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

ICPPRN394 Mapping and Delivery Guide
Produce complex relief printed product

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency ICPPRN394 - Produce complex relief printed product
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to safely operate, monitor and clean a platen, cylinder or rotary printing machine using an efficient non-routine production flow.It applies to skilled individuals working as print machinists in the printing and graphic arts industry who set up, operate and monitor equipment and machinery, and who may have to prepare material and apply solutions to problems. They may also provide leadership and guidance to others with some limited responsibility for the output of others.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.

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 system
  • Reel stand and rewind section are monitored and adjusted to maintain correct tension, avoid marks, blemishes or damage to finished product, and to ensure efficient continuous operation
  • Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web for efficient operation
  • Substrate is added to and removed from the 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 the printed product meets the approved proof standard
       
Element: Maintain operation of sheet system
  • Feeder and delivery are monitored and adjusted to ensure continuous and efficient feed to machine
  • Sheet pick-up and transport system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation
  • Transfer systems are monitored and adjusted to ensure correct and continuous sheet handling and efficient operation
  • Substrate is added to and removed from process according to job instructions
       
Element: Maintain complex relief printing process
  • Relief polymer forme or plate cylinder condition is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard
  • Relief polymer impression surface condition is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard
  • Relief polymer inking system is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard
  • Drying systems are monitored and adjusted to ensure quality of the printed product meets the approved proof standard
       
Element: Maintain production process
  • Production process is operated in association with fellow workers and according to company specifications and planned daily schedule
  • In-line printing/converting/binding/finishing processes are monitored and adjusted to ensure quality of the product meets the approved proof standard
  • Production is maintained within work health and safety (WHS) requirements and company and manufacturer’s specifications
  • Manual and/or automatic control is used according to specification
  • Performance is monitored and verified using the process control system according to enterprise procedures
  • Ink performance, colour, register and embellishment 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 problems
  • Problems in relief machine operation are identified and reported according to enterprise procedures
  • Faulty performance of equipment is identified and reported according to enterprise procedures
  • Adjustments or corrections are carried out according to specified procedures
  • Relief 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
  • Unused ink is 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
  • 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 system

1.1 Reel stand and rewind section are monitored and adjusted to maintain correct tension, avoid marks, blemishes or damage to finished product, and to ensure efficient continuous operation

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

1.3 Substrate is added to and removed from the process according to job instructions

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

1.5 Set-off / marking prevention system is monitored and adjusted to ensure quality of the printed product meets the approved proof standard

2. Maintain operation of sheet system

2.1 Feeder and delivery are monitored and adjusted to ensure continuous and efficient feed to machine

2.2 Sheet pick-up and transport system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation

2.3 Transfer systems are monitored and adjusted to ensure correct and continuous sheet handling and efficient operation

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

3. Maintain complex relief printing process

3.1 Relief polymer forme or plate cylinder condition is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard

3.2 Relief polymer impression surface condition is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard

3.3 Relief polymer inking system is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard

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

4. Maintain production process

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

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

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

4.4 Manual and/or automatic control is used according to specification

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

4.6 Ink performance, colour, register and embellishment of print are monitored and adjusted throughout production run

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

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

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

4.10 Waste is sorted according to enterprise procedures

5. Identify and rectify problems

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

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

5.3 Adjustments or corrections are carried out according to specified procedures

5.4 Relief 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 Unused ink is correctly labelled and stored according to manufacturer’s/supplier’s specifications and enterprise procedures

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

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

6.6 Repair/adjustment is verified prior to resumption of operations

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

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

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

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

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

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

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

Evidence of the ability to:

accurately monitor production output and make necessary adjustments to maintain print quality on a relief printing machine while producing a complex print on TWO occasions (if possible using different substrates and at least two in-line processes) according to job specifications, enterprise procedures and work health and safety (WHS) requirements.

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 major WHS concerns of setting up the reel transportation system

describe possible causes of reel wandering and web breaks at the unwind unit

outline print faults resulting from the reel being run out of centre

outline major WHS concerns of setting up the sheet transportation system

identify the result of worn suckers at the feeder suction head

describe the two-sheet detection on the machine, and the amount of movement the sheet should have when being registered by the side lay

outline possible causes of mis-register of the sheet feeder and visible signs of the sheet being registered in the feeder

describe a gripper malfunction of sheet control and transfer, and the sheet transfer mechanisms that require adjusting

identify causes of the feeder stack becoming uneven, and the result if the feeder stack not loaded level

describe the process of reel delivery for rewinding and sheeting and the associated WHS risks

list the safety feature in the delivery system if the web jams up, and reasons for sheet cut-off wander

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

outline the effect machine speed has on sheet delivery, and the advantage of spraying moving sheets with anti-set-off powder in delivery

outline items in the delivery that can cause marking on the printed image, and remedial steps necessary to eliminate marking

outline faults from incorrectly set grippers in the transfer section of a machine, and devices to adjust to maintain sheet control in the delivery

identify the result if the plate lifts at the grip edge during a print run, and build-up of ink on the impression cylinder affecting printed product

list possible causes of ink leaking back in the duct

outline the problem of paper surface picking being rectified

identify causes of diminished impression during the print run

identify causes of plate surface prematurely wearing during production

describe possible issues if eating or drinking near the machine when using UV inks

identify link between driers and set-off and marking, and what causes UV ink to dry

identify causes of substrate blistering and the effect of incorrect drying temperature on finished product

outline major WHS concerns when operating cutting devices, and importance of checking consistency of the cutting and creasing unit

identify the result of excessive pressure on the slitters, and the benefit of die cutting using a rotary die

outline advantages of using a perforation wheel to perforate

describe the effect of inadequate communication within the work team on a relief printing machine

describe importance of safety features within organisation and in maintaining effective production

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

explain legal responsibility for removal of machine guards and/or disconnection of micro switches

identify measurement other than optimum solid ink density that can be used to assess print quality

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

explain actions to take when production problems are anticipated and to eliminate further processing of unacceptable printed product

describe the effect on a stack of paper if relative humidity is increased in the press room, and the procedure to care for a newly delivered skid of paper to the press room

explain reasons for sorting waste and advantages of keeping reusable waste

explain industry standards to enhance effective communication with clients and necessary procedures clients should follow to approve a printed product

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

outline enterprise procedures to report any machine operating problems

describe the result if correct shutdown procedures are not followed, and correct shutdown procedures to be followed with fellow workers

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

explain importance of clearly labelling printed product prior to removal from the press room

explain WHS requirements for handling ink and cleaning printing cylinders

explain cleaning and washing techniques for the printing unit prior to the next print run and procedures for storing plates so as to minimise damage

outline WHS precautions for cleaning the feed, transportation, delivery and in-line sections of the machine

explain importance of maintaining a clean substrate handling section of the machine

explain importance of completing records used in final analysis of the job, and benefits for future jobs

identify machine manuals, safety and other documentation relevant to the production of complex relief printed products and other sources of relevant information.

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 system

1.1 Reel stand and rewind section are monitored and adjusted to maintain correct tension, avoid marks, blemishes or damage to finished product, and to ensure efficient continuous operation

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

1.3 Substrate is added to and removed from the process according to job instructions

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

1.5 Set-off / marking prevention system is monitored and adjusted to ensure quality of the printed product meets the approved proof standard

2. Maintain operation of sheet system

2.1 Feeder and delivery are monitored and adjusted to ensure continuous and efficient feed to machine

2.2 Sheet pick-up and transport system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation

2.3 Transfer systems are monitored and adjusted to ensure correct and continuous sheet handling and efficient operation

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

3. Maintain complex relief printing process

3.1 Relief polymer forme or plate cylinder condition is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard

3.2 Relief polymer impression surface condition is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard

3.3 Relief polymer inking system is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard

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

4. Maintain production process

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

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

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

4.4 Manual and/or automatic control is used according to specification

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

4.6 Ink performance, colour, register and embellishment of print are monitored and adjusted throughout production run

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

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

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

4.10 Waste is sorted according to enterprise procedures

5. Identify and rectify problems

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

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

5.3 Adjustments or corrections are carried out according to specified procedures

5.4 Relief 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 Unused ink is correctly labelled and stored according to manufacturer’s/supplier’s specifications and enterprise procedures

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

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

6.6 Repair/adjustment is verified prior to resumption of operations

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

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

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

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

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

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

7.6 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 and rewind section are monitored and adjusted to maintain correct tension, avoid marks, blemishes or damage to finished product, and to ensure efficient continuous operation 
Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web for efficient operation 
Substrate is added to and removed from the 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 the printed product meets the approved proof standard 
Feeder and delivery are monitored and adjusted to ensure continuous and efficient feed to machine 
Sheet pick-up and transport system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation 
Transfer systems are monitored and adjusted to ensure correct and continuous sheet handling and efficient operation 
Substrate is added to and removed from process according to job instructions 
Relief polymer forme or plate cylinder condition is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard 
Relief polymer impression surface condition is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard 
Relief polymer inking system is monitored and adjusted to ensure quality of the printed product meets the sample sheet standard 
Drying systems are monitored and adjusted to ensure quality of the printed product meets the approved proof standard 
Production process is operated in association with fellow workers and according to company specifications and planned daily schedule 
In-line printing/converting/binding/finishing processes are monitored and adjusted to ensure quality of the product meets the approved proof standard 
Production is maintained within work health and safety (WHS) requirements and company and manufacturer’s specifications 
Manual and/or automatic control is used according to specification 
Performance is monitored and verified using the process control system according to enterprise procedures 
Ink performance, colour, register and embellishment 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 relief machine operation are identified and reported according to enterprise procedures 
Faulty performance of equipment is identified and reported according to enterprise procedures 
Adjustments or corrections are carried out according to specified procedures 
Relief 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 
Unused ink is 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 
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

ICPPRN394 - Produce complex relief 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

ICPPRN394 - Produce complex relief 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: