Assessor Resource

ICPCF3107C
Produce double-faced web

Assessment tool

Version 1.0
Issue Date: March 2024


This unit requires the individual to perform runs on the double backer machine, maintain production, identify and rectify problems and faults, and correctly shut down the machine.

This unit describes the performance outcomes, skills and knowledge required to produce a double-faced web for corrugated board manufacture.

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

Prerequisites

Not applicable.


Employability Skills

This unit contains employability skills.




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.

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of the following is essential:

perform runs on the double backer machine, maintain production, identify and rectify problems and faults, and correctly shut down the machine

perform at least TWO runs on the double backer to produce TWO different types/classes of product, according to manufacturer's and job specifications, enterprise procedures and the listed Performance Criteria

evidence for assessment may be gathered from assessment of the unit of competency alone or through an integrated assessment activity.

Context of and specific resources for assessment

Assessment must ensure:

assessment may take place on the job, off the job or a combination of these. Assessment off the job must be undertaken in a closely simulated workplace environment

in-line double backer corrugating equipment.

Method of assessment

A range of assessment methods should be used to assess practical skills and knowledge. The following examples are appropriate for this unit:

direct questioning combined with review of portfolios of evidence and third party workplace reports of on-the-job performance by the candidate.

Guidance information for assessment

Holistic assessment with other units relevant to the industry sector, workplace and job role is recommended, for example:

ICPCF2106C Set up double-faced web

ICPCF220C Produce basic converted or finished product

ICPCF231C Set up machine for basic flat-bed cutting

ICPCF235C Set up machine for basic rotary cutting

ICPSU201C Prepare, load and unload reels and cores on and off machine.


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.

Required skills

OHS in relation to operating machinery such as safely switching off machinery before cleaning is started

communication skills when reading and interpreting job requirements from job documentation or production control system

planning and organising by shutting down equipment in the correct sequence

teamwork when maintaining production processes in association with colleagues

using technology by producing double-faced web on the corrugator

problem solving by selecting and checking a sample from the machine to ensure it conforms to the required quality standards

Required knowledge

significant risks that are posed to workers in this activity

measures that are employed to prevent injury and/or illness in the case of the above identified risks

principle support systems on line to the corrugating machine

effective control and monitoring of the corrugator by the operator

sections of the double backer that have the higher potential for operational problems during the run

product faults that are commonly found to arise during production runs and how can they be corrected

settings monitoring and adjustment made during the run, for the following factors: : in-feed, web alignment control, adhesive application, double backer, steam delivery, heating of web and speed

product factors that can be monitored visually/manually by staff operating end stages of the corrugator machine

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

functions that must be attended to for the wash-up and shutdown of the single facer for an idle period of at least two days

machine manuals, safety and other documentation that are relevant to this task and where they are kept and information that is included in these documents

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Machines may include:

range of corrugating machines with manual, semi-automated and fully automated process control systems.

Substrate handling may include:

wide reel handling systems.

In-line processes may include:

range of wax and coating systems operations, slitters and cutters. Note that slitting and cutting may be separately assessable as flat-bed or rotary cutting.

Substrate types may include:

range of substrates within the major categories of board or paper.

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 
Adjustment changes 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 down-time 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 OHS 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 OHS 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 up 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

ICPCF3107C - 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

ICPCF3107C - 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: