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

ICPPRN422 Mapping and Delivery Guide
Produce specialised gravure printed product

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency ICPPRN422 - Produce specialised gravure printed product
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to operate a gravure press, ensuring an efficient production flow for specialised jobs while maintaining 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.It applies to individuals working as print machinists in the printing and graphic arts industry. They prepare material, set up, monitor and operate equipment and machinery, apply solutions to a defined range of problems associated with the print medium, and 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 gravure printing machine.

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 gravure printing process
  • Gravure cylinder condition is monitored, evaluated and adjusted to ensure quality of printed product meets the sample sheet standard
  • Gravure impression roller condition is monitored, evaluated and maintained to ensure quality of the specialised printed product meets the sample sheet standard
  • Gravure inking system and doctor blade are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard
  • Drying systems are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the approved proof standard
  • In-line printing/converting/binding/finishing processes are monitored, evaluated and adjusted to ensure quality of specialised product meets the approved proof standard
       
Element: Maintain specialised production process
  • Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule
  • Production is maintained according to WHS requirements, manufacturer’s specifications and enterprise procedures
  • Manual and/or automatic control is used according to job specifications
  • Performance is monitored and verified using the process control system according to enterprise procedures
  • Ink performance, colour, register and position of print are monitored, evaluated 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: Tune and adjust machinery
  • Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate, or exploit the idiosyncrasy within manufacturer’s specifications
  • Test run confirms correct options and settings or 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
  • 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
  • All product is removed from operating area
  • Machine faults requiring repair are identified and reported to designated person according to 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 specialised gravure printing process

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

1.2 Gravure impression roller condition is monitored, evaluated and maintained to ensure quality of the specialised printed product meets the sample sheet standard

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

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

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

2. Maintain specialised production process

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

2.2 Production is maintained according to 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 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

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

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

2.8 Waste is sorted according to enterprise procedures

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

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

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

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

5.5 All product is removed from operating area

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

Evidence of the ability to:

operate a gravure press ensuring production flow that maintains product quality standards and minimises downtime from production problems

shut down and clean a gravure press 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, 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:

describe what can cause reel to wander

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

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

outline the print fault that results from the reel being run out of centre

list possible faults in the unwind section that can cause a web break

identify WHS risks associated with rewinding and sheeting

identify the safety feature in the delivery system for when the web jams up

explain why the sheet cut-off might wander

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

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

list causes of ink foaming in the ink tray

outline the effect of too much reducer in ink

describe what action can reduce wear of the doctor blade

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

describe link between driers and set off and marking

explain the cause of substrate distortion

describe the effect in the chillers, if the drying temperature was too low

identify the effect of incorrect drying temperature on the finished product

outline the effect of inadequate communication within the work team on a gravure printing machine

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

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

identify who is legally responsibility for the removal of machine guards and/or disconnection of micro switches

demonstrate knowledge of the most accurate method of checking register during a production run

explain 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

explain what happens to the substrate if relative humidity is increased in the press room

list procedures to care for a newly delivered substrate to the press room

demonstrate knowledge of how to correctly sort waste

outline advantages of keeping reusable waste

identify industry standards to enhance effective communication with clients

list necessary procedures clients should follow to approve a printed product

explain when to call service personnel to correct a machine problem

outline enterprise procedures to report any machine operating problems

describe consequences if correct shutdown procedures are not followed

explain why it is necessary for correct shutdown procedures to be conducted with fellow workers

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

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

outline any additional operations required for printed reels after they are removed from the printing machine

describe how the printed job should be stored after it is removed from the printing machine

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

describe benefits of comprehensive records when considering production of future jobs

locate machine manuals, safety and other documentation relevant to this task and outline 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 gravure printing process

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

1.2 Gravure impression roller condition is monitored, evaluated and maintained to ensure quality of the specialised printed product meets the sample sheet standard

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

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

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

2. Maintain specialised production process

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

2.2 Production is maintained according to 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 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

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

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

2.8 Waste is sorted according to enterprise procedures

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

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

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

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

5.5 All product is removed from operating area

5.6 Machine faults requiring repair are identified and reported to designated person according to 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
Gravure cylinder condition is monitored, evaluated and adjusted to ensure quality of printed product meets the sample sheet standard 
Gravure impression roller condition is monitored, evaluated and maintained to ensure quality of the specialised printed product meets the sample sheet standard 
Gravure inking system and doctor blade are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard 
Drying systems are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the approved proof standard 
In-line printing/converting/binding/finishing processes are monitored, evaluated and adjusted to ensure quality of specialised product meets the approved proof standard 
Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule 
Production is maintained according to WHS requirements, manufacturer’s specifications and enterprise procedures 
Manual and/or automatic control is used according to job specifications 
Performance is monitored and verified using the process control system according to enterprise procedures 
Ink performance, colour, register and position of print are monitored, evaluated 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 
Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate, or exploit the idiosyncrasy within manufacturer’s specifications 
Test run confirms correct options and settings or 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 
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 
All product is removed from operating area 
Machine faults requiring repair are identified and reported to designated person according to enterprise procedures 

Forms

Assessment Cover Sheet

ICPPRN422 - Produce specialised 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

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Assessor name:

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Date:

Assessment Record Sheet

ICPPRN422 - Produce specialised 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:

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