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Elements and Performance Criteria

  1. Confirm routine job specifications
  2. Set up routine reel system (OR Element 3)
  3. Set up routine sheet system (OR Element 2)
  4. Select and prepare inks and solvents
  5. Set up machine for basic flexographic printing
  6. Set up in-line units for basic process(es)
  7. Conduct proof run
  8. Organise proof inspection and/or testing
  9. Readjust settings to production speed

Required Skills

Required skills

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

communication of ideas and information by interpreting job tickets and requirements

collecting analysing and organising information by collecting and assessing data about printing process and machine specifications and characteristics and how these interact

planning and organising activities by providing input into production scheduling about time requirements for set up to ensure efficient operation

teamwork when working with other workers to coordinate set up to ensure efficient operation

mathematical ideas and techniques by calculating substrate requirements

problemsolving skills by recognising proofing faults and determining adjustments to correct them

use of technology by using monitoring equipment and interpreting readouts

Required knowledge

action if vital information was missing from the job ticket

checks that are undertaken prior to set up availability of materials etc

flexographic printing plates and cylinders or sleeves or plate mounting sheets

precautions that should be taken to avoid damaging plates and cylinders

OHS factors that need to be considered when operating the reel infeed and delivery system

choosing the printing side of the material

effect of low web tension on the print

types of web splices that could be used appropriately for the job

sheet infeed

OHS factors that need to be considered when operating the sheet infeed and delivery system

sheet is normally set up in the middle of the machine

effect that side lay selection has on the job

appropriate front lays to be selected

determining the position of the sheet before it is transported to the printing unit

registering check be carried out

twosheet cut is used on most feeders

sheet is missing or late

reel delivery system

effect of excessive web tension at the rewind of the machine

minimising risks associated with the rewind of the machine

sheet delivery system

application of spray powder is sometimes advisable

effects of too much spray powder

slowdown devices may be used in the delivery

effect excessive jogging would have on the stack

selection and preparation of inks and additives

major environmental and OHS concerns with regard to inks and additives

suitability of ink matched to the particular job

implications if the ink were too viscose

modifying ink that was slightly light

methods that are available to check the ink for correct colour

who passes the colour prior to running the job

machine set up

OHS factors that need to be considered when setting up the machine

how machine specifications are determined relating to the specific job

steps that should be taken to ensure that the inking system is adjusted correctly

why inking system ink level is maintained at a certain level

precautions that are necessary when handling doctorchamber blades

optimum make ready speed for the job

basic inline processes

steps that are taken to incorporate the inline processes into the make ready

equipment used in inline processing is protected against damage during set up

precautions that should be taken if UV drying is utilised to dry the ink film

proofing and adjustment

methods that can be used to minimise waste during make ready

procedures that are followed to have the print approved

quality control measurements that should be applied to the proof to test against known standards

checking the initial print prior to running

determining settings to be adjusted

processes to be used to plot the success of the machine adjustment

final results recorded for future reference

relevant test procedures

identifying and describing the tests for scuffing and coefficient of friction

circumstances in which these tests should be applied

leaching

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

Evidence Required

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 ability to

set up flexographic printing machines for routine print jobs The individual will conduct a proof run and adjust settings to ensure production speeds are attained

demonstrate use of computerised control monitoring and data entry systems if available and appropriate

demonstrate an ability to find and use information relevant to the task from a variety of information sources

demonstrate all safety devices on the machine

set up a press on TWO occasions for basic flexographic printing if possible including at least ONE inline process according to manufacturers specifications enterprise procedures and the 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 Off the job assessment must be undertaken in a closely simulated workplace environment

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 onthejob 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

ICPSUC Prepare load and unload reels and cores on and off machine

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

ICPSUC Prepare load and unload product on and off machine

ICPSU202C Prepare, load and unload product on and off machine

ICPSUC Prepare machine for operation basic

ICPSU207C Prepare machine for operation (basic)

ICPSUC Prepare ink and additives

ICPSU211C Prepare ink and additives

ICPPRC Mount and proof flexographic plates for basic printing

ICPPR211C Mount and proof flexographic plates for basic printing

ICPPRC Produce basic flexographic printed product

ICPPR214C Produce basic flexographic printed product.

Range Statement

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.

Substrate handling may include:

wide or narrow reel and small or large sheet handling systems.

Substrate types may include:

range of substrates within the major categories of paper, pressure sensitive material, board, corrugated board, plastics and related films, or metal.

Inks/coatings may include:

range of standard inks commonly used in colour printing.

Routine may include:

routine within this context relates to the set up and production of print runs. The set up of equipment and production are straightforward and do not involve a significant amount of deviation from using standard equipment settings. In this sense, routine does not refer to a job that an individual might repeat on a regular basis.

Machines may include:

a range of stack, in-line and central impression flexographic printing machines with manual, semi-automated, fully automated or computerised process control.

In-line processes may include:

minor processes that are integral to this competency can include basic in-line operations such as perforating, numbering, date coding, slitting that do not in themselves constitute another defined unit of competency. Where a major in-line process is defined as a separate competency (eg flat-bed cutting, folding) it should be assessed as such.

Colour matching systems may include:

use of visual colour assessment and densitometry to match basic standard colours under controlled lighting conditions.

Design may include:

colours, simple graphics and text. Minor variation in registration and position.