Application
This unit describes the skills and knowledge required to produce a single-faced web for corrugated board manufacture, including inspecting and maintaining production quality, and identifying and rectifying problems.
It applies to individuals who generally work under direct supervision and perform a range of mainly routine tasks such as maintaining, cleaning and shutting down machinery and equipment.
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. Inspect and adjust quality | 1.1 Inspection and/or testing of sample is organised 1.2 Sample is visually inspected and/or tested according to enterprise procedures 1.3 Results are interpreted to determine adjustment requirements 1.4 Adjustments are carried out according to product and machine specifications |
2. Maintain operation of reel transportation system | 2.1 Reel stand is monitored and adjusted to ensure efficient continuous operation 2.2 Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web and efficient operation 2.3 Substrate is added to the process according to job specifications |
3. Maintain single facing process | 3.1 Starch delivery system is monitored and adjusted to suit corrugating process and according to job specifications 3.2 Heat delivery system is monitored and adjusted to suit corrugating process and according to job specifications 3.3 Steam delivery system is monitored and adjusted to suit corrugating process and according to job specifications 3.4 Corrugating roll and pressure rolls are monitored and adjusted to suit corrugating process and according to job specifications 3.5 Speed of machine is optimised according to running conditions 3.6 Appropriate quantity of paper is run with a minimum of wastage |
4. Maintain in-line process(es) | 4.1 Coating units are monitored and adjusted to suit corrugating process and according to job specifications 4.2 Waxing units are monitored and adjusted to suit corrugating process and according to job specifications 4.3 Slitters are monitored and adjusted according to job specifications 4.4 Cut-off knife is monitored and adjusted according to job specifications |
5. Synchronise machine operation | 5.1 Machine down-time is minimised during flute, grade or deckle changes 5.2 Quality of board is maintained according to enterprise procedures or client acceptance standard 5.3 Machine speed is optimised and waste minimised |
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 Starch performance is monitored and adjusted throughout production run 6.6 Quality checks are carried out on a regular basis and adjustments made as necessary |
7. Identify and rectify problems | 7.1 Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention 7.2 Process adjustments to eliminate problems are reported according to enterprise procedures 7.3 Faulty performance of equipment is identified and reported according to enterprise procedures 7.4 Waste is sorted according to enterprise procedures 7.5 Problems in corrugator operation are identified and reported according to enterprise procedures 7.6 Adjustments or corrections are carried out according to specified procedures and are consistent with operator’s skill level 7.7 Corrugator 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 Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures 8.4 All product is removed from operating area 8.5 Machine faults requiring repair are identified and reported to designated person according to enterprise procedures 8.6 Repair/adjustment is verified prior to resumption of operations |
9. Clean and wash up | 9.1 In-line wax and coating units are cleaned ready for next run 9.2 Starch delivery system is washed ready for next run and liquid waste is disposed of according to regulatory requirements and enterprise procedures 9.3 Reel feed and transportation systems are disengaged and cleaned ready for next run 9.4 Production records or other documentation are accurately completed where required by enterprise procedures |
Evidence of Performance
Evidence of the ability to:
perform at least TWO runs on the single-facer to produce TWO different types of single-faced web for corrugated board manufacture, according to manufacturer’s and job specifications and enterprise procedures including inspecting the quality of the product and identifying and rectifying problems.
Note: 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:
explain significant work health and safety risks workers face when producing single-faced web, and measures employed to prevent injury and/or illness
identify principle support systems on line to the corrugating machine and describe how the operator can effectively control and monitor these systems
explain which sections of the single-facer have higher potential for operational problems during the run
describe product faults commonly found during production runs and explain how can they be corrected
describe how settings are monitored and adjusted during the run to cater for the following: in-feed, web alignment control, pre-conditioners, adhesive application, corrugation, single-facer, steam delivery, heating of web and speed
identify which product factors can be monitored visually/manually, and explain how these can be adjusted to respond to problems found by staff operating end stages of the corrugator machine
explain functions that must be attended to for the wash-up and shutdown of the single-facer if it will be idle for two or more days
identify machine manuals, safety and other documentation relevant to the task, where they are kept, and the information contained 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 special purpose tools, materials and equipment including an in-line corrugating machine.
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 | 1.4, 2.3, 3.1-3.4, 4.1-4.4, 6.2, 6.3, 8.1 | Recognises and evaluates text to establish job requirements from information contained within relevant systems |
Writing | 7.2, 7.3, 7.5, 8.5, 9.4 | Uses clear and specific language to record problems and document other information according to enterprise procedures |
Oral Communication | 6.1, 7.2, 7.3, 7.5, 8.2, 8.5 | Participates effectively in spoken interactions to report issues or to confirm or clarify requirements |
Navigate the world of work | 1.2, 6.1, 6.2, 6.4, 6.6, 7.2-7.6, 8.1-8.3, 8.5, 9.1-9.4 | Complies with legislative requirements and follows organisational policies and procedures relevant to own role |
Interact with others | 6.1, 7.2, 7.3, 7.5, 8.2, 8.5 | 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 | 1.1-1.4, 2.1-2.3, 3.1-3.6, 4.1-4.4, 6.1- 6.6, 7.1, 7.4, 7.6, 7.7, 8.1-8.4, 8.6, 9.4 | Sequences and schedules activities required to complete tasks and monitors implementation making adjustments as necessary Plans, identifies and assembles resources required to complete tasks Recognises and anticipates an increasing range of familiar problems, 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 |
Sectors
Converting, Binding and Finishing