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

ICPCBF320 Mapping and Delivery Guide
Produce complex converted or finished product

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency ICPCBF320 - Produce complex converted or finished product
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to cover complex die cutting, embossing, folding, collating or fastening.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 relevant facilities, special purpose tools, machinery, equipment and materials.

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 delivery systems
  • Delivery systems are monitored and adjusted to ensure continuous and efficient operation and avoid damage to finished product
  • Substrate is added and removed to and from the process according to job specifications
       
Element: Maintain cutting system
  • Knife or die condition is monitored and adjusted to ensure product quality meets the approved sample standard
  • Cutting pressures are monitored and adjusted to ensure product quality meets the approved sample standard
  • Registration of cutting devices and knives or dies are monitored and adjusted to ensure product quality meets the approved sample standard
  • Packing of cutting devices or dies is monitored and adjusted to ensure product quality meets the approved sample standard
       
Element: Maintain complex process
  • Registration and squareness of folds are monitored and adjusted to ensure product quality meets the approved sample standard, if relevant
  • Collating/inserting process is monitored and adjusted to ensure product quality meets the approved sample standard, if relevant
       
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 manufacturer’s specifications
  • 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 devices and knives or dies are cleaned or replaced ready for next run
  • Cutting devices are sharpened according to WHS procedures
  • All units are disengaged and cleaned ready for next run
  • 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 delivery systems

1.1 Delivery systems are monitored and adjusted to ensure continuous and efficient operation and avoid damage to finished product

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

2. Maintain cutting system

2.1 Knife or die condition is monitored and adjusted to ensure product quality meets the approved sample standard

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

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

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

3. Maintain complex process

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

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

4. Maintain production process

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

4.2 Production is maintained according to work health and safety (WHS) requirements, manufacturer’s specifications and enterprise procedures

4.3 Manual and/or automatic control is used according to job specifications

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

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

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

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

4.8 Waste is sorted according to enterprise procedures

5. Identify and rectify problems or faults

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

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

5.3 Adjustments or corrections are carried out according to specified procedures and manufacturer’s specifications

5.4 Converting/finishing machine operation is checked to ensure correct operation

6. Conduct shutdown of production process

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

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

6.3 Substrate waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

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

6.5 Repair/adjustment is verified prior to resumption of operations

7. Clean converting/finishing machine at end of run

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

7.2 Cutting devices are sharpened according to WHS procedures

7.3 All units are disengaged and cleaned ready for next run

7.4 Delivery systems are disengaged and cleaned ready for next run

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

Evidence of the ability to:

demonstrate all safety devices on the machinery

correctly produce complex converted or finished product involving complex die cutting, embossing, folding, collating or fastening for TWO different jobs involving different types, sizes and weights of substrate according to manufacturer’s and job specifications, enterprise procedures and listed performance criteria.

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

individual must:

identify work health and safety (WHS) factors for:

setting up and/or operating machine transport systems

setting up and/or operating machine delivery systems

maintaining the cutting process

using the folding machine

adjusting/correcting the machine, and prior to any required adjustments

maintaining or adjusting the operation of the machine

using hot melt adhesive

cleaning the machine

identify safety clothing available for use when operating adhesive binders

explain how to carry out buckle, knife and pharmaceutical folding

outline the actions required if:

the gate fold unit is out of timing

the right angle fold is out-of-square

double sheet feeds occur

identify areas of the machine to adjust if:

the sheet is creasing

the sheet is caught in the fold plate

the sheet is not entering the machine

sheets are not entering delivery neatly

list and describe common machine faults and how to correct them

explain why gluing units and delivery systems require careful monitoring

identify indicators showing replacement of a knife/cutting edge is required

list checks required when cutting pressure is adjusted, and the points to monitor when maintaining cutting pressures

list checks made when:

sections fail to open on the chain

packing cutting devices

correcting dull cutting edges on equipment

correcting depth of embossing

substrate is removed from the machine

explain the terms:

side lay

deflector

glue line

determine segments of quality assurance inspected at the completion of the sample run

determine action if the:

viscosity of adhesive in the gluing unit is too low/high

gluing unit is out of timing

explain solutions when:

job is out-of-square

ink is too wet for production

job does not coincide with the sample

sheet is creasing

sheet is caught in the fold plate

sheet is not entering the machine

sheet falls out of the machine after folding

sheets misfeed during production

‘bruising’ of the NCR sheets occurs

determine factors that govern speed the machine operates at

identify indicators the machine needs lubrication

explain consequence/s of too much or too little adhesive

determine factors indicating:

the machine need to be adjusted

the machine need to be slowed down

when machine speed can be increased

explain how to adjust position and quantity of adhesive on an adhesive binder/gluer

explain how to adjust adhesive thickness and pressure on an adhesive binder/gluer

explain how to achieve more spine milling on an adhesive binder

explain how to straighten or adjust wire in the wire feed on a wire stitcher

explain how to increase/decrease dwell time on a high frequency welder

list checks for shutting down a given machine, and identify the key reasons for the checks

identify materials to clean from the machine

list recommended cleaning agents for this machine and how to keep the machine clear of surface rust

determine quality aspects to monitor during production as well as those to check on the finished product

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

identify items to check against the client sample

explain required production records and the information to include

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

For Reel Systems Only

identify areas of the reel stand to monitor to ensure trouble-free operation

explain how to adjust the web control system to maintain correct web tension and correct positioning of the web

For Sheet Systems Only

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

determine parts of the sheet or section pick-up system to adjust to ensure accurate and continuous sheet handling.

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 delivery systems

1.1 Delivery systems are monitored and adjusted to ensure continuous and efficient operation and avoid damage to finished product

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

2. Maintain cutting system

2.1 Knife or die condition is monitored and adjusted to ensure product quality meets the approved sample standard

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

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

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

3. Maintain complex process

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

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

4. Maintain production process

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

4.2 Production is maintained according to work health and safety (WHS) requirements, manufacturer’s specifications and enterprise procedures

4.3 Manual and/or automatic control is used according to job specifications

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

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

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

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

4.8 Waste is sorted according to enterprise procedures

5. Identify and rectify problems or faults

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

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

5.3 Adjustments or corrections are carried out according to specified procedures and manufacturer’s specifications

5.4 Converting/finishing machine operation is checked to ensure correct operation

6. Conduct shutdown of production process

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

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

6.3 Substrate waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

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

6.5 Repair/adjustment is verified prior to resumption of operations

7. Clean converting/finishing machine at end of run

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

7.2 Cutting devices are sharpened according to WHS procedures

7.3 All units are disengaged and cleaned ready for next run

7.4 Delivery systems are disengaged and cleaned ready for next run

7.5 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 delivery system

OR

sheet delivery system

OR

complex fastening (adhesive/mechanical/sewing) system.

Monitoring and adjusting MUST include EITHER:

reel stand and rewind section

web control system to ensure correct tension

delivery system

sheeting system

OR

feeder

sheet pick-up and transportation

transfer system to ensure correct and continuous sheet handling

OR

fastening registration

wire straightening, length, cut off and clinching pressures

adhesion

thread tension and stitch quality.

Units MUST include EITHER:

machine bed

OR

glue system

OR

laminating machine.

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 continuous and efficient operation and avoid damage to finished product 
Substrate is added and removed to and from the process according to job specifications 
Knife or die condition is monitored and adjusted to ensure product quality meets the approved sample standard 
Cutting pressures are monitored and adjusted to ensure product quality meets the approved sample standard 
Registration of cutting devices and knives or dies are monitored and adjusted to ensure product quality meets the approved sample standard 
Packing of cutting devices or dies is monitored and adjusted to ensure product quality meets the approved sample standard 
Registration and squareness of folds are monitored and adjusted to ensure product quality meets the approved sample standard, if relevant 
Collating/inserting process is monitored and adjusted to ensure product quality meets the approved sample standard, if relevant 
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 manufacturer’s specifications 
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 devices and knives or dies are cleaned or replaced ready for next run 
Cutting devices are sharpened according to WHS procedures 
All units are disengaged and cleaned ready for next run 
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

ICPCBF320 - Produce complex 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

ICPCBF320 - Produce complex 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: