Google Links

Follow the links below to find material targeted to the unit's elements, performance criteria, required skills and knowledge

Elements and Performance Criteria

1. Maintain routine operation of reel system
   • Reel stand and rewind section are monitored and adjusted to ensure efficient continuous operation and maintain correct tension, without marks, blemishes or damage to finished product
   • Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web for efficient operation
   • Substrate is added to and removed from process according to job instructions
   • Sheeting section is monitored and adjusted to ensure quality and efficient product delivery
   • Set-off / marking prevention system is monitored and adjusted to ensure quality of printed product, without set-off or marking, meeting the approved proof standard
2. Maintain basic gravure printing process
   • Gravure cylinder condition is monitored and adjusted to ensure quality of printed product meets the approved proof standard
   • Gravure impression roller condition is monitored and maintained to ensure quality of printed product meets the approved proof standard
   • Gravure inking system and doctor blade are monitored and adjusted to ensure quality of printed product meets the approved proof standard
   • Drying systems are monitored and adjusted to ensure quality of printed product meets the approved proof standard
   • Basic in-line printing/converting/binding/finishing process(es) are monitored and adjusted to ensure quality of product meets the approved proof standard
3. Maintain routine production process
   • Production process is operated in association with fellow workers and according to company specifications and planned daily schedule
   • Production is maintained within work health and safety (WHS) requirements and company and manufacturer’s specifications
   • Manual and/or automatic control is used as per specification
   • Performance is monitored and verified using the process control system according to enterprise procedures
   • Ink performance, colour, register and position of print are 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
   • Waste is sorted according to enterprise procedures
4. Identify and rectify faults
   • Problems in gravure machine operation are identified and reported according to enterprise procedures
   • Adjustments or corrections are carried out according to specified procedures and consistent with operator’s skill level
   • Gravure machine operation is checked to ensure correct operation
   • Faulty performance of equipment is identified and reported according to enterprise procedures
5. Conduct shutdown of production process
   • 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
   • Unused ink is correctly labelled and stored according to manufacturer/supplier specifications and enterprise procedures
   • 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
6. Clean and wash up printing machine at end of print run
   • Cylinders and roller surfaces are cleaned ready for next run
   • Inking system is washed up ready for next run, and liquid waste is disposed of according to company and regulatory requirements
   • In-line printing/converting/binding/finishing units are cleaned ready for next run
   • Reel feed, transportation and delivery systems are disengaged and cleaned ready for next run
   • Production records or other documentation are accurately completed where required by enterprise procedures

Performance Evidence

Evidence of the ability to:

safely operate a gravure press consistent with efficient routine production flow that maintains product quality standards; ensuring any production problems are rectified with minimum downtime

correctly shutdown production process and clean and wash printing machine according to work health and safety (WHS) guidelines

demonstrate use of control, monitoring and data entry systems

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

produce TWO basic gravure printing jobs (if possible including at least one in-line process) according to job specifications and enterprise procedures.

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

---

Knowledge Evidence

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

Reel transportation and delivery

identify WHS concerns applicable to loading and handling heavy reels

identify how to determine printing side of the substrate

describe effect on the print of excessive tension on the unwinding reel

identify implication if the web is not spliced correctly

Gravure printing operations

identify how frequently product quality should be assessed

identify appropriate action/s if print is filling in when printing

describe effect of dirt under the doctor blade has on the print and the cylinder

identify importance of oscillation of the doctor blade

describe how to address a nick in the doctor blade

identify appropriate action/s if ink in the duct is foaming

describe how to identify signs of wear in the plate image area

identify level ink should be maintained at

In-line processes

identify WHS concerns for in-line component of the press

identify how often in-line components of the job should be examined

Quality control and problem-solving

identify what needs to be monitored to ensure quality

identify precautions required to ensure the rewound product is of consistent, acceptable quality

describe how to identify printed material below acceptable standard

identify how to mark product deemed unacceptable by the operator

identify the appropriate person to consult if the operator is unable to fix a problem with the print

Shut down and wash up the press

identify dangers from solvents and solutions used to clean the inking system, plate and press

identify methods used to ensure proper storage of plates following printing

list parts of the machine to be thoroughly cleaned following the print run

list components to be inspected for wear following the print run

describe record keeping requirements important for following or repeat prints

Information sources

identify relevant information sources (including machine manuals, safety documentation and other information) relevant to these tasks including where they are located and what they cover.

---