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

ICPPRN214 Mapping and Delivery Guide
Produce basic flexographic printed product

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency ICPPRN214 - Produce basic flexographic printed product
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to safely operate either a reel- or sheet-fed flexographic print, ensuring efficient production flow and quality standards.It applies to individuals working in the printing and graphic arts industry who perform a range of mainly routine tasks, work under direct supervision and use limited practical skills and knowledge in a defined context.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 printing field of work and include access to:

special purpose tools, equipment and materials

a reel or sheet-fed flexographic press.

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 systems
  • Delivery systems are monitored and adjusted to ensure efficient and continuous operation and ensure no damage to finished product
  • Substrate is added to and removed from process according to job instructions
       
Element: Maintain basic flexographic printing process
  • Flexographic plate and plate cylinder or sleeve condition is monitored and adjusted to ensure quality of printed product meets the approved proof standard
  • Flexographic impression roller condition is monitored to ensure quality of printed product meets the approved proof standard
  • Flexographic 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 printed product meets the approved proof standard
       
Element: Maintain routine 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
  • 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
  • Faulty performance of equipment is identified and reported according to enterprise procedures
  • Waste is sorted according to enterprise procedures
       
Element: Identify and rectify faults
  • Problem in flexographic machine operation is identified and reported according to enterprise procedures
  • Adjustments or corrections are carried out according to specified procedures and consistent with operator’s skill level
  • Flexographic machine operation is checked to ensure efficient operation
  • Machine faults requiring repair are identified and reported to designated person according to enterprise procedures
       
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
  • Reels and cores are removed from press if web-fed
  • Unused ink is drained back into containers and correctly labelled and stored according to manufacturer’s/supplier’s 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
  • Product is removed from operating area
       
Element: Clean and wash printing machine
  • Cylinders or sleeves, plate and roller surfaces are cleaned ready for next run
  • Inking rollers and doctor blades or chamber blade systems are cleaned with correct solvents according to WHS guidelines
  • Ink pumps, tanks and hoses are cleaned correctly
  • Impression rollers/central impression and press rollers are cleaned
  • In-line printing/converting/binding/finishing units are cleaned ready for next run
  • Reel or sheet-feed transportation and delivery systems are disengaged and cleaned ready for next run
  • Press is lubricated and protected according to duration of shutdown
  • 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 systems

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

1.2 Substrate is added to and removed from process according to job instructions

2. Maintain basic flexographic printing process

2.1 Flexographic plate and plate cylinder or sleeve condition is monitored and adjusted to ensure quality of printed product meets the approved proof standard

2.2 Flexographic impression roller condition is monitored to ensure quality of printed product meets the approved proof standard

2.3 Flexographic inking system and doctor blade are monitored and adjusted to ensure quality of printed product meets the approved proof standard

2.4 Drying systems are monitored and adjusted to ensure quality of printed product meets the approved proof standard

2.5 Basic in-line printing/converting/binding/finishing process(es) are monitored and adjusted to ensure quality of printed product meets the approved proof standard

3. Maintain routine production process

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

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

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

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

3.5 Ink performance, colour, register and position of print are monitored and adjusted throughout production run

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

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

3.8 Waste is sorted according to enterprise procedures

4. Identify and rectify faults

4.1 Problem in flexographic machine operation is identified and reported according to enterprise procedures

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

4.3 Flexographic machine operation is checked to ensure efficient operation

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

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 Reels and cores are removed from press if web-fed

5.4 Unused ink is drained back into containers and correctly labelled and stored according to manufacturer’s/supplier’s specifications and enterprise procedures

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

5.6 Product is removed from operating area

6. Clean and wash printing machine

6.1 Cylinders or sleeves, plate and roller surfaces are cleaned ready for next run

6.2 Inking rollers and doctor blades or chamber blade systems are cleaned with correct solvents according to WHS guidelines

6.3 Ink pumps, tanks and hoses are cleaned correctly

6.4 Impression rollers/central impression and press rollers are cleaned

6.5 In-line printing/converting/binding/finishing units are cleaned ready for next run

6.6 Reel or sheet-feed transportation and delivery systems are disengaged and cleaned ready for next run

6.7 Press is lubricated and protected according to duration of shutdown

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

Evidence of the ability to:

accurately produce TWO basic flexographic printing jobs (if possible including at least ONE in-line process) according to job specifications, enterprise procedures and work health and safety (WHS) requirements

correctly shut down and clean flexographic press and, if possible, rectify any production problems with minimum downtime.

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:

outline process for transportation and delivery

describe process for determining the substrate printing side

For reel systems only

outline WHS concerns when loading and handling heavy reels

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

describe process for correct web splicing and implications if web is not spliced correctly

For sheet systems only

outline WHS concerns when operating sheet transportation and delivery systems

identify reasons for fanning sheets before loading into the press

describe the process for setting, and the check to be made to the double sheet detector during the print run, and components that can be adjusted to ensure correct delivery

describe effect excessive suction can have on slow-down wheels

state how often product quality should be assessed, and what action taken if print fills in when printing

describe effect of dirt under the doctor blade on the print and the motion of doctor blade oscillation

describe action taken if ink in duct is foaming

name signs of wear in the plate image area

outline WHS concerns for the in-line component of the press and how often in-line components of the job should be examined

describe the process of monitoring to ensure quality

outline precautions to ensure the rewound product is consistent, acceptable quality and how to identify if printed material is not of an acceptable standard

outline marking of product deemed unacceptable by the operator

describe the process of consultation needed when there is a problem with the print that cannot be fixed by the operator

identify location of information concerning correct operation of the machine

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

describe methods used to ensure proper storage of plates following printing

list parts of the machine that should be thoroughly cleaned following the print run and components to be inspected for wear following the print run

identify records important for following or repeat prints

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


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 systems

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

1.2 Substrate is added to and removed from process according to job instructions

2. Maintain basic flexographic printing process

2.1 Flexographic plate and plate cylinder or sleeve condition is monitored and adjusted to ensure quality of printed product meets the approved proof standard

2.2 Flexographic impression roller condition is monitored to ensure quality of printed product meets the approved proof standard

2.3 Flexographic inking system and doctor blade are monitored and adjusted to ensure quality of printed product meets the approved proof standard

2.4 Drying systems are monitored and adjusted to ensure quality of printed product meets the approved proof standard

2.5 Basic in-line printing/converting/binding/finishing process(es) are monitored and adjusted to ensure quality of printed product meets the approved proof standard

3. Maintain routine production process

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

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

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

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

3.5 Ink performance, colour, register and position of print are monitored and adjusted throughout production run

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

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

3.8 Waste is sorted according to enterprise procedures

4. Identify and rectify faults

4.1 Problem in flexographic machine operation is identified and reported according to enterprise procedures

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

4.3 Flexographic machine operation is checked to ensure efficient operation

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

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 Reels and cores are removed from press if web-fed

5.4 Unused ink is drained back into containers and correctly labelled and stored according to manufacturer’s/supplier’s specifications and enterprise procedures

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

5.6 Product is removed from operating area

6. Clean and wash printing machine

6.1 Cylinders or sleeves, plate and roller surfaces are cleaned ready for next run

6.2 Inking rollers and doctor blades or chamber blade systems are cleaned with correct solvents according to WHS guidelines

6.3 Ink pumps, tanks and hoses are cleaned correctly

6.4 Impression rollers/central impression and press rollers are cleaned

6.5 In-line printing/converting/binding/finishing units are cleaned ready for next run

6.6 Reel or sheet-feed transportation and delivery systems are disengaged and cleaned ready for next run

6.7 Press is lubricated and protected according to duration of shutdown

6.8 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 sections

web control system

sheeting action

set off / marking prevention system

OR

feeder and delivery system

sheet pick-up and transportation 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 and ensure no damage to finished product 
Substrate is added to and removed from process according to job instructions 
Flexographic plate and plate cylinder or sleeve condition is monitored and adjusted to ensure quality of printed product meets the approved proof standard 
Flexographic impression roller condition is monitored to ensure quality of printed product meets the approved proof standard 
Flexographic 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 printed product meets the approved proof 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 
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 
Faulty performance of equipment is identified and reported according to enterprise procedures 
Waste is sorted according to enterprise procedures 
Problem in flexographic machine operation is identified and reported according to enterprise procedures 
Adjustments or corrections are carried out according to specified procedures and consistent with operator’s skill level 
Flexographic machine operation is checked to ensure efficient operation 
Machine faults requiring repair are identified and reported to designated person according to enterprise procedures 
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 
Reels and cores are removed from press if web-fed 
Unused ink is drained back into containers and correctly labelled and stored according to manufacturer’s/supplier’s 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 
Product is removed from operating area 
Cylinders or sleeves, plate and roller surfaces are cleaned ready for next run 
Inking rollers and doctor blades or chamber blade systems are cleaned with correct solvents according to WHS guidelines 
Ink pumps, tanks and hoses are cleaned correctly 
Impression rollers/central impression and press rollers are cleaned 
In-line printing/converting/binding/finishing units are cleaned ready for next run 
Reel or sheet-feed transportation and delivery systems are disengaged and cleaned ready for next run 
Press is lubricated and protected according to duration of shutdown 
Production records or other documentation are accurately completed where required by enterprise procedures 

Forms

Assessment Cover Sheet

ICPPRN214 - Produce basic flexographic printed 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

ICPPRN214 - Produce basic flexographic printed 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: