Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

ICPCBF220 Mapping and Delivery Guide
Produce basic converted or finished product

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency ICPCBF220 - Produce basic converted or finished product
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to cover most converting and finishing operations including how to maintain substrate operations and complete relevant finishing processes.It applies to individuals who prepare materials and set up and run a range of equipment and machinery for cutting, embossing, folding, collating and fastening. They work under direct supervision, however have certain responsibilities in the production process. No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

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 relevant facilities, and equipment and materials used to produce a converted or finished product.

Assessors must satisfy NVR/AQTF assessor requirements.
Prerequisites/co-requisites
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Maintain operation of delivery system
  • Delivery systems are monitored and adjusted to ensure efficient and continuous operation of the process and ensure no damage to finished product
  • Substrate is added to and removed from the process according to job specifications
       
Element: Maintain basic cutting or embossing process
  • Cutting edge and knife or die condition is monitored and adjusted to ensure quality of product meets the approved sample standard
  • Cutting/embossing pressures are monitored and adjusted to ensure quality of product meets the approved sample standard
  • Registration of cutting devices and knives or dies is monitored and adjusted to ensure quality of product meets the approved sample standard
  • Packing of cutting/embossing devices is monitored and adjusted to ensure quality of product meets the approved sample standard
       
Element: Maintain folding process
  • Registration and squareness of fold are monitored and adjusted to ensure quality of product meets the approved sample standard, if relevant
  • Collating/inserting process is monitored and adjusted to ensure quality of product meets the approved sample standard, if relevant
       
Element: Maintain basic fastening (adhesive/ mechanical/thermal) process
  • Registration of fastening is monitored and adjusted to ensure quality of product meets the approved sample standard
  • Wire straightness, length, cut-off and clinching pressures or power current and dwell time are monitored and adjusted to ensure quality of product meets the approved sample standard
       
Element: Maintain basic laminating process
  • Registration of laminating is monitored and adjusted to ensure quality of product meets the approved sample standard
  • Pressures are monitored and adjusted to ensure quality of product meets the approved sample standard
  • Adhesion is monitored and adjusted to ensure quality of product meets the approved sample standard
  • Basic in-line printing/coating processes are monitored and adjusted to ensure quality of product meets the approved sample standard
       
Element: Maintain production process
  • 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
  • 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
       
Element: Identify and rectify problems or faults
  • Product and substrate are monitored and tested to ensure conformance to client requirements
  • Problems in converting/finishing machine 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
  • Converting/finishing machine operation is checked to ensure correct operation
       
Element: 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
  • Substrate waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures
  • Machine faults requiring repair are identified and reported to designated person according to enterprise procedures
  • Repair/adjustment is verified prior to resumption of operations
       
Element: Clean converting/ finishing machine at end of run
  • Cutting units are disengaged and cleaned ready for next run
  • Cutting devices are sharpened according to WHS procedures
  • Machine bed is cleaned ready for next run
  • Cutting devices and knives are cleaned or replaced ready for next run
  • All units are disengaged and cleaned ready for next run
  • Adhesive or glue system is washed ready for next run, and liquid waste is disposed of according to regulatory requirements and enterprise procedures
  • 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
       


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. Maintain operation of delivery system

1.1 Delivery systems are monitored and adjusted to ensure efficient and continuous operation of the process and ensure no damage to finished product

1.2 Substrate is added to and removed from the process according to job specifications

2. Maintain basic cutting or embossing process

2.1 Cutting edge and knife or die condition is monitored and adjusted to ensure quality of product meets the approved sample standard

2.2 Cutting/embossing pressures are monitored and adjusted to ensure quality of product meets the approved sample standard

2.3 Registration of cutting devices and knives or dies is monitored and adjusted to ensure quality of product meets the approved sample standard

2.4 Packing of cutting/embossing devices is monitored and adjusted to ensure quality of product meets the approved sample standard

3. Maintain folding process

3.1 Registration and squareness of fold are monitored and adjusted to ensure quality of product meets the approved sample standard, if relevant

3.2 Collating/inserting process is monitored and adjusted to ensure quality of product meets the approved sample standard, if relevant

4. Maintain basic fastening (adhesive/ mechanical/thermal) process

4.1 Registration of fastening is monitored and adjusted to ensure quality of product meets the approved sample standard

4.2 Wire straightness, length, cut-off and clinching pressures or power current and dwell time are monitored and adjusted to ensure quality of product meets the approved sample standard

5. Maintain basic laminating process

5.1 Registration of laminating is monitored and adjusted to ensure quality of product meets the approved sample standard

5.2 Pressures are monitored and adjusted to ensure quality of product meets the approved sample standard

5.3 Adhesion is monitored and adjusted to ensure quality of product meets the approved sample standard

5.4 Basic in-line printing/coating processes are monitored and adjusted to ensure quality of product meets the approved sample standard

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

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

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

6.8 Waste is sorted according to enterprise procedures

7. Identify and rectify problems or faults

7.1 Product and substrate are monitored and tested to ensure conformance to client requirements

7.2 Problems in converting/finishing machine operation are identified and reported according to enterprise procedures

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

7.4 Converting/finishing machine 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 Substrate waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

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

8.5 Repair/adjustment is verified prior to resumption of operations

9. Clean converting/ finishing machine at end of run

9.1 Cutting units are disengaged and cleaned ready for next run

9.2 Cutting devices are sharpened according to WHS procedures

9.3 Machine bed is cleaned ready for next run

9.4 Cutting devices and knives are cleaned or replaced ready for next run

9.5 All units are disengaged and cleaned ready for next run

9.6 Adhesive or glue system is washed ready for next run, and liquid waste is disposed of according to regulatory requirements and enterprise procedures

9.7 Transportation and delivery systems are disengaged and cleaned ready for next run

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

Evidence of the ability to:

correctly use any converting or finishing equipment (involving one process or a sequence of processes) to complete TWO different jobs involving different types, sizes and weights of substrate according to manufacturer’s specifications, job specifications and enterprise procedures OR in the case of standalone minor flat-bed or rotary cutting processes THREE processes must be demonstrated

correctly maintain substrate operation and complete relevant finishing process according to job specifications and within the production timeframe

demonstrate all safety devices on the machine

demonstrate use of computerised control, monitoring and data entry.

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:

Work health and safety (WHS)

identify WHS factors for:

setting up/adjusting the collating machine

setting up and/or operating machine transport and machine delivery systems

maintaining the cutting process

using the folding machine

using hot melt adhesive

maintaining laminating and in-line processes

keeping the machine clear of surface rust (condensation)

conducting machine shutdown procedures

identify safety clothing for use when operating adhesive binders

Reel Delivery Systems Only

list areas of the reel stand to be monitored to ensure trouble-free operation

identify the area of the web control system to adjust to maintain correct web tension

identify WHS factors for straightening the wire feed of a wire stitcher

Sheet Delivery Systems Only

name THREE procedures to ensure smooth transport of sections through the machine

list steps to ensure smooth delivery of sections

list FOUR important factors to consider when setting the feeder

explain the setting of the double/misfeed sheet calliper system

name different types of sheet/section delivery systems

list checks required when substrate is removed from the machine

Paper sizes and weights

determine largest and smallest sheet or section size that can be run through this machine

identify which areas of the machine should be adjusted to allow for 42gsm stock

maintenance of cutting processes

explain indicators of the need to replace a knife and how cutting pressure is adjusted

list FOUR requirements to maintain the cutting process to ensure the machine can be kept running without interruption

Cutting machine faults and problems

identify checks required when packing cutting devices

explain the procedure for correcting THREE common machine faults

list adjustments required if the cover is marked (scuffed) when trimming

Maintaining basic folding processes

list THREE areas to continuously observe to ensure smooth, trouble-free operation of the machine

list areas of the in-line process to monitor to assure quality of the product

Folding machine faults and minor problem-solving

identify TWO causes of out-of-square folding and explain how each may be corrected

list areas of the client’s sample to be inspected to determine quality assurance

explain communication to instigate if the:

job is out-of-square

ink is too wet for production

job does not coincide with the sample

list parts of the machine to adjust if the sheet is creasing

Collating machine operation, problems and fault correction

list factors that govern speed the machine operates at

list indicators the machine needs lubrication

identify how to prevent double sheet feeds

identify circumstances indicating the machine needs adjustment

list FOUR items to check against the client sample to constitute an acceptable collating result

Maintaining basic fastening (adhesive/mechanical/thermal) process

list areas of the in-line process to monitor to ensure product quality

name TWO sectors to observe to ensure the production process is trouble-free and continuous

Fastening operating problems and minor fault correction

list circumstances when the machine needs to be adjusted

explain how adhesive application is adjusted

explain how wire can be straightened in the wire feed

identify TWO possible reasons welding might be unsuccessful for a high-frequency welder

determine quality aspects to consider in a completed:

adhesive-bound job

high-frequency welded job

wire-stitched job

explain how production may need to be altered to meet client requirements

Maintaining laminating production processes and minor fault correction

explain methods for assuring registration of laminating

list areas of the in-line process to monitor to ensure a quality product

identify TWO laminating problems that may occur during operation of the machine and adjustments or correction procedures required to ensure accurate operation

determine quality aspects to consider in a completed laminated job, and ways production may need to be altered to meet client requirements

Machine shutdown procedures

determine checks required when waste is removed from the machine and surrounding area for disposal or recycling

list checks required during the machine shutdown procedure

list checks required when cutting devices or knives are cleaned or replaced ready for the next run

identify materials to be cleaned from the machine, and areas of the machine that require cleaning at the end of the run

Quality assurance

list features to check on the finished product

list THREE common faults that cause the finished product to be rejected, and how they can be fixed/avoided

explain available testing procedures and why they are used

list production records to be kept or written up, and the information that should be included

Information sources

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

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, 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. Maintain operation of delivery system

1.1 Delivery systems are monitored and adjusted to ensure efficient and continuous operation of the process and ensure no damage to finished product

1.2 Substrate is added to and removed from the process according to job specifications

2. Maintain basic cutting or embossing process

2.1 Cutting edge and knife or die condition is monitored and adjusted to ensure quality of product meets the approved sample standard

2.2 Cutting/embossing pressures are monitored and adjusted to ensure quality of product meets the approved sample standard

2.3 Registration of cutting devices and knives or dies is monitored and adjusted to ensure quality of product meets the approved sample standard

2.4 Packing of cutting/embossing devices is monitored and adjusted to ensure quality of product meets the approved sample standard

3. Maintain folding process

3.1 Registration and squareness of fold are monitored and adjusted to ensure quality of product meets the approved sample standard, if relevant

3.2 Collating/inserting process is monitored and adjusted to ensure quality of product meets the approved sample standard, if relevant

4. Maintain basic fastening (adhesive/ mechanical/thermal) process

4.1 Registration of fastening is monitored and adjusted to ensure quality of product meets the approved sample standard

4.2 Wire straightness, length, cut-off and clinching pressures or power current and dwell time are monitored and adjusted to ensure quality of product meets the approved sample standard

5. Maintain basic laminating process

5.1 Registration of laminating is monitored and adjusted to ensure quality of product meets the approved sample standard

5.2 Pressures are monitored and adjusted to ensure quality of product meets the approved sample standard

5.3 Adhesion is monitored and adjusted to ensure quality of product meets the approved sample standard

5.4 Basic in-line printing/coating processes are monitored and adjusted to ensure quality of product meets the approved sample standard

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

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

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

6.8 Waste is sorted according to enterprise procedures

7. Identify and rectify problems or faults

7.1 Product and substrate are monitored and tested to ensure conformance to client requirements

7.2 Problems in converting/finishing machine operation are identified and reported according to enterprise procedures

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

7.4 Converting/finishing machine 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 Substrate waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

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

8.5 Repair/adjustment is verified prior to resumption of operations

9. Clean converting/ finishing machine at end of run

9.1 Cutting units are disengaged and cleaned ready for next run

9.2 Cutting devices are sharpened according to WHS procedures

9.3 Machine bed is cleaned ready for next run

9.4 Cutting devices and knives are cleaned or replaced ready for next run

9.5 All units are disengaged and cleaned ready for next run

9.6 Adhesive or glue system is washed ready for next run, and liquid waste is disposed of according to regulatory requirements and enterprise procedures

9.7 Transportation and delivery systems are disengaged and cleaned ready for next run

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

This section specifies different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Delivery systems MUST include EITHER:

reel

OR

sheet

Monitoring and adjusting MUST include EITHER:

reel stand and rewind

web control system

sheeting section

OR

feeder and delivery system

sheet pick-up and transport system

transfer system

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
Delivery systems are monitored and adjusted to ensure efficient and continuous operation of the process and ensure no damage to finished product 
Substrate is added to and removed from the process according to job specifications 
Cutting edge and knife or die condition is monitored and adjusted to ensure quality of product meets the approved sample standard 
Cutting/embossing pressures are monitored and adjusted to ensure quality of product meets the approved sample standard 
Registration of cutting devices and knives or dies is monitored and adjusted to ensure quality of product meets the approved sample standard 
Packing of cutting/embossing devices is monitored and adjusted to ensure quality of product meets the approved sample standard 
Registration and squareness of fold are monitored and adjusted to ensure quality of product meets the approved sample standard, if relevant 
Collating/inserting process is monitored and adjusted to ensure quality of product meets the approved sample standard, if relevant 
Registration of fastening is monitored and adjusted to ensure quality of product meets the approved sample standard 
Wire straightness, length, cut-off and clinching pressures or power current and dwell time are monitored and adjusted to ensure quality of product meets the approved sample standard 
Registration of laminating is monitored and adjusted to ensure quality of product meets the approved sample standard 
Pressures are monitored and adjusted to ensure quality of product meets the approved sample standard 
Adhesion is monitored and adjusted to ensure quality of product meets the approved sample standard 
Basic in-line printing/coating processes are monitored and adjusted to ensure quality of product meets the approved sample standard 
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 
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 
Product and substrate are monitored and tested to ensure conformance to client requirements 
Problems in converting/finishing machine 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 
Converting/finishing machine 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 
Substrate waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures 
Machine faults requiring repair are identified and reported to designated person according to enterprise procedures 
Repair/adjustment is verified prior to resumption of operations 
Cutting units are disengaged and cleaned ready for next run 
Cutting devices are sharpened according to WHS procedures 
Machine bed is cleaned ready for next run 
Cutting devices and knives are cleaned or replaced ready for next run 
All units are disengaged and cleaned ready for next run 
Adhesive or glue system is washed ready for next run, and liquid waste is disposed of according to regulatory requirements and enterprise procedures 
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 

Forms

Assessment Cover Sheet

ICPCBF220 - Produce basic converted or finished product
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

ICPCBF220 - Produce basic converted or finished product

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: