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

ICPPRN432 Mapping and Delivery Guide
Produce specialised lithographic printed product

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency ICPPRN432 - Produce specialised lithographic printed product
Description
Employability Skills
Learning Outcomes and Application This unit describes the skills and knowledge required to operate a lithographic press, ensuring an efficient, specialised production flow that maintains product quality standards. Any production problems are anticipated and rectified with minimum downtime. The machine is correctly shut down and cleaned according to work health and safety (WHS) guidelines.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

lithographic printing machine with 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 specialised lithographic printing process
  • Lithographic plate and plate cylinder conditions are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard
  • Lithographic blanket and blanket cylinder conditions are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard
  • Lithographic impression cylinder condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard
  • Lithographic inking system is checked and maintained to ensure quality of specialised printed product meets the sample sheet standard
  • Lithographic dampening system condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard
  • Set off / marking prevention and drying system is 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
       
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, evaluated 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
  • Faulty performance of equipment is identified and 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 to 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 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
  • Plate cylinder is set up and adjusted according to job specifications
  • 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
  • Repair/adjustment is verified prior to resumption of operations
       


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 lithographic printing process

1.1 Lithographic plate and plate cylinder conditions are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard

1.2 Lithographic blanket and blanket cylinder conditions are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard

1.3 Lithographic impression cylinder condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard

1.4 Lithographic inking system is checked and maintained to ensure quality of specialised printed product meets the sample sheet standard

1.5 Lithographic dampening system condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard

1.6 Set off / marking prevention and drying system is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard

1.7 Drying systems are monitored, evaluated and adjusted to ensure quality of specialised printed 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, evaluated 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 Faulty performance of equipment is identified and reported according to enterprise procedures

2.9 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 to 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 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 Plate cylinder is set up and adjusted according to job specifications

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

5.7 Repair/adjustment is verified prior to resumption of operations

Evidence of the ability to:

operate a lithographic press using an efficient, specialised production flow that maintains product quality standards, including rectifying production problems with minimum downtime, and cleaning and shutting down the machine according to work health and safety (WHS) guidelines

monitor production output and make necessary adjustments to maintain print quality on a lithographic machine while producing a specialised print on TWO occasions (if possible using different types and sizes of substrates) according to job specifications, enterprise procedures and the performance criteria.

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 WHS concerns when operating the reel transportation system

explain what can cause the reel to wander

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

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

list print faults that can result from the reel being run out of centre

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

identify WHS concerns of operating the sheet transportation system

describe the result of worn suckers at the feeder suction head

describe sheet detection types on this machine

describe the amount of movement the sheet should have when being registered by the side lay

explain what causes a miss-register of the sheet at the feeder

outline visible signs of the sheet being registered in the feeder

explain how gripper malfunction can affect sheet control and transfer

describe when sheet transfer mechanisms require adjusting

outline what can cause the feeder stack to become uneven

describe the result of the feeder stack being loaded unevenly

explain how unevenness of the feeder stack can be rectified

identify WHS risks associated with rewinding and sheeting

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

explain why a sheet cut-off might wander

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

describe further operations required for printed reels on removal from the printing machine

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

explain the need to label each printed reel

outline the effect machine speed has on sheet delivery

explain the advantage of spraying moving sheets with anti-set off powder in delivery

identify items in delivery that cause marking of the printed image

describe remedial steps to eliminate marking of the printed image

describe the function of a sheet de-curler fitted to the delivery of some machines

provide a list of faults from incorrectly set grippers in the transfer section of a machine

describe what can happen if the plate develops a crack at the grip edge during a print run

outline the effect of a sticky blanket surface

list print faults from the blanket not being tensioned correctly

explain the cause of blanket packing creep during printing

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

explain what can cause ink to lie back in the duct

explain what can cause ink stripping on the inking rollers

describe print faults that result from excessive use of fountain solution on the plate

demonstrate knowledge of the recommended pH range for fountain solutions

explain what can cause conductivity of the fountain solution to change over an eight-hour shift

identify problems that can be caused by excessive conductivity of the fountain solutions

explain risks of eating or drinking near the machine when using UV inks

describe link between driers and set off and marking

explain what causes UV ink to dry

explain what can cause the substrate to blister

outline the effect in the chillers if the drying temperature is too low

describe the effect of incorrect drying temperature on the finished product

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

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

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

identify who is held legally responsible for removal of machine guards and/or disconnection of micro switches

describe the disadvantage of using a closed looped system for automatic control of the printed product

list alternative measurement, besides optimum solid ink density, to assess print quality

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

explain the need to take immediate action when production problems are anticipated

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

explain how a stack of paper is affected if the relative humidity is increased in the press room

explain the procedure to care for a newly delivered skid of paper to the press room

explain why waste should be sorted

list advantages of keeping reusable waste

list industry standards to enhance effective communication with clients

describe the necessary procedures clients should follow to approve a printed product

outline when to call service personnel to correct a machine problem

describe enterprise procedures in place to report any machine operating problems

outline the result if correct shutdown procedures are not followed

explain the need for correct shutdown procedures conducted with fellow workers

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

explain the use of completed records in final analysis of the job

outline the benefits of comprehensive records when considering production of future jobs

locate machine manuals, safety and other documentation relevant to this task, and outline included 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 specialised lithographic printing process

1.1 Lithographic plate and plate cylinder conditions are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard

1.2 Lithographic blanket and blanket cylinder conditions are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard

1.3 Lithographic impression cylinder condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard

1.4 Lithographic inking system is checked and maintained to ensure quality of specialised printed product meets the sample sheet standard

1.5 Lithographic dampening system condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard

1.6 Set off / marking prevention and drying system is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard

1.7 Drying systems are monitored, evaluated and adjusted to ensure quality of specialised printed 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, evaluated 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 Faulty performance of equipment is identified and reported according to enterprise procedures

2.9 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 to 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 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 Plate cylinder is set up and adjusted according to job specifications

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

5.7 Repair/adjustment is verified prior to resumption of operations

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
Lithographic plate and plate cylinder conditions are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard 
Lithographic blanket and blanket cylinder conditions are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard 
Lithographic impression cylinder condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard 
Lithographic inking system is checked and maintained to ensure quality of specialised printed product meets the sample sheet standard 
Lithographic dampening system condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard 
Set off / marking prevention and drying system is 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 
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, evaluated 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 
Faulty performance of equipment is identified and 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 to 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 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 
Plate cylinder is set up and adjusted according to job specifications 
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 
Repair/adjustment is verified prior to resumption of operations 

Forms

Assessment Cover Sheet

ICPPRN432 - Produce specialised lithographic 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

ICPPRN432 - Produce specialised lithographic 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: