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

ICPPRN314 Mapping and Delivery Guide
Produce complex flexographic printed product

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency ICPPRN314 - Produce complex flexographic printed product
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to set up machines for non-routine flexographic printing.It applies to individuals who work as print machinists who prepare material, and monitor and run equipment and machinery and apply solutions to printing difficulties as they arise.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 range of standard inks and substrates

a variety of stack, in-line and central impression flexographic printing machines.

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 non-routine operation of reel transportation system
  • Reel stand is monitored and adjusted to ensure efficient, continuous operation
  • Web control system is monitored and adjusted to ensure correct tension and accurate continuous web positioning for efficient operation
  • Substrate is added to process according to job instructions
       
Element: Maintain non-routine operation of reel delivery system on web-fed machine
  • Reel rewind section is monitored and adjusted to maintain correct tension and avoid marks, blemishes or damage to finished product
  • Substrate is removed from process according to non-routine job instructions
  • Sheeting section is monitored and adjusted to ensure quality and efficient product delivery
  • Set-off / marking prevention system is monitored and adjusted to ensure quality of printed product without set-off or marking meets the approved proof standard
       
Element: Maintain complex 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 the quality of printed product meets the approved proof standard
  • Flexographic inking system and doctor blade condition 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
  • In-line printing/converting/binding/finishing processes are monitored and adjusted to ensure quality of product meets the approved proof standard
       
Element: Maintain non-routine production process
  • Production process is operated in association with fellow workers and according to company specifications and planned daily schedule
  • Production is maintained within work health and safety (WHS) requirements and company and manufacturer’s specifications
  • Automatic control is used as per specification
  • Manual control is used as per specification
  • Ink performance, colour, register and position of print are monitored and adjusted throughout production run
  • Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention
  • Process adjustments to eliminate problems are reported according to enterprise procedures
  • Faulty performance of equipment is identified and reported according to enterprise procedures
  • Waste is sorted according to enterprise procedures
       
Element: Identify and rectify faults
  • Problems in flexographic machine are identified and reported according to enterprise procedures
  • Adjustments or corrections are carried out according to specified procedures and consistent with operator’s skill level
  • Flexographic machine operation is checked to ensure correct 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
  • 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
  • All product is removed from operating area
       
Element: Clean and wash up printing machine at end of print run
  • 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 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 non-routine operation of reel transportation system

1.1 Reel stand is monitored and adjusted to ensure efficient, continuous operation

1.2 Web control system is monitored and adjusted to ensure correct tension and accurate continuous web positioning for efficient operation

1.3 Substrate is added to process according to job instructions

2. Maintain non-routine operation of reel delivery system on web-fed machine

2.1 Reel rewind section is monitored and adjusted to maintain correct tension and avoid marks, blemishes or damage to finished product

2.2 Substrate is removed from process according to non-routine job instructions

2.3 Sheeting section is monitored and adjusted to ensure quality and efficient product delivery

2.4 Set-off / marking prevention system is monitored and adjusted to ensure quality of printed product without set-off or marking meets the approved proof standard

3. Maintain complex flexographic printing process

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

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

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

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

3.5 In-line printing/converting/binding/finishing processes are monitored and adjusted to ensure quality of product meets the approved proof standard

4. Maintain non-routine production process

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

4.2 Production is maintained within work health and safety (WHS) requirements and company and manufacturer’s specifications

4.3 Automatic control is used as per specification

4.4 Manual control is used as per specification

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

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

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

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

4.9 Waste is sorted according to enterprise procedures

5. Identify and rectify faults

5.1 Problems in flexographic machine are identified and reported according to enterprise procedures

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

5.3 Flexographic machine operation is checked to ensure correct operation

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

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 Reels and cores are removed from press

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

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

6.6 All product is removed from operating area

7. Clean and wash up printing machine at end of print run

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

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

7.3 Ink pumps, tanks and hoses are cleaned correctly

7.4 Impression rollers/central impression and press rollers are cleaned

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

7.6 Reel feed, transportation and delivery systems are disengaged and cleaned ready for next run

7.7 Press is lubricated and protected according to duration of shutdown

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

Evidence of the ability to:

operate a reel-fed flexographic press ensuring an efficient THREE or more colour production flow that maintains product quality standards. Any production problems are anticipated and rectified with minimum downtime. The machine is correctly shut down and cleaned according to work health and safety (WHS) guidelines

demonstrate use of control, monitoring and data entry systems

monitor production output and make necessary adjustments to maintain print quality on a flexographic machine while producing a complex print on TWO occasions (if possible using different substrates, and if possible including at least TWO in-line processes) according to job specifications and enterprise procedures.

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

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

Reel transportation and web control

explain what causes the reel to wander

explain what causes web to break at the unwind unit

describe the difference between a ‘flying paster’ and ‘zero speed’ type reel-stand

explain what print fault results from the reel being run out of centre

identify possible faults in the unwind section that could cause a web break

Reel delivery for rewinding and sheeting

identify WHS risks associated with rewinding and sheeting

identify the safety feature in the delivery system that helps if the web jams up

explain why the sheet cut-off might wander

describe the effect of poorly adjusted nip rollers when rewinding and sheeting

Printing and drying units

explain what happens if the plate lifts on the leading edge during a print run

explain how a build-up of ink on the impression cylinder affects the printed product

explain what causes ink to foam in the ink tray

explain the effect of too much reducer in the ink

list actions that reduce wear of the doctor blade

explain why it is necessary that all solvents be removed from the final ink film

describe the link between driers and set off and marking

explain what causes UV ink to dry

explain what causes substrate to distort

list the effect in the chillers if the drying temperature was too low

explain the effect of incorrect drying temperature on the finished product

discuss why it is advisable not to eat or drink near the machine when using UV inks

In-line processes

explain why it is necessary to frequently examine in-line components of the job

describe how consistency of the punching unit is checked

explain the outcome of excessive pressure on the slitters

Maintaining production process

describe safety features within the organisation that aid in maintaining effective production

identify who is legally responsible if removal of machine guards and/or disconnection of micro switches occurs

describe the effect of inadequate communication within the work team

explain ramifications if machine guards are removed and/or micro switches are disconnected on a machine

explain what other measurements besides optimum solid ink density can be measured to assess print quality

determine the accurate method of checking register during a production run

describe why it is necessary to take immediate action when anticipating production problems

explain actions to eliminate further processing of unacceptable printed product

determine result to the substrate if relative humidity is increased in the press room

explain the procedure to care for a newly delivered substrate to the press room

describe why waste should be sorted and the advantage of keeping reusable waste

Client liaison

identify what industry standards that can be applied to enhance client communication

describe necessary procedures clients should follow to OK a printed product

Flexographic machine operating problems

explain when it is necessary to call service personnel to correct a machine problem

describe enterprise procedures in place to report any machine operating problems

Shutdown procedures

explain what happens if correct shutdown procedures are not followed

explain why it is necessary that correct shutdown procedures are conducted with fellow workers

list advantages of proper labelling and storage of excess inks and materials

identify why printed product needs to be clearly labelled prior to removal from the press room

determine what further operations are required for printed reels once they are removed from the printing machine

explain how the printed job should be stored after removal from the printing machine

detail cleaning and washing the printing unit

explain what WHS concerns should be observed when handling ink

identify safety precautions for cleaning the printing cylinders

explain why it is necessary to thoroughly clean and wash the printing unit prior to the next print run

explain why anilox cells should be thoroughly cleaned

describe how plates can be stored to minimise damage

Cleaning feed, transportation, delivery and in-line sections

explain work health and safety (WHS) precautions for cleaning these sections of the machine

explain why it is necessary to maintain a clean substrate handling section of the machine

Completing production records

identify what completed records are used in the final analysis of the job

explain benefits of comprehensive records when considering production of future jobs

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

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 non-routine operation of reel transportation system

1.1 Reel stand is monitored and adjusted to ensure efficient, continuous operation

1.2 Web control system is monitored and adjusted to ensure correct tension and accurate continuous web positioning for efficient operation

1.3 Substrate is added to process according to job instructions

2. Maintain non-routine operation of reel delivery system on web-fed machine

2.1 Reel rewind section is monitored and adjusted to maintain correct tension and avoid marks, blemishes or damage to finished product

2.2 Substrate is removed from process according to non-routine job instructions

2.3 Sheeting section is monitored and adjusted to ensure quality and efficient product delivery

2.4 Set-off / marking prevention system is monitored and adjusted to ensure quality of printed product without set-off or marking meets the approved proof standard

3. Maintain complex flexographic printing process

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

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

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

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

3.5 In-line printing/converting/binding/finishing processes are monitored and adjusted to ensure quality of product meets the approved proof standard

4. Maintain non-routine production process

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

4.2 Production is maintained within work health and safety (WHS) requirements and company and manufacturer’s specifications

4.3 Automatic control is used as per specification

4.4 Manual control is used as per specification

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

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

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

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

4.9 Waste is sorted according to enterprise procedures

5. Identify and rectify faults

5.1 Problems in flexographic machine are identified and reported according to enterprise procedures

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

5.3 Flexographic machine operation is checked to ensure correct operation

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

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 Reels and cores are removed from press

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

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

6.6 All product is removed from operating area

7. Clean and wash up printing machine at end of print run

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

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

7.3 Ink pumps, tanks and hoses are cleaned correctly

7.4 Impression rollers/central impression and press rollers are cleaned

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

7.6 Reel feed, transportation and delivery systems are disengaged and cleaned ready for next run

7.7 Press is lubricated and protected according to duration of shutdown

7.8 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
Reel stand is monitored and adjusted to ensure efficient, continuous operation 
Web control system is monitored and adjusted to ensure correct tension and accurate continuous web positioning for efficient operation 
Substrate is added to process according to job instructions 
Reel rewind section is monitored and adjusted to maintain correct tension and avoid marks, blemishes or damage to finished product 
Substrate is removed from process according to non-routine job instructions 
Sheeting section is monitored and adjusted to ensure quality and efficient product delivery 
Set-off / marking prevention system is monitored and adjusted to ensure quality of printed product without set-off or marking meets the approved proof standard 
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 the quality of printed product meets the approved proof standard 
Flexographic inking system and doctor blade condition 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 
In-line printing/converting/binding/finishing processes are monitored and adjusted to ensure quality of product meets the approved proof standard 
Production process is operated in association with fellow workers and according to company specifications and planned daily schedule 
Production is maintained within work health and safety (WHS) requirements and company and manufacturer’s specifications 
Automatic control is used as per specification 
Manual control is used as per specification 
Ink performance, colour, register and position of print are monitored and adjusted throughout production run 
Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention 
Process adjustments to eliminate problems are reported according to enterprise procedures 
Faulty performance of equipment is identified and reported according to enterprise procedures 
Waste is sorted according to enterprise procedures 
Problems in flexographic machine are identified and reported according to enterprise procedures 
Adjustments or corrections are carried out according to specified procedures and consistent with operator’s skill level 
Flexographic machine operation is checked to ensure correct 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 
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 
All 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 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

ICPPRN314 - Produce complex 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

ICPPRN314 - Produce complex 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: