This unit describes the skills and knowledge required to set up and adjust a machine for complex carton folding and gluing to maintain the production process.

It applies to individuals who have limited responsibility for preparation of materials and equipment in accordance with job specifications and procedures, and ensuring quality of output.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

Evidence of the ability to:

set up at least THREE crash lock, six-corner and specialty work carton jobs using different carton sizes and weights, which include use of multiple gluing units, according to manufacturer’s and job specifications and 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:

Documentation

identify information concerning folding requirements found in the job documentation or production control system, and how it is interpreted to ensure smooth workflow throughout the factory

list factors to consider when planning a folding sample

Sheet transportation and delivery systems

explain work health and safety (WHS) factors for setting folder transportation and delivery systems

identify areas of the carton blank transportation system to monitor to ensure trouble-free operation

list parts of the carton blank pick-up system to adjust to ensure accurate and continuous sheet handling

identify areas of the delivery system to observe to maintain neat delivery of finished work and to prevent damage to the finished product

explain checks required when substrate is removed from the machine

Machine setting for complex folding and gluing

explain WHS factors for setting and/or adjusting the folding unit

identify the largest/smallest size carton blank that can be processed on this machine

describe ways the machine can be adapted to facilitate smaller/larger stock

identify accuracy of a carton blank entering folding rollers

describe causes of scratching/scuffing of substrate during transportation

identify machine speed variations

describe problems that can be expected if:

the machine is running too fast

the machine rollers are set too loose

there is too much roller pressure

the delivery system is not set correctly

identify how correct roller pressure is determined for a given job

describe how roller pressures checks are made

describe required adjustments if the carton blank is out-of-square

list reasons for the sheet being out-of-square

describe adjustment required to eliminate smudging/scuffing on carton blanks

describe adjustment required if the sheet will not leave the folding unit

In-line processes

list necessary steps to set up gluing units

describe how a neat and clean gluing job is achieved

identify adhesive used in the gluing unit and how length of the glue line is adjusted

Checking and adjustment

identify causes of out-of-square folding and how they are rectified

list segments of quality assurance inspected at sample run completion

identify areas of the machine to adjust if carton blank is creasing

identify areas of the machine to adjust if carton blank is not entering the machine

explain items to check against client sample

Information sources

identify machine manuals and safety documentation relevant to this task, where they are kept, and the information included in them.

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:

Royal 40, Bobst Media or Bobst Domino machine, which includes multiple gluing units

relevant materials and equipment.

Assessors must satisfy NVR/AQTF assessor requirements.

This section describes language, literacy, numeracy and employment skills incorporated in the performance criteria that are required for competent performance.

Converting, Binding and Finishing