Assessor Resource

ICPCBF410
Set up machine for complex carton folding and gluing

Assessment tool

Version 1.0
Issue Date: March 2024


This unit describes the skills and knowledge required to set up and adjust a machine for complex carton folding and gluing to maintain the production process.

It applies to individuals who have limited responsibility for preparation of materials and equipment in accordance with job specifications and procedures, and ensuring quality of output.

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. Prepare for job

1.1 Read and interpret job requirements from job documentation or production control system

1.2 Set-up is planned and carried out correctly in minimum time with minimum wastage

2. Set up carton blank transportation system

2.1 Feeder is set up and adjusted according to job specifications

2.2 Carton blank pick-up and transportation system is set up and adjusted according to job specifications

2.3 Transfer systems are set up and adjusted according to job specifications

3. Set up machine for complex carton folding/gluing

3.1 Folding units are set up and adjusted according to job specifications

3.2 Folding rollers/belts/rails are set up and adjusted according to job specifications

3.3 Gluing system is set up and adjusted according to job specifications using glue wheel and/or multiple glue heads

4. Set up carton delivery system

4.1 Delivery is set up and adjusted according to job specifications

4.2 Substrate is removed from process according to job specifications

4.3 Carton transfer and control system is set up and adjusted according to job specifications

5. Conduct sample run

5.1 Material to be used for sample is organised correctly

5.2 Machine is set up and operated according to work health and safety requirements, manufacturer’s specifications and enterprise procedures to produce a specified sample

5.3 Sample is visually inspected and/or tested for accuracy of folds, fibre tear, opening force, and fluff and glue placement according to enterprise procedures

6. Readjust settings

6.1 Results are interpreted to determine adjustment requirements

6.2 Adjustments are carried out according to product and machine specifications

Evidence of the ability to:

set up at least THREE crash lock, six-corner and specialty work carton jobs using different carton sizes and weights, which include use of multiple gluing units, according to manufacturer’s and job specifications and enterprise procedures.

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:

Documentation

identify information concerning folding requirements found in the job documentation or production control system, and how it is interpreted to ensure smooth workflow throughout the factory

list factors to consider when planning a folding sample

Sheet transportation and delivery systems

explain work health and safety (WHS) factors for setting folder transportation and delivery systems

identify areas of the carton blank transportation system to monitor to ensure trouble-free operation

list parts of the carton blank pick-up system to adjust to ensure accurate and continuous sheet handling

identify areas of the delivery system to observe to maintain neat delivery of finished work and to prevent damage to the finished product

explain checks required when substrate is removed from the machine

Machine setting for complex folding and gluing

explain WHS factors for setting and/or adjusting the folding unit

identify the largest/smallest size carton blank that can be processed on this machine

describe ways the machine can be adapted to facilitate smaller/larger stock

identify accuracy of a carton blank entering folding rollers

describe causes of scratching/scuffing of substrate during transportation

identify machine speed variations

describe problems that can be expected if:

the machine is running too fast

the machine rollers are set too loose

there is too much roller pressure

the delivery system is not set correctly

identify how correct roller pressure is determined for a given job

describe how roller pressures checks are made

describe required adjustments if the carton blank is out-of-square

list reasons for the sheet being out-of-square

describe adjustment required to eliminate smudging/scuffing on carton blanks

describe adjustment required if the sheet will not leave the folding unit

In-line processes

list necessary steps to set up gluing units

describe how a neat and clean gluing job is achieved

identify adhesive used in the gluing unit and how length of the glue line is adjusted

Checking and adjustment

identify causes of out-of-square folding and how they are rectified

list segments of quality assurance inspected at sample run completion

identify areas of the machine to adjust if carton blank is creasing

identify areas of the machine to adjust if carton blank is not entering the machine

explain items to check against client sample

Information sources

identify machine manuals and safety documentation relevant to this task, where they are kept, and the information included in them.

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:

Royal 40, Bobst Media or Bobst Domino machine, which includes multiple gluing units

relevant materials and equipment.

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. Prepare for job

1.1 Read and interpret job requirements from job documentation or production control system

1.2 Set-up is planned and carried out correctly in minimum time with minimum wastage

2. Set up carton blank transportation system

2.1 Feeder is set up and adjusted according to job specifications

2.2 Carton blank pick-up and transportation system is set up and adjusted according to job specifications

2.3 Transfer systems are set up and adjusted according to job specifications

3. Set up machine for complex carton folding/gluing

3.1 Folding units are set up and adjusted according to job specifications

3.2 Folding rollers/belts/rails are set up and adjusted according to job specifications

3.3 Gluing system is set up and adjusted according to job specifications using glue wheel and/or multiple glue heads

4. Set up carton delivery system

4.1 Delivery is set up and adjusted according to job specifications

4.2 Substrate is removed from process according to job specifications

4.3 Carton transfer and control system is set up and adjusted according to job specifications

5. Conduct sample run

5.1 Material to be used for sample is organised correctly

5.2 Machine is set up and operated according to work health and safety requirements, manufacturer’s specifications and enterprise procedures to produce a specified sample

5.3 Sample is visually inspected and/or tested for accuracy of folds, fibre tear, opening force, and fluff and glue placement according to enterprise procedures

6. Readjust settings

6.1 Results are interpreted to determine adjustment requirements

6.2 Adjustments are carried out according to product and machine specifications

Evidence of the ability to:

set up at least THREE crash lock, six-corner and specialty work carton jobs using different carton sizes and weights, which include use of multiple gluing units, according to manufacturer’s and job specifications and enterprise procedures.

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:

Documentation

identify information concerning folding requirements found in the job documentation or production control system, and how it is interpreted to ensure smooth workflow throughout the factory

list factors to consider when planning a folding sample

Sheet transportation and delivery systems

explain work health and safety (WHS) factors for setting folder transportation and delivery systems

identify areas of the carton blank transportation system to monitor to ensure trouble-free operation

list parts of the carton blank pick-up system to adjust to ensure accurate and continuous sheet handling

identify areas of the delivery system to observe to maintain neat delivery of finished work and to prevent damage to the finished product

explain checks required when substrate is removed from the machine

Machine setting for complex folding and gluing

explain WHS factors for setting and/or adjusting the folding unit

identify the largest/smallest size carton blank that can be processed on this machine

describe ways the machine can be adapted to facilitate smaller/larger stock

identify accuracy of a carton blank entering folding rollers

describe causes of scratching/scuffing of substrate during transportation

identify machine speed variations

describe problems that can be expected if:

the machine is running too fast

the machine rollers are set too loose

there is too much roller pressure

the delivery system is not set correctly

identify how correct roller pressure is determined for a given job

describe how roller pressures checks are made

describe required adjustments if the carton blank is out-of-square

list reasons for the sheet being out-of-square

describe adjustment required to eliminate smudging/scuffing on carton blanks

describe adjustment required if the sheet will not leave the folding unit

In-line processes

list necessary steps to set up gluing units

describe how a neat and clean gluing job is achieved

identify adhesive used in the gluing unit and how length of the glue line is adjusted

Checking and adjustment

identify causes of out-of-square folding and how they are rectified

list segments of quality assurance inspected at sample run completion

identify areas of the machine to adjust if carton blank is creasing

identify areas of the machine to adjust if carton blank is not entering the machine

explain items to check against client sample

Information sources

identify machine manuals and safety documentation relevant to this task, where they are kept, and the information included in them.

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:

Royal 40, Bobst Media or Bobst Domino machine, which includes multiple gluing units

relevant materials and equipment.

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
Read and interpret job requirements from job documentation or production control system 
Set-up is planned and carried out correctly in minimum time with minimum wastage 
Feeder is set up and adjusted according to job specifications 
Carton blank pick-up and transportation system is set up and adjusted according to job specifications 
Transfer systems are set up and adjusted according to job specifications 
Folding units are set up and adjusted according to job specifications 
Folding rollers/belts/rails are set up and adjusted according to job specifications 
Gluing system is set up and adjusted according to job specifications using glue wheel and/or multiple glue heads 
Delivery is set up and adjusted according to job specifications 
Substrate is removed from process according to job specifications 
Carton transfer and control system is set up and adjusted according to job specifications 
Material to be used for sample is organised correctly 
Machine is set up and operated according to work health and safety requirements, manufacturer’s specifications and enterprise procedures to produce a specified sample 
Sample is visually inspected and/or tested for accuracy of folds, fibre tear, opening force, and fluff and glue placement according to enterprise procedures 
Results are interpreted to determine adjustment requirements 
Adjustments are carried out according to product and machine specifications 

Forms

Assessment Cover Sheet

ICPCBF410 - Set up machine for complex carton folding and gluing
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

ICPCBF410 - Set up machine for complex carton folding and gluing

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: