Assessor Resource

ICPCBF307
Produce double-faced web

Assessment tool

Version 1.0
Issue Date: March 2024


This unit describes the skills and knowledge required to safely operate, adjust, monitor and shut down equipment and machinery used to produce double-faced web for corrugated board manufacture.

It applies to performing tasks such as monitoring machinery operations, dealing with routine problems and reporting production and machinery faults.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)



Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

ELEMENT

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1. Inspect and adjust quality

1.1 Inspection and/or testing of sample is organised

1.2 Sample is visually inspected and/or tested according to enterprise procedures

1.3 Results are interpreted to determine adjustment requirements

1.4 Adjustments are carried out according to product and machine specifications

2. Maintain operation of reel transportation system

2.1 Reel stand is monitored and adjusted to ensure efficient continuous operation

2.2 Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web and efficient operation

2.3 Substrate is added to the process according to job specifications

3. Maintain double-facing process

3.1 Starch delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.2 Heat delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.3 Speed of machine is optimised according to running conditions

3.4 Appropriate quantity of paper is run

4. Maintain in-line process(es)

4.1 Waxing units are monitored and adjusted to suit corrugating process and according to job specifications

4.2 Coating units are monitored and adjusted to suit corrugating process and according to job specifications

4.3 Tape dispensing units are monitored and adjusted to suit corrugating process and according to job specifications

4.4 Slitters are monitored and adjusted according to job specifications

4.5 Cut-off knife is monitored and adjusted according to job specifications

5. Synchronise machine operation

5.1 Machine downtime is minimised during flute, grade or deckle changes

5.2 Quality of board is maintained according to enterprise procedures or client acceptance standard

5.3 Machine speed is optimised and waste minimised

6. Maintain production process

6.1 Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule

6.2 Production is maintained according to Work Health and Safety (WHS) requirements, manufacturer’s specifications and enterprise procedures

6.3 Manual and/or automatic control is used according to job specifications

6.4 Performance is monitored and verified using the process control system according to enterprise procedures

6.5 Starch performance is monitored and adjusted throughout production run

6.6 Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention

6.7 Process adjustments to eliminate problems are reported according to enterprise procedures

6.8 Faulty performance of equipment is identified and reported according to enterprise procedures

6.9 Waste is sorted according to enterprise procedures

6.10 Quality checks of product are undertaken on a regular basis and adjustments made as required

7. Identify and rectify problems

7.1 Problems in corrugator operation are identified and reported according to enterprise procedures

7.2 Adjustments or corrections are carried out according to specified procedures and are consistent with operator’s skill level

7.3 Corrugator operation is checked to ensure correct operation

8. Conduct shutdown of production process

8.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures

8.2 Shutdown is conducted in association with fellow workers and in compliance with WHS requirements

8.3 Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

8.4 All product is removed from operating area

8.5 Machine faults requiring repair are identified and reported to designated person according to enterprise procedures

8.6 Repair/adjustment is verified prior to resumption of operations

9. Clean and wash up corrugator at end of run

9.1 In-line wax, coating and tape dispensing units are cleaned ready for next run

9.2 Starch delivery system is washed ready for next run, and liquid waste is disposed of according to regulatory requirements and enterprise procedures

9.3 Reel feed and transportation systems are disengaged and cleaned ready for next run

9.4 Production records or other documentation are accurately completed where required by enterprise procedures

Evidence of the ability to:

correctly and safely perform at least TWO runs on the double backer machine to produce TWO different types/classes of product, according to manufacturer’s and job specifications and enterprise procedures

monitor operations and adjust equipment and machinery as required to ensure production quality

accurately complete relevant enterprise production records/reports when producing double-faced web.

Note: If a specific volume or frequency is not stated, then evidence must be provided at least once.

To complete the unit requirements safely and effectively, the individual must:

identify significant work health and safety risks to workers operating machinery and undertaking this activity

identify measures employed to prevent injury and/or illness in the case of the risks identified previously

identify principle support systems on line to the corrugating machine

explain how support systems are used to effectively control and monitor the corrugator

identify sections of the double backer with the highest potential for operational problems during the run

describe product faults commonly found during production runs, and how they can be corrected

describe how settings for the following factors are monitored and adjusted during the run: in-feed, web alignment control, adhesive application, double backer, steam delivery, heating of web and speed

identify product factors monitored visually/manually by staff operating end stages of the corrugator machine

outline adjustments to make in response to problems found by staff operating end stages of the corrugator machine

identify functions that must be attended to during wash-up and shutdown of the machine if it will be idle for two or more days

identify key information contained in machine manuals, safety and other documentation relevant to producing double-faced web, and where they are kept.

Gather evidence to demonstrate consistent performance in conditions that are safe and replicate the workplace. Noise levels, production flow, interruptions and time variances must be typical of those experienced in the Converting, Binding and Finishing field of work and include access to and use of special purpose tools, equipment (including in-line double back corrugating equipment) and materials used to produce double-faced web.

Assessors must satisfy NVR/AQTF assessor requirements.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

ELEMENT

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1. Inspect and adjust quality

1.1 Inspection and/or testing of sample is organised

1.2 Sample is visually inspected and/or tested according to enterprise procedures

1.3 Results are interpreted to determine adjustment requirements

1.4 Adjustments are carried out according to product and machine specifications

2. Maintain operation of reel transportation system

2.1 Reel stand is monitored and adjusted to ensure efficient continuous operation

2.2 Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web and efficient operation

2.3 Substrate is added to the process according to job specifications

3. Maintain double-facing process

3.1 Starch delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.2 Heat delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.3 Speed of machine is optimised according to running conditions

3.4 Appropriate quantity of paper is run

4. Maintain in-line process(es)

4.1 Waxing units are monitored and adjusted to suit corrugating process and according to job specifications

4.2 Coating units are monitored and adjusted to suit corrugating process and according to job specifications

4.3 Tape dispensing units are monitored and adjusted to suit corrugating process and according to job specifications

4.4 Slitters are monitored and adjusted according to job specifications

4.5 Cut-off knife is monitored and adjusted according to job specifications

5. Synchronise machine operation

5.1 Machine downtime is minimised during flute, grade or deckle changes

5.2 Quality of board is maintained according to enterprise procedures or client acceptance standard

5.3 Machine speed is optimised and waste minimised

6. Maintain production process

6.1 Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule

6.2 Production is maintained according to Work Health and Safety (WHS) requirements, manufacturer’s specifications and enterprise procedures

6.3 Manual and/or automatic control is used according to job specifications

6.4 Performance is monitored and verified using the process control system according to enterprise procedures

6.5 Starch performance is monitored and adjusted throughout production run

6.6 Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention

6.7 Process adjustments to eliminate problems are reported according to enterprise procedures

6.8 Faulty performance of equipment is identified and reported according to enterprise procedures

6.9 Waste is sorted according to enterprise procedures

6.10 Quality checks of product are undertaken on a regular basis and adjustments made as required

7. Identify and rectify problems

7.1 Problems in corrugator operation are identified and reported according to enterprise procedures

7.2 Adjustments or corrections are carried out according to specified procedures and are consistent with operator’s skill level

7.3 Corrugator operation is checked to ensure correct operation

8. Conduct shutdown of production process

8.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures

8.2 Shutdown is conducted in association with fellow workers and in compliance with WHS requirements

8.3 Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

8.4 All product is removed from operating area

8.5 Machine faults requiring repair are identified and reported to designated person according to enterprise procedures

8.6 Repair/adjustment is verified prior to resumption of operations

9. Clean and wash up corrugator at end of run

9.1 In-line wax, coating and tape dispensing units are cleaned ready for next run

9.2 Starch delivery system is washed ready for next run, and liquid waste is disposed of according to regulatory requirements and enterprise procedures

9.3 Reel feed and transportation systems are disengaged and cleaned ready for next run

9.4 Production records or other documentation are accurately completed where required by enterprise procedures

Evidence of the ability to:

correctly and safely perform at least TWO runs on the double backer machine to produce TWO different types/classes of product, according to manufacturer’s and job specifications and enterprise procedures

monitor operations and adjust equipment and machinery as required to ensure production quality

accurately complete relevant enterprise production records/reports when producing double-faced web.

Note: If a specific volume or frequency is not stated, then evidence must be provided at least once.

To complete the unit requirements safely and effectively, the individual must:

identify significant work health and safety risks to workers operating machinery and undertaking this activity

identify measures employed to prevent injury and/or illness in the case of the risks identified previously

identify principle support systems on line to the corrugating machine

explain how support systems are used to effectively control and monitor the corrugator

identify sections of the double backer with the highest potential for operational problems during the run

describe product faults commonly found during production runs, and how they can be corrected

describe how settings for the following factors are monitored and adjusted during the run: in-feed, web alignment control, adhesive application, double backer, steam delivery, heating of web and speed

identify product factors monitored visually/manually by staff operating end stages of the corrugator machine

outline adjustments to make in response to problems found by staff operating end stages of the corrugator machine

identify functions that must be attended to during wash-up and shutdown of the machine if it will be idle for two or more days

identify key information contained in machine manuals, safety and other documentation relevant to producing double-faced web, and where they are kept.

Gather evidence to demonstrate consistent performance in conditions that are safe and replicate the workplace. Noise levels, production flow, interruptions and time variances must be typical of those experienced in the Converting, Binding and Finishing field of work and include access to and use of special purpose tools, equipment (including in-line double back corrugating equipment) and materials used to produce double-faced web.

Assessors must satisfy NVR/AQTF assessor requirements.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Inspection and/or testing of sample is organised 
Sample is visually inspected and/or tested according to enterprise procedures 
Results are interpreted to determine adjustment requirements 
Adjustments are carried out according to product and machine specifications 
Reel stand is monitored and adjusted to ensure efficient continuous operation 
Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web and efficient operation 
Substrate is added to the process according to job specifications 
Starch delivery system is monitored and adjusted to suit corrugating process and according to job specifications 
Heat delivery system is monitored and adjusted to suit corrugating process and according to job specifications 
Speed of machine is optimised according to running conditions 
Appropriate quantity of paper is run 
Waxing units are monitored and adjusted to suit corrugating process and according to job specifications 
Coating units are monitored and adjusted to suit corrugating process and according to job specifications 
Tape dispensing units are monitored and adjusted to suit corrugating process and according to job specifications 
Slitters are monitored and adjusted according to job specifications 
Cut-off knife is monitored and adjusted according to job specifications 
Machine downtime is minimised during flute, grade or deckle changes 
Quality of board is maintained according to enterprise procedures or client acceptance standard 
Machine speed is optimised and waste minimised 
Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule 
Production is maintained according to Work Health and Safety (WHS) requirements, manufacturer’s specifications and enterprise procedures 
Manual and/or automatic control is used according to job specifications 
Performance is monitored and verified using the process control system according to enterprise procedures 
Starch performance is monitored and adjusted throughout production run 
Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention 
Process adjustments to eliminate problems are reported according to enterprise procedures 
Faulty performance of equipment is identified and reported according to enterprise procedures 
Waste is sorted according to enterprise procedures 
Quality checks of product are undertaken on a regular basis and adjustments made as required 
Problems in corrugator operation are identified and reported according to enterprise procedures 
Adjustments or corrections are carried out according to specified procedures and are consistent with operator’s skill level 
Corrugator operation is checked to ensure correct operation 
Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures 
Shutdown is conducted in association with fellow workers and in compliance with WHS requirements 
Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures 
All product is removed from operating area 
Machine faults requiring repair are identified and reported to designated person according to enterprise procedures 
Repair/adjustment is verified prior to resumption of operations 
In-line wax, coating and tape dispensing units are cleaned ready for next run 
Starch delivery system is washed ready for next run, and liquid waste is disposed of according to regulatory requirements and enterprise procedures 
Reel feed and transportation systems are disengaged and cleaned ready for next run 
Production records or other documentation are accurately completed where required by enterprise procedures 

Forms

Assessment Cover Sheet

ICPCBF307 - Produce double-faced web
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:


Assessment Record Sheet

ICPCBF307 - Produce double-faced web

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: