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

ICPCBF309 Mapping and Delivery Guide
Produce complex folded and glued cartons

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency ICPCBF309 - Produce complex folded and glued cartons
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to produce complex folded and glued products while maintaining the production process and machinery operation.It applies to individuals who work under direct supervision with limited responsibility in preparing materials and equipment and resolving issues to produce a finished product.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 special purpose tools, equipment and materials used to produce folded and glued cartons.

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 carton blank system
  • Feeder is monitored and adjusted to ensure continuous and efficient feeding to machine
  • Carton blank pick-up and transportation system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation
  • Transfer systems are monitored and adjusted to ensure correct and continuous carton blank handling and efficient operation
  • Substrate is added to process according to job specifications
  • Delivery is monitored and adjusted to ensure quality and efficient product delivery
       
Element: Maintain complex carton folding and gluing process
  • Registration and accuracy of folds are monitored and adjusted to ensure product quality meets the approved sample standard
  • Gluing process is monitored and adjusted to ensure accuracy of glue application and strength of adhesion conforms to quality standards
       
Element: Maintain operation of production process
  • Production process is operated in association with fellow workers and according to enterprise specifications and planned daily schedule
  • Production is maintained according to work health and safety requirements, manufacturer’s specifications and enterprise procedures
  • 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
  • Problems in folding and gluing machine operation are identified and reported according to enterprise requirements
  • Adjustments or corrections are carried out according to specified procedures and consistent with operator’s skill level
  • Complex folding/gluing 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
  • 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 folding/gluing machine at end of run
  • Folding unit is cleaned ready for next run
  • Gluing unit is disengaged and cleaned ready for next run
  • Transport and delivery systems are 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 carton blank system

1.1 Feeder is monitored and adjusted to ensure continuous and efficient feeding to machine

1.2 Carton blank pick-up and transportation system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation

1.3 Transfer systems are monitored and adjusted to ensure correct and continuous carton blank handling and efficient operation

1.4 Substrate is added to process according to job specifications

1.5 Delivery is monitored and adjusted to ensure quality and efficient product delivery

2. Maintain complex carton folding and gluing process

2.1 Registration and accuracy of folds are monitored and adjusted to ensure product quality meets the approved sample standard

2.2 Gluing process is monitored and adjusted to ensure accuracy of glue application and strength of adhesion conforms to quality standards

3. Maintain operation of production process

3.1 Production process is operated in association with fellow workers and according to enterprise specifications and planned daily schedule

3.2 Production is maintained according to work health and safety requirements, manufacturer’s specifications and enterprise procedures

3.3 Performance is monitored and verified using the process control system according to enterprise procedures

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

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

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

3.7 Waste is sorted according to enterprise procedures

4. Identify and rectify problems

4.1 Problems in folding and gluing machine operation are identified and reported according to enterprise requirements

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

4.3 Complex folding/gluing machine operation is checked to ensure correct operation

5. Conduct shutdown of production process

5.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures

5.2 Shutdown is conducted in association with fellow workers and in compliance with WHS requirements

5.3 Waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

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

5.5 Repair/adjustment is verified prior to resumption of operations

6. Clean folding/gluing machine at end of run

6.1 Folding unit is cleaned ready for next run

6.2 Gluing unit is disengaged and cleaned ready for next run

6.3 Transport and delivery systems are cleaned ready for next run

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

Evidence of the ability to:

complete THREE crashlock, six-corner and specialty work carton jobs, with different sizes and weights of carton board, using multiple gluing units, according to manufacturer’s and job specifications and enterprise procedures on either a Royal 40, a Bobst Media or Bobst Domino.

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:

explain work health and safety factors for:

setting and/or operating folder/gluer transport and delivery systems

adjusting/correcting the machine

cleaning the machine

identify areas of the feeder to monitor to ensure trouble-free operation

identify parts of the pick-up system to adjust to ensure accurate and continuous feeding

explain which areas of the delivery system to observe to prevent damage to the finished product

describe areas to observe continually to ensure smooth, trouble-free operation of the machine

explain areas of the gluing unit to monitor continuously

list causes of incorrect folding, and explain how each can be corrected

identify segments of quality assurance inspected at sample run completion

describe action to take if adhesive viscosity in gluing unit is too low/high

explain how application of glue is adjusted

identify areas of the machine to adjust if:

sheets are not neatly entering delivery

carton blanks are creasing

carton blanks are not entering the machine

explain checks to correctly shut down the machine

describe checks to make when preparing finished work for dispatch

identify areas of the machine to clean regularly, and materials to clean from the machine

explain how to keep the machine clear of surface rust (condensation)

identify recommended cleaning agents

identify production records to keep or write-up, and information to include

explain quality aspects to consider in a completed folded carton

list steps to ensure important features of the production control system are followed

explain how production needs to be altered to meet client requirements

list items to check against the client sample

identify machine manuals, safety and other documentation relevant to this task, where they are kept, and the 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 carton blank system

1.1 Feeder is monitored and adjusted to ensure continuous and efficient feeding to machine

1.2 Carton blank pick-up and transportation system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation

1.3 Transfer systems are monitored and adjusted to ensure correct and continuous carton blank handling and efficient operation

1.4 Substrate is added to process according to job specifications

1.5 Delivery is monitored and adjusted to ensure quality and efficient product delivery

2. Maintain complex carton folding and gluing process

2.1 Registration and accuracy of folds are monitored and adjusted to ensure product quality meets the approved sample standard

2.2 Gluing process is monitored and adjusted to ensure accuracy of glue application and strength of adhesion conforms to quality standards

3. Maintain operation of production process

3.1 Production process is operated in association with fellow workers and according to enterprise specifications and planned daily schedule

3.2 Production is maintained according to work health and safety requirements, manufacturer’s specifications and enterprise procedures

3.3 Performance is monitored and verified using the process control system according to enterprise procedures

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

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

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

3.7 Waste is sorted according to enterprise procedures

4. Identify and rectify problems

4.1 Problems in folding and gluing machine operation are identified and reported according to enterprise requirements

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

4.3 Complex folding/gluing machine operation is checked to ensure correct operation

5. Conduct shutdown of production process

5.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures

5.2 Shutdown is conducted in association with fellow workers and in compliance with WHS requirements

5.3 Waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

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

5.5 Repair/adjustment is verified prior to resumption of operations

6. Clean folding/gluing machine at end of run

6.1 Folding unit is cleaned ready for next run

6.2 Gluing unit is disengaged and cleaned ready for next run

6.3 Transport and delivery systems are cleaned ready for next run

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

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
Feeder is monitored and adjusted to ensure continuous and efficient feeding to machine 
Carton blank pick-up and transportation system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation 
Transfer systems are monitored and adjusted to ensure correct and continuous carton blank handling and efficient operation 
Substrate is added to process according to job specifications 
Delivery is monitored and adjusted to ensure quality and efficient product delivery 
Registration and accuracy of folds are monitored and adjusted to ensure product quality meets the approved sample standard 
Gluing process is monitored and adjusted to ensure accuracy of glue application and strength of adhesion conforms to quality standards 
Production process is operated in association with fellow workers and according to enterprise specifications and planned daily schedule 
Production is maintained according to work health and safety requirements, manufacturer’s specifications and enterprise procedures 
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 
Problems in folding and gluing machine operation are identified and reported according to enterprise requirements 
Adjustments or corrections are carried out according to specified procedures and consistent with operator’s skill level 
Complex folding/gluing 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 
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 
Folding unit is cleaned ready for next run 
Gluing unit is disengaged and cleaned ready for next run 
Transport and delivery systems are cleaned ready for next run 
Production records or other documentation are accurately completed where required by enterprise procedures 

Forms

Assessment Cover Sheet

ICPCBF309 - Produce complex folded and glued cartons
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

ICPCBF309 - Produce complex folded and glued cartons

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: