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

ICPPRN414 Mapping and Delivery Guide
Produce specialised flexographic printed product

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency ICPPRN414 - Produce specialised flexographic printed product
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to produce specialised flexographic printing that needs a certain amount of problem-solving and experimentation with the substrate and press settings.It applies to skilled individuals working as print machinists in the printing and graphic arts industry who prepare material, set up, monitor, operate and clean equipment and machinery, problem-solve, analyse and evaluate information from a variety of sources. 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, including a reel-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 specialised flexographic printing process
  • Flexographic plate and plate cylinder or sleeve condition is monitored, evaluated and adjusted to ensure quality of printed product meets the approved proof standard
  • Flexographic impression roller condition is monitored and evaluated to ensure the quality of printed product meets the approved proof standard
  • Flexographic inking system and doctor blade condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the approved proof standard
  • Drying systems are monitored, evaluated and adjusted to ensure quality of the specialised printed product meets the approved proof standard
       
Element: Maintain specialised production process
  • Production process is maintained 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, adjusted and verified using the process control system according to enterprise procedures
  • Ink performance, colour, register and position of print are monitored, evaluated and adjusted throughout production run
       
Element: Tune and adjust machinery
  • Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate, or exploit the idiosyncrasy, within manufacturer’s specifications
  • Options are assessed to determine most effective/efficient method of production, ensuring highest quality and yield from machinery
  • Test run confirms correct options and settings or the need for further adjustment or tuning to meet quality standards
  • Options and recommendations are documented for future reference according to enterprise procedures
  • Instruction on new practices is provided to machine operator or finisher, if required
       
Element: Troubleshoot machinery and material problems
  • Corrective or preventive action is recommended and implemented where appropriate
  • Changes are communicated to relevant personnel in a logical and easily understood manner
  • Changes are monitored to confirm improvement to production efficiency
  • Ongoing problems are 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
  • 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
  • Product is removed from operating area
       


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 specialised flexographic printing process

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

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

1.3 Flexographic inking system and doctor blade condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the approved proof standard

1.4 Drying systems are monitored, evaluated and adjusted to ensure quality of the specialised printed product meets the approved proof standard

2. Maintain specialised production process

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

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

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

2.4 Performance is monitored, adjusted and verified using the process control system according to enterprise procedures

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

3. Tune and adjust machinery

3.1 Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate, or exploit the idiosyncrasy, within manufacturer’s specifications

3.2 Options are assessed to determine most effective/efficient method of production, ensuring highest quality and yield from machinery

3.3 Test run confirms correct options and settings or the need for further adjustment or tuning to meet quality standards

3.4 Options and recommendations are documented for future reference according to enterprise procedures

3.5 Instruction on new practices is provided to machine operator or finisher, if required

4. Troubleshoot machinery and material problems

4.1 Corrective or preventive action is recommended and implemented where appropriate

4.2 Changes are communicated to relevant personnel in a logical and easily understood manner

4.3 Changes are monitored to confirm improvement to production efficiency

4.4 Ongoing problems are reported 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

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

Evidence of the ability to:

safely 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, enterprise procedures and work health and safety (WHS) guidelines.

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:

identify causes of reel wander and the print fault that results from the reel being run out of centre

identify causes of web breaking at the unwind unit, and possible faults in the unwind section that cause a web break

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

outline WHS risks associated with rewinding and sheeting, and identify the safety feature in the delivery system for when the web jams up

identify causes of sheet cut-off wander

outline the effect of poorly adjusted nip rollers when rewinding and sheeting, and what happens if the plate lifts on the leading edge during a print run

describe the effect on printed product of a build-up of ink on the impression cylinder, and the cause of ink foaming in the ink tray

identify the effect of too much reducer in the ink

name the action that reduces doctor blade wear

describe why all solvents need to be removed from the final ink film

identify link between driers and set off and marking and the causes of UV ink drying

describe faults that cause substrate distortion

outline the effect in the chillers if the drying temperature is too low, and the effect of incorrect drying temperature on the finished product

describe the effect of eating or drinking near the machine when using UV inks

describe the need to frequently examine in-line components of the job

outline consistency checks for the punching unit

describe the result of excessive pressure on the slitters

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

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

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

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

outline other measurement, besides optimum solid ink density, to assess print quality

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

outline the need to take immediate action when production problems are anticipated, and action taken to eliminate further processing of unacceptable printed product

outline the result to the substrate if relative humidity is increased in the press room, and how to care for a newly delivered substrate to the press room

describe the process for waste sorting and the advantage of keeping reusable waste

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

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

outline enterprise procedures in place to report any machine operating problems, and what happens if correct shutdown procedures are not followed with fellow workers

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

describe the process for clear labelling of printed product prior to removal from the press room

outline operations required for printed reels after they are removed from the printing machine, and how to store printed jobs after they are removed from the printing machine

outline use of completed records in the final analysis of the job, and 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 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 specialised flexographic printing process

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

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

1.3 Flexographic inking system and doctor blade condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the approved proof standard

1.4 Drying systems are monitored, evaluated and adjusted to ensure quality of the specialised printed product meets the approved proof standard

2. Maintain specialised production process

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

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

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

2.4 Performance is monitored, adjusted and verified using the process control system according to enterprise procedures

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

3. Tune and adjust machinery

3.1 Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate, or exploit the idiosyncrasy, within manufacturer’s specifications

3.2 Options are assessed to determine most effective/efficient method of production, ensuring highest quality and yield from machinery

3.3 Test run confirms correct options and settings or the need for further adjustment or tuning to meet quality standards

3.4 Options and recommendations are documented for future reference according to enterprise procedures

3.5 Instruction on new practices is provided to machine operator or finisher, if required

4. Troubleshoot machinery and material problems

4.1 Corrective or preventive action is recommended and implemented where appropriate

4.2 Changes are communicated to relevant personnel in a logical and easily understood manner

4.3 Changes are monitored to confirm improvement to production efficiency

4.4 Ongoing problems are reported 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

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

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
Flexographic plate and plate cylinder or sleeve condition is monitored, evaluated and adjusted to ensure quality of printed product meets the approved proof standard 
Flexographic impression roller condition is monitored and evaluated to ensure the quality of printed product meets the approved proof standard 
Flexographic inking system and doctor blade condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the approved proof standard 
Drying systems are monitored, evaluated and adjusted to ensure quality of the specialised printed product meets the approved proof standard 
Production process is maintained 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, adjusted and verified using the process control system according to enterprise procedures 
Ink performance, colour, register and position of print are monitored, evaluated and adjusted throughout production run 
Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate, or exploit the idiosyncrasy, within manufacturer’s specifications 
Options are assessed to determine most effective/efficient method of production, ensuring highest quality and yield from machinery 
Test run confirms correct options and settings or the need for further adjustment or tuning to meet quality standards 
Options and recommendations are documented for future reference according to enterprise procedures 
Instruction on new practices is provided to machine operator or finisher, if required 
Corrective or preventive action is recommended and implemented where appropriate 
Changes are communicated to relevant personnel in a logical and easily understood manner 
Changes are monitored to confirm improvement to production efficiency 
Ongoing problems are 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 
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 
Product is removed from operating area 

Forms

Assessment Cover Sheet

ICPPRN414 - Produce specialised 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

ICPPRN414 - Produce specialised 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: