ICPCF2104C
Set up single-faced web

This unit describes the performance outcomes, skills and knowledge required to set up a single-faced web for corrugated board manufacture.

Application

This unit requires the individual to set up the reel in-feed, splicer, pre-conditioner, pre-heater, single facer, curing, coating and/or waxing sections of a corrugator.


Elements and Performance Criteria

ELEMENT

PERFORMANCE CRITERIA

1. Prepare for set up

1.1. Job specifications are read and interpreted from job documentation or process control system

1.2. Set-up is carried out correctly and in minimum time

1.3. Paper/board quantity requirements are estimated, ordered and checked

2. Set up reel transportation system

2.1. Unwind reel is set up and adjusted according to job specifications

2.2. Webbing procedures are carried out according to machinery requirements

2.3. Web control system is set up and adjusted according to job specifications

2.4. Reels are spliced/joined according to job specifications

3. Set up machine for single facing

3.1. Steam delivery system is set up and adjusted to suit corrugating process and according to job specifications

3.2. Corrugating rolls and pressure roll are set to correct pressure

3.3. Starch delivery system is set up and adjusted to suit corrugating process and according to job specifications

3.4. Heat delivery system is set up and adjusted to suit corrugating process and according to job specifications

4. Set up in-line units

4.1. Wax units are set up and adjusted to suit corrugating process and according to job specifications

4.2. Coating units are set up and adjusted to suit corrugating process and according to job specifications

4.3. Slitters are set up and adjusted according to job specifications

4.4. Cut-off knife is set up and adjusted according to job specifications

5. Inspect and adjust quality

5.1. Inspection and/or testing of sample is organised

5.2. Sample is visually inspected and/or tested according to enterprise procedures

5.3. Results are interpreted to determine adjustment requirements

5.4. Adjustment changes are carried out according to product and machine specifications

Required Skills

Required skills

communication by checking and confirming all details required for the job against job specifications

problem solving by selecting and checking a sample from the machine to ensure it conforms to the required quality standards

planning and organising by preparing the job before setting up the sewing machine; planning the job to meet the required timeframe

teamwork by maintaining the production process in association with others

use of technology by setting roll pressures, adjusting steam delivery system and calibrating the equipment

Required knowledge

significant risks that are posed to workers in this activity

measures that are employed to prevent injury and/or illness in the case of the above identified risks

identifying the different types/categories of rolled paperboard accurately

end products commonly made from each of the rolled paperboard types

principal components of a typical, single-face corrugated board adhesive

determining satisfactory performance of this adhesive

main tools and/or equipment items necessary for the efficient handling of paperboard rolls in the corrugation in-feed section

setting up the machine checks

correct settings

product factors that are monitored automatically during production

achieving the monitoring function

machine manuals, safety and other documentation that are relevant to this task and where they are kept and information that is included in these documents

Evidence Required

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of the following is essential:

set up the reel in-feed, splicer, pre-conditioner, pre-heater, single facer, curing, coating and/or waxing sections of a corrugator

set up the reel in-feed, splicer, pre-conditioner, pre-heater, single facer, curing, coating and/or waxing sections of a corrugator for at least TWO different product runs, according to manufacturer's and job specifications, enterprise procedures and the listed Performance Criteria

evidence for assessment may be gathered from assessment of the unit of competency alone or through an integrated assessment activity.

Context of and specific resources for assessment

Assessment must ensure:

assessment may take place on the job, off the job or a combination of these. Off the job assessment must be undertaken in a closely simulated workplace environment

in-line corrugating machinery.

Method of assessment

A range of assessment methods should be used to assess practical skills and knowledge. The following examples are appropriate for this unit:

direct questioning combined with review of portfolios of evidence and third party workplace reports of on-the-job performance by the candidate.

Guidance information for assessment

Holistic assessment with other units relevant to the industry sector, workplace and job role is recommended, for example:

ICPCF220C Produce basic converted or finished product

ICPCF231C Set up machine for basic flat-bed cutting

ICPCF235C Set up machine for basic rotary cutting

ICPCF281C Set up machine for basic laminating

ICPCF3105C Produce single-faced web

ICPSU201C Prepare, load and unload reels and cores on and off machine.


Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Machines may include:

range of corrugating machines with manual, semi-automated and fully automated process control systems.

In-line processes may include:

range of wax and coating systems operations, slitters and cutters. Note that slitting and cutting may be separately assessable as flat-bed or rotary cutting.

Substrate types may include:

range of substrates within the major categories of board or paper.

Substrate handling may include:

wide reel handling systems.


Sectors

Unit sector


Competency Field

Converting, Binding and Finishing


Employability Skills

This unit contains employability skills.


Licensing Information

Not applicable.