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

ICPPRN322 Mapping and Delivery Guide
Produce complex gravure printed product

Version 1.0
Issue Date: November 2018


Qualification -
Unit of Competency ICPPRN322 - Produce complex gravure printed product
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to produce non-routine gravure printed product.It applies to individuals who operate a gravure press and maintain product quality standards. Individuals may also provide leadership and guidance to members of their team.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

gravure printing machines and in-line units.

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 positioning of web for efficient operation
  • Substrate is added to process according to job instructions
       
Element: Maintain non-routine operation of reel delivery system
  • Reel rewind section is monitored and adjusted to maintain correct tension and to avoid marks, blemishes or damage to finished product
  • Substrate is removed from process according to 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 gravure printing process
  • Gravure cylinder condition is monitored and adjusted to ensure quality of printed product meets the sample sheet standard
  • Gravure impression roller condition is monitored and maintained to ensure quality of printed product meets the sample sheet standard
  • Gravure inking system and doctor blade are monitored and adjusted to ensure quality of printed product meets the sample sheet standard
  • Drying systems are monitored and adjusted to ensure quality of printed product meets the approved proof standard
       
Element: Maintain operation of in-line processes
  • In-line printing/converting/binding/finishing processes are monitored
  • In-line printing/converting/binding/finishing process are 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
  • Manual and/or automatic control is used as per specification
  • 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
  • Process adjustments to eliminate problems are reported according to enterprise procedures
  • Waste is sorted according to enterprise procedures
       
Element: Identify and rectify faults
  • Problems in gravure 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
  • Gravure machine operation is checked to ensure correct operation
  • Faulty performance of equipment is identified and reported 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
  • Unused ink is correctly labelled and stored according to manufacturer/supplier 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
  • 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 and wash up printing machine at end of print run
  • Cylinders, plate and roller surfaces are cleaned ready for next run
  • Inking system is washed ready for next run, and liquid waste is disposed of according to company and regulatory requirements
  • 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
  • Sheet feed, transport 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 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 positioning of web for efficient operation

1.3 Substrate is added to process according to job instructions

2. Maintain non-routine operation of reel delivery system

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

2.2 Substrate is removed from process according to 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 gravure printing process

3.1 Gravure cylinder condition is monitored and adjusted to ensure quality of printed product meets the sample sheet standard

3.2 Gravure impression roller condition is monitored and maintained to ensure quality of printed product meets the sample sheet standard

3.3 Gravure inking system and doctor blade are monitored and adjusted to ensure quality of printed product meets the sample sheet standard

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

4. Maintain operation of in-line processes

4.1 In-line printing/converting/binding/finishing processes are monitored

4.2 In-line printing/converting/binding/finishing process are adjusted to ensure quality of product meets the approved proof standard

5. Maintain non-routine production process

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

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

5.3 Manual and/or automatic control is used as per specification

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

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

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

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

5.8 Waste is sorted according to enterprise procedures

6. Identify and rectify faults

6.1 Problems in gravure machine are identified and reported according to enterprise procedures

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

6.3 Gravure machine operation is checked to ensure correct operation

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

7. Conduct shutdown of production process

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

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

7.3 Unused ink is correctly labelled and stored according to manufacturer/supplier specifications and enterprise procedures

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

7.5 All product is removed from operating area

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

7.7 Repair/adjustment is verified prior to resumption of operations

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

8.1 Cylinders, plate and roller surfaces are cleaned ready for next run

8.2 Inking system is washed ready for next run, and liquid waste is disposed of according to company and regulatory requirements

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

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

8.5 Sheet feed, transport and delivery systems are disengaged and cleaned ready for next run

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

Evidence of the ability to:

operate a gravure press ensuring an efficient non-routine production flow that maintains product quality standards; any production problems are rectified with minimum downtime; and the machine is correctly shut down and cleaned according to work health and safety (WHS) guidelines

monitor production output and make necessary adjustments to maintain print quality on a gravure 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

identify what can cause the reel to wander

describe what can cause the web to break at the unwind unit

outline the difference between a "flying paster" and "zero speed" type reel-stand

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

describe types of faults in the unwind section which can cause a web break

Reel delivery for rewinding and sheeting

discuss WHS risks associated with rewinding and sheeting

describe the safety feature in the delivery system for when the web jams

discuss the cause of sheet cut-off wander

outline effects of poorly adjusted nip rollers when rewinding and sheeting

Printing and drying unit

discuss how a build-up of ink on the impression cylinder can affect printed product

outline the cause of ink foaming in the ink tray

describe the effect of too much reducer in the ink

identify how to reduce doctor blade wear

describe why it is necessary to remove all solvents from the final ink film

discuss the link between driers and set-off and marking

identify what causes the substrate to distort

discuss what happens in the chillers if the drying temperature is too low

outline the effect of incorrect drying temperature on finished product

In-line processes

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

outline how consistency of the punching unit is checked

describe the impact of excessive pressure on the slitters

discuss the benefit of identification numbers on jobs with multiple similar images

describe how the ratio of print to in-line speed is controlled

Maintaining production process

discuss possible effects of inadequate communication within the work team on a gravure printing machine

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

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

name the person held legally responsible for the removal of machine guards and/or disconnection of micro switches

discuss the most accurate method of checking register during a production run

outline why it is necessary to take immediate action when production problems are anticipated

describe what to do to eliminate further processing of unacceptable printed product

discuss what happens to the substrate if the relative humidity increases in the press room

outline the correct procedure to care for a newly delivered substrate to the press room

discuss why waste should be sorted

describe advantages of keeping reusable waste

outline industry standards to enhance effective communication with clients

discuss procedures a client should follow to OK a printed product

Gravure machine operating problems

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

identify enterprise procedures to report machine operating problems

Shutdown procedures

discuss what happens if correct shutdown procedures are not followed

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

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

discuss why printed product should be clearly labelled prior to removal from the press room

outline further operations required for printed reels after removal from the printing machine

describe how printed jobs should be stored after removal from the printing machine

Cleaning and washing the printing unit

list WHS concerns of handling ink

outline safety precautions for cleaning the printing cylinders

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

describe why the doctor blades should be thoroughly cleaned

explain why doctor blades should be handled with extreme care

describe how to store printing cylinders to minimise damage

Cleaning feed, transportation, delivery and in-line sections

list WHS precautions for cleaning these sections of the machine

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

Completing production records

outline how completed records are used in the final analysis of the job

describe benefits of comprehensive records when considering production of future jobs

identify what machine manuals, safety and other documentation are relevant to this task, where they are they kept and describe the 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 positioning of web for efficient operation

1.3 Substrate is added to process according to job instructions

2. Maintain non-routine operation of reel delivery system

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

2.2 Substrate is removed from process according to 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 gravure printing process

3.1 Gravure cylinder condition is monitored and adjusted to ensure quality of printed product meets the sample sheet standard

3.2 Gravure impression roller condition is monitored and maintained to ensure quality of printed product meets the sample sheet standard

3.3 Gravure inking system and doctor blade are monitored and adjusted to ensure quality of printed product meets the sample sheet standard

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

4. Maintain operation of in-line processes

4.1 In-line printing/converting/binding/finishing processes are monitored

4.2 In-line printing/converting/binding/finishing process are adjusted to ensure quality of product meets the approved proof standard

5. Maintain non-routine production process

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

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

5.3 Manual and/or automatic control is used as per specification

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

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

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

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

5.8 Waste is sorted according to enterprise procedures

6. Identify and rectify faults

6.1 Problems in gravure machine are identified and reported according to enterprise procedures

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

6.3 Gravure machine operation is checked to ensure correct operation

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

7. Conduct shutdown of production process

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

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

7.3 Unused ink is correctly labelled and stored according to manufacturer/supplier specifications and enterprise procedures

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

7.5 All product is removed from operating area

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

7.7 Repair/adjustment is verified prior to resumption of operations

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

8.1 Cylinders, plate and roller surfaces are cleaned ready for next run

8.2 Inking system is washed ready for next run, and liquid waste is disposed of according to company and regulatory requirements

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

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

8.5 Sheet feed, transport and delivery systems are disengaged and cleaned ready for next run

8.6 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 positioning of web for efficient operation 
Substrate is added to process according to job instructions 
Reel rewind section is monitored and adjusted to maintain correct tension and to avoid marks, blemishes or damage to finished product 
Substrate is removed from process according to 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 
Gravure cylinder condition is monitored and adjusted to ensure quality of printed product meets the sample sheet standard 
Gravure impression roller condition is monitored and maintained to ensure quality of printed product meets the sample sheet standard 
Gravure inking system and doctor blade are monitored and adjusted to ensure quality of printed product meets the sample sheet 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 
In-line printing/converting/binding/finishing process are 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 
Manual and/or automatic control is used as per specification 
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 
Process adjustments to eliminate problems are reported according to enterprise procedures 
Waste is sorted according to enterprise procedures 
Problems in gravure 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 
Gravure machine operation is checked to ensure correct operation 
Faulty performance of equipment is identified and reported 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 
Unused ink is correctly labelled and stored according to manufacturer/supplier 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 
Machine faults requiring repair are identified and reported to designated person according to enterprise procedures 
Repair/adjustment is verified prior to resumption of operations 
Cylinders, plate and roller surfaces are cleaned ready for next run 
Inking system is washed ready for next run, and liquid waste is disposed of according to company and regulatory requirements 
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 
Sheet feed, transport 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

ICPPRN322 - Produce complex gravure 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

ICPPRN322 - Produce complex gravure 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: