Application
This unit describes the skills and knowledge required to cover most converting and finishing operations including how to maintain substrate operations and complete relevant finishing processes.
It applies to individuals who prepare materials and set up and run a range of equipment and machinery for cutting, embossing, folding, collating and fastening. They work under direct supervision, however have certain responsibilities in the production process.
No licensing, legislative or certification requirements apply to this unit at the time of publication.
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
Elements describe the essential outcomes. | Performance criteria describe the performance needed to demonstrate achievement of the element. |
1. Maintain operation of delivery system | 1.1 Delivery systems are monitored and adjusted to ensure efficient and continuous operation of the process and ensure no damage to finished product 1.2 Substrate is added to and removed from the process according to job specifications |
2. Maintain basic cutting or embossing process | 2.1 Cutting edge and knife or die condition is monitored and adjusted to ensure quality of product meets the approved sample standard 2.2 Cutting/embossing pressures are monitored and adjusted to ensure quality of product meets the approved sample standard 2.3 Registration of cutting devices and knives or dies is monitored and adjusted to ensure quality of product meets the approved sample standard 2.4 Packing of cutting/embossing devices is monitored and adjusted to ensure quality of product meets the approved sample standard |
3. Maintain folding process | 3.1 Registration and squareness of fold are monitored and adjusted to ensure quality of product meets the approved sample standard, if relevant 3.2 Collating/inserting process is monitored and adjusted to ensure quality of product meets the approved sample standard, if relevant |
4. Maintain basic fastening (adhesive/ mechanical/thermal) process | 4.1 Registration of fastening is monitored and adjusted to ensure quality of product meets the approved sample standard 4.2 Wire straightness, length, cut-off and clinching pressures or power current and dwell time are monitored and adjusted to ensure quality of product meets the approved sample standard |
5. Maintain basic laminating process | 5.1 Registration of laminating is monitored and adjusted to ensure quality of product meets the approved sample standard 5.2 Pressures are monitored and adjusted to ensure quality of product meets the approved sample standard 5.3 Adhesion is monitored and adjusted to ensure quality of product meets the approved sample standard 5.4 Basic in-line printing/coating processes are monitored and adjusted to ensure quality of product meets the approved sample standard |
6. Maintain production process | 6.1 Production process is operated in association with fellow workers, and according to enterprise procedures and planned daily schedule 6.2 Production is maintained according to work health and safety (WHS) requirements, manufacturer’s specifications and enterprise procedures 6.3 Manual and/or automatic control is used according to job specifications 6.4 Performance is monitored and verified using the process control system according to enterprise procedures 6.5 Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention 6.6 Process adjustments to eliminate problems are reported according to enterprise procedures 6.7 Faulty performance of equipment is identified and reported according to enterprise procedures 6.8 Waste is sorted according to enterprise procedures |
7. Identify and rectify problems or faults | 7.1 Product and substrate are monitored and tested to ensure conformance to client requirements 7.2 Problems in converting/finishing machine operation are identified and reported according to enterprise procedures 7.3 Adjustments or corrections are carried out according to specified procedures and are consistent with operator’s skill level 7.4 Converting/finishing machine operation is checked to ensure correct operation |
8. Conduct shutdown of production process | 8.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures 8.2 Shutdown is conducted in association with fellow workers and in compliance with WHS requirements 8.3 Substrate waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures 8.4 Machine faults requiring repair are identified and reported to designated person according to enterprise procedures 8.5 Repair/adjustment is verified prior to resumption of operations |
9. Clean converting/ finishing machine at end of run | 9.1 Cutting units are disengaged and cleaned ready for next run 9.2 Cutting devices are sharpened according to WHS procedures 9.3 Machine bed is cleaned ready for next run 9.4 Cutting devices and knives are cleaned or replaced ready for next run 9.5 All units are disengaged and cleaned ready for next run 9.6 Adhesive or glue system is washed ready for next run, and liquid waste is disposed of according to regulatory requirements and enterprise procedures 9.7 Transportation and delivery systems are disengaged and cleaned ready for next run 9.8 Production records or other documentation are accurately completed where required by enterprise procedures |
Evidence of Performance
Evidence of the ability to:
correctly use any converting or finishing equipment (involving one process or a sequence of processes) to complete TWO different jobs involving different types, sizes and weights of substrate according to manufacturer’s specifications, job specifications and enterprise procedures OR in the case of standalone minor flat-bed or rotary cutting processes THREE processes must be demonstrated
correctly maintain substrate operation and complete relevant finishing process according to job specifications and within the production timeframe
demonstrate all safety devices on the machine
demonstrate use of computerised control, monitoring and data entry.
If a specific volume or frequency is not stated, then evidence must be provided at least once.
Evidence of Knowledge
To complete the unit requirements safely and effectively, the individual must:
Work health and safety (WHS)
identify WHS factors for:
setting up/adjusting the collating machine
setting up and/or operating machine transport and machine delivery systems
maintaining the cutting process
using the folding machine
using hot melt adhesive
maintaining laminating and in-line processes
keeping the machine clear of surface rust (condensation)
conducting machine shutdown procedures
identify safety clothing for use when operating adhesive binders
Reel Delivery Systems Only
list areas of the reel stand to be monitored to ensure trouble-free operation
identify the area of the web control system to adjust to maintain correct web tension
identify WHS factors for straightening the wire feed of a wire stitcher
Sheet Delivery Systems Only
name THREE procedures to ensure smooth transport of sections through the machine
list steps to ensure smooth delivery of sections
list FOUR important factors to consider when setting the feeder
explain the setting of the double/misfeed sheet calliper system
name different types of sheet/section delivery systems
list checks required when substrate is removed from the machine
Paper sizes and weights
determine largest and smallest sheet or section size that can be run through this machine
identify which areas of the machine should be adjusted to allow for 42gsm stock
maintenance of cutting processes
explain indicators of the need to replace a knife and how cutting pressure is adjusted
list FOUR requirements to maintain the cutting process to ensure the machine can be kept running without interruption
Cutting machine faults and problems
identify checks required when packing cutting devices
explain the procedure for correcting THREE common machine faults
list adjustments required if the cover is marked (scuffed) when trimming
Maintaining basic folding processes
list THREE areas to continuously observe to ensure smooth, trouble-free operation of the machine
list areas of the in-line process to monitor to assure quality of the product
Folding machine faults and minor problem-solving
identify TWO causes of out-of-square folding and explain how each may be corrected
list areas of the client’s sample to be inspected to determine quality assurance
explain communication to instigate if the:
job is out-of-square
ink is too wet for production
job does not coincide with the sample
list parts of the machine to adjust if the sheet is creasing
Collating machine operation, problems and fault correction
list factors that govern speed the machine operates at
list indicators the machine needs lubrication
identify how to prevent double sheet feeds
identify circumstances indicating the machine needs adjustment
list FOUR items to check against the client sample to constitute an acceptable collating result
Maintaining basic fastening (adhesive/mechanical/thermal) process
list areas of the in-line process to monitor to ensure product quality
name TWO sectors to observe to ensure the production process is trouble-free and continuous
Fastening operating problems and minor fault correction
list circumstances when the machine needs to be adjusted
explain how adhesive application is adjusted
explain how wire can be straightened in the wire feed
identify TWO possible reasons welding might be unsuccessful for a high-frequency welder
determine quality aspects to consider in a completed:
adhesive-bound job
high-frequency welded job
wire-stitched job
explain how production may need to be altered to meet client requirements
Maintaining laminating production processes and minor fault correction
explain methods for assuring registration of laminating
list areas of the in-line process to monitor to ensure a quality product
identify TWO laminating problems that may occur during operation of the machine and adjustments or correction procedures required to ensure accurate operation
determine quality aspects to consider in a completed laminated job, and ways production may need to be altered to meet client requirements
Machine shutdown procedures
determine checks required when waste is removed from the machine and surrounding area for disposal or recycling
list checks required during the machine shutdown procedure
list checks required when cutting devices or knives are cleaned or replaced ready for the next run
identify materials to be cleaned from the machine, and areas of the machine that require cleaning at the end of the run
Quality assurance
list features to check on the finished product
list THREE common faults that cause the finished product to be rejected, and how they can be fixed/avoided
explain available testing procedures and why they are used
list production records to be kept or written up, and the information that should be included
Information sources
identify machine manuals, safety and other documentation relevant to this task, where are they kept and information included in them.
Assessment Conditions
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 converting, binding and finishing field of work and include access to and use of relevant facilities, and equipment and materials used to produce a converted or finished product.
Assessors must satisfy NVR/AQTF assessor requirements.
Foundation Skills
This section describes language, literacy, numeracy and employment skills incorporated in the performance criteria that are required for competent performance.
Skill | Performance Criteria | Description |
Reading | 6.2, 6.3, 8.1 | Recognises and interprets texts to establish job requirements from information contained within relevant procedures and specifications |
Writing | 6.6, 6.7, 7.2, 8.4, 9.8 | Enters routine data associated with production processes and enterprise procedures |
Oral Communication | 6.1, 6.6, 6.7, 7.2, 8.2, 8.4 | Speaks clearly using appropriate vocabulary, tone and pace to report faults and discrepancies to supervisors or discuss job requirements with colleagues |
Navigate the world of work | 2.1-2.4, 3.1, 3.2, 4.1, 4.2, 5.1-5.4, 6.1, 6.2, 6.4, 6.6-6.8, 7.2, 7.3, 8.1-8.4, 9.1-9.9 | Complies with legislative requirements and follows organisational policies and procedures relevant to own role |
Interact with others | 6.1, 6.6, 6.7, 7.2, 8.2, 8.4 | Cooperates with others as part of familiar routine activities, and contributes to specific activities requiring joint responsibility and accountability Follows accepted practices and protocols for reporting issues to supervisors |
Get the work done | 1.1, 1.2, 2.1-2.4, 3.1, 3.2, 4.1, 4.2, 5.1-5.4, 6.1, 6.4, 6.5, 6.8, 7.1, 7.3, 7.4, 8.3, 8.5 | Determines priorities and sequences steps involved in clearly defined, familiar tasks Recognises and anticipates an increasing range of familiar problems, their symptoms and causes; actively looking for early warning signs and implementing contingency plans Follows routine procedures for using digital technology by reading data from electronic monitoring and control systems |
Range Statement
This section specifies different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Delivery systems MUST include EITHER: | reel OR sheet |
Monitoring and adjusting MUST include EITHER: | reel stand and rewind web control system sheeting section OR feeder and delivery system sheet pick-up and transport system transfer system |
Sectors
Converting, Binding and Finishing