Expert | How This Business Works | Urdu Hindi
Punjabi

https://www.youtube.com/watch?v=tIQ0CWgszI0

Failure to Millionaire - How to Make Money Online | Fiverr Superhero Aaliyaan Success
Story

https://www.youtube.com/watch?v=d1hocXWSpus

Success Story - (EN) improved production for Flaro Prod S.A with FANUC ROBOSHOT

https://www.youtube.com/watch?v=R69xmONvmlY

Plastics Injection Molding: Step-By-Step at the Factory - Field Notes

https://www.youtube.com/watch?v=2qAnJy8x8WA

20 | Plastic Injection Moulding Machine Operator

Annexure-II
SUGGESTIVE FORMAT AND SEQUENCE ORDER OF MOTIVATIONAL
LECTURE.
Mentor
Mentors are provided an observation checklist form to evaluate and share their observational
feedback on how students within each team engage and collaborate in a learning environment.
The checklist is provided at two different points: Once towards the end of the course. The
checklists are an opportunity for mentors to share their unique perspective on group dynamics
based on various team activities, gameplay sessions, pitch preparation, and other sessions, giving
insights on the nature of communication and teamwork taking place and how both learning
outcomes and the student experience can be improved in the future.

Session- 1 (Communication):
Please find below an overview of the activities taking place Session plan that will support your
delivery and an overview of this session’s activity.

Session- 1 OVERVIEW
Aims and Objectives:
 To introduce the communication skills and how it will work
 Get to know mentor and team - build rapport and develop a strong sense of a
team
 Provide an introduction to communication skills
 Team to collaborate on an activity sheet developing their communication,
teamwork, and problem-solving
 Gain an understanding of participants’ own communication skills rating at the
start of the program

Activity: Participant Time Teacher Time Mentor Time

Intro Attend and
contribute to the
scheduled.
Understand good
communication
skills and how it
works.
Understand what
good
communication
skills mean
Understand what
skills are important
for good
communication
skills
Key learning Resources: Enterprise skills
outcomes: developed:
 Understand the  Podium  Communication
21 | Plastic Injection Moulding Machine Operator
 communication  Projector  Self Confidence
skills and how it  Computer  Teamwork
works.  Flip Chart
 Understand what  Marker
communication
skills mean
 Understand what
skills are
important for
communication
skills

Schedule Mentor Should do

Welcome: Short welcome and ask the Mentor to introduce
5 min him/herself.
Provide a brief welcome to the qualification for the class.
Note for Instructor: Throughout this session, please
monitor the session to ensure nothing inappropriate is
being happened.
Icebreaker: Start your session by delivering an icebreaker, this will
10 min enable you and your team to start to build rapport and
create a team presentation for the tasks ahead.
The icebreaker below should work well at introductions
and encouraging communication, but feel free to use
others if you think they are more appropriate. It is
important to encourage young people to get to know
each other and build strong team links during the first
hour; this will help to increase their motivation and
communication throughout the sessions.
Introduction & Provide a brief introduction of the qualification to the
Onboarding: class and play the “Onboarding Video or Presentation”.
20mins In your introduction cover the following:
1. Explanation of the program and structure. (Kamyab
jawan Program)
2. How you will use your communication skills in your
professional life.
3. Key contacts and key information – e.g. role of
teacher, mentor, and SEED. Policies and procedures
(user agreements and “contact us” section). Everyone to
go to the Group Rules tab at the top of their screen,
read out the rules, and ask everyone to verbally agree.
Ensure that the consequences are clear for using the
platform outside of hours. (9am-8pm)
4. What is up next for the next 2 weeks ahead so young
people know what to expect (see pages 5-7 for an
overview of the challenge). Allow young people to ask
any questions about the session topic.
Team Activity Planning: MENTOR: Explain to the whole team that you will now
30 minutes be planning how to collaborate for the first and second
collaborative Team Activities that will take place outside
of the session. There will not be another session until
22 | Plastic Injection Moulding Machine Operator
 the next session so this step is required because
communicating and making decisions outside of a
session requires a different strategy that must be
agreed upon so that everyone knows what they are
doing for this activity and how.
 “IDENTIFY ENTREPRENEURS” TEAM
ACTIVITY
 “BRAINSTORMING SOCIAL PROBLEMS” TEAM
ACTIVITY”
As a team, collaborate on a creative brainstorm on
social problems in your community. Vote on the areas
you feel most passionate about as a team, then write
down what change you would like to see happen.
Make sure the teams have the opportunity to talk about
how they want to work as a team through the activities
e.g. when they want to complete the activities, how to
communicate, the role of the project manager, etc.
Make sure you allocate each young person a specific
week that they are the project manager for the weekly
activities and make a note of this.
Type up notes for their strategy if this is helpful - it can
be included underneath the Team Contract.

Session Close: MENTOR: Close the session with the opportunity for
5 minutes anyone to ask any remaining questions.
Instructor:
Facilitate the wrap-up of the session. A quick reminder
of what is coming up next and when the next session
will be.

23 | Plastic Injection Moulding Machine Operator

MOTIVATIONAL LECTURES LINKS.

TOPIC SPEAKER LINK

How to Face Qasim Ali Shah https://www.youtube.com/watch?v=OrQte08Ml90
Problems In
Life
Just Control Qasim Ali Shah https://www.youtube.com/watch?v=JzFs__yJt-w
Your
Emotions
How to Qasim Ali Shah https://www.youtube.com/watch?v=PhHAQEGehKc
Communicate
Effectively
Your Tony Robbins https://www.youtube.com/watch?v=5fS3rj6eIFg
ATTITUDE is Les Brown
Everything David Goggins
Jocko Willink
Wayne Dyer
Eckart Tolle
Control Your Jim Rohn https://www.youtube.com/watch?v=chn86sH0O5U
EMOTIONS Les Brown
TD Jakes
Tony Robbins
Defeat Fear, Shaykh Atif https://www.youtube.com/watch?v=s10dzfbozd4
Build Ahmed
Confidence
Wisdom of Learn Kurooji https://www.youtube.com/watch?v=bEU7V5rJTtw
the Eagle
The Power of Titan Man https://www.youtube.com/watch?v=r8LJ5X2ejqU
ATTITUDE
STOP Arnold https://www.youtube.com/watch?v=kzSBrJmXqdg
WASTING Schwarzenegger
TIME
Risk of Denzel https://www.youtube.com/watch?v=tbnzAVRZ9Xc
Success Washington

24 | Plastic Injection Moulding Machine Operator

 Annexure-III
SUCCESS STORY

S. No Key Information Detail/Description

1. Self & Family background Danyal Saleem, who lives in Mirpur (AJK), is an
example of how hard work and perseverance can reap
rich rewards when bidding for projects online.
The graphic designer works exclusively on an online
freelancing platform and has earned, on average,
US$20,000 per month for the past several months. But
this isn’t a story of overnight success – Danyal has had
to work hard to differentiate himself and stay true to his
goal.

It was a full year later, in May 2017, when Danyal finally

decided to jump in. He signed up for one of the
numerous sites that connect designers or coders with
people or companies that have small projects, like
designing a logo or building a website.
He had already started a small business to help pay for
his college education, so he was nervous and
apprehensive about the decision. “I gave myself two or
three months at most. If I didn’t succeed, then I would
go back to running the business as it was showing
potential,” he says.
If at first, you don’t succeed, try try again

2. How he came on board Certification in graphic designing from STEPS(NAVTTC

NAVTTC Training/ or got partner institute)
trained through any other
source

3. Post-training activities Danyal’s area of expertise is in graphic design. In his

first month using Fiverr, he pitched mostly for projects
centered around logo designing. But it wasn’t so simple.
In the first few weeks, he didn’t hear back from even a
single client, despite pitching for dozens of projects.

“I needed to understand what worked, so I read blogs,

participated in forums, and analyzed profiles of
successful freelancers. It was an uphill struggle, but I
didn’t want to give up,” he explains.

Danyal says he understands why clients would be

apprehensive giving projects to untested freelancers.
They have hundreds of options to choose from, he

25 | Plastic Injection Moulding Machine Operator

 explains, and to give a project to someone with no
experience requires a strong leap of faith.

A slow stream of projects started to come Danyal’s way.

Within a few months, he was landing an average of a
hundred projects every month, with a large number of
repeat clients. He also expanded the range of his
professional services, branching out from logo design to
business cards, banners, Facebook cover pages,
letterheads, and stationery.

But he’s had to face his fair share of challenges too.

The shoddy state of internet infrastructure in his city,
Mirpur, threatened to derail his freelancing career.
“Sometimes I haven’t had connectivity for two days
straight,” he explains. “That’s unthinkable for someone
who makes his livelihood on the internet.”

4. Message to others Take the training opportunity seriously

Impose self-discipline and ensure regularity
(under training) Make Hard work pays in the end so be always ready for
the same.

Note: Success story is a source of motivation for the trainees and can be presented in several
ways/forms in a NAVTTC skill development course as under: -

1. To call a passed out successful trainee of the institute. He will narrate his success story to
the trainees in his own words and meet trainees as well.
2. To see and listen to a recorded video/clip (5 to 7 minutes) showing a successful trainee
Audio-video recording that has to cover the above-mentioned points.*
3. The teacher displays the picture of a successful trainee (name, trade, institute,
organization, job, earning, etc) and narrates his/her story in the teacher’s own motivational
words.

* The online success stories of renowned professional can also be obtained from Annex-II

26 | Plastic Injection Moulding Machine Operator

 Annexure-IV:
Workplace/Institute Ethics Guide

Work ethic is a standard of conduct and values for job performance. The modern definition of what
constitutes good work ethics often varies. Different businesses have different expectations. Work
ethic is a belief that hard work and diligence have a moral benefit and an inherent ability, virtue, or
value to strengthen character and individual abilities. It is a set of values-centered on the
importance of work and manifested by determination or desire to work hard.

The following ten work ethics are defined as essential for student success:

1. Attendance:
Be at work every day possible, plan your absences don’t abuse leave time. Be punctual
every day.
2. Character:
Honesty is the single most important factor having a direct bearing on the final success of
an individual, corporation, or product. Complete assigned tasks correctly and promptly.
Look to improve your skills.
3. Team Work:
The ability to get along with others including those you don’t necessarily like. The ability to
carry your weight and help others who are struggling. Recognize when to speak up with an
idea and when to compromise by blend ideas together.
4. Appearance:
Dress for success set your best foot forward, personal hygiene, good manner, remember
that the first impression of who you are can last a lifetime
5. Attitude:
Listen to suggestions and be positive, accept responsibility. If you make a mistake, admit it.
Values workplace safety rules and precautions for personal and co-worker safety. Avoids
unnecessary risks. Willing to learn new processes, systems, and procedures in light of
changing responsibilities.
6. Productivity:
Do the work correctly, quality and timelines are prized. Get along with fellows, cooperation
is the key to productivity. Help out whenever asked, do extra without being asked. Take
pride in your work, do things the best you know-how. Eagerly focuses energy on
accomplishing tasks, also referred to as demonstrating ownership. Takes pride in work.

27 | Plastic Injection Moulding Machine Operator

 7. Organizational Skills:
Make an effort to improve, learn ways to better yourself. Time management; utilize time and
resources to get the most out of both. Take an appropriate approach to social interactions
at work. Maintains focus on work responsibilities.
8. Communication:
Written communication, being able to correctly write reports and memos.
Verbal communications, being able to communicate one on one or to a group.
9. Cooperation:
Follow institute rules and regulations, learn and follow expectations. Get along with fellows,
cooperation is the key to productivity. Able to welcome and adapt to changing work
situations and the application of new or different skills.
10. Respect:
Work hard, work to the best of your ability. Carry out orders, do what’s asked the first time.
Show respect, accept, and acknowledge an individual’s talents and knowledge. Respects
diversity in the workplace, including showing due respect for different perspectives,
opinions, and suggestions.

28 | Plastic Injection Moulding Machine Operator