This unit requires the individual to monitor and adjust machinery, maintain transportation of the substrate, identify and rectify faults, and correctly clean and shut down equipment.

ELEMENT

PERFORMANCE CRITERIA

1. Maintain reel transportation system (OR Element 2)

1.1. Reel stand and rewind section are monitored and adjusted to ensure efficient continuous operation and maintain correct tension and to ensure no marks, blemishes or damage to finished product

1.2. Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web for efficient operation

1.3. Substrate is added to and removed from the process according to job specifications

1.4. Sheeting section is monitored and adjusted to ensure quality and efficient product delivery

2. Maintain sheet transportation system (OR Element 1)

2.1. Feeder and delivery systems are monitored and adjusted to ensure continuous and efficient feeding to machine

2.2. Sheet pick-up and transport system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation

2.3. Transfer systems are monitored and adjusted to ensure correct and continuous sheet handling and efficient operation

2.4. Substrate is added to process according to job specifications

3. Maintain basic rotary cutting process

3.1. Cutting edges and knife condition are monitored and adjusted to ensure the quality of product meets the standard of the approved sample

3.2. Cutting pressures are monitored and adjusted to ensure the quality of product meets the standard of the approved sample

3.3. Registration of cutting devices and knife(s) are monitored and adjusted to ensure quality of product meets the standard of the approved sample

3.4. Packing of cutting devices is monitored and adjusted to ensure quality of product meets the standard of the approved sample

4. Maintain production process

4.1. Basic in-line printing/converting/binding/finishing process(es) are monitored and adjusted to ensure the quality of product meets the standard of the approved sample

4.2. Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule

4.3. Production is maintained according to OHS requirements, manufacturer's specifications and enterprise procedures

4.4. Manual and/or automatic control is used according to job specifications

4.5. Performance is monitored and verified using the process control system according to enterprise procedures

4.6. Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention

4.7. Process adjustments to eliminate problems are reported according to enterprise procedures

4.8. Faulty performance of equipment is identified and reported according to enterprise procedures

4.9. Waste is sorted according to enterprise procedures

5. Identify and rectify problems and faults

5.1. Problem in rotary cutting machine operation is identified and reported according to enterprise procedures

5.2. Adjustments or corrections are carried out according to specified procedures and are consistent with operator's skill level

5.3. Rotary cutting machine operation is checked to ensure correct operation

5.4. Machine faults requiring repair are identified and reported to designated person according to enterprise procedures

5.5. Repair/adjustment is verified prior to resumption of operations

6. Conduct shutdown of production process

6.1. Correct shutdown sequence is followed according to manufacturer's specifications and enterprise procedures

6.2. Shutdown is conducted in association with fellow workers and in compliance with OHS requirements

6.3. Substrate waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

7. Clean rotary cutting machine at end of run

7.1. Cutting devices and knife(s) are cleaned or replaced ready for next run

7.2. Cutting devices are sharpened

7.3. Machine bed is cleaned ready for next run

7.4. Cutting units are disengaged and cleaned ready for next run

7.5. In-line printing/converting/binding/finishing units are cleaned ready for next run

7.6. Reel feed, transportation and delivery systems are disengaged and cleaned ready for next run

7.7. Sheet feed, transport and delivery systems are disengaged and cleaned ready for next run

7.8. Production records or other documentation are accurately completed where required by enterprise procedures

Required skills

OHS in relation to operating machinery

communication skills by monitoring and verifying performance using process control systems

planning and organising when monitoring and adjusting transportation systems

teamwork by conducting the shutdown with fellow workers

using technology by adjusting machinery to improve performance

identifying problems and faults and developing solutions

Required knowledge

OHS factors that must be considered when setting up and/or operating machine transport systems

areas of the reel stand that should be monitored to ensure trouble-free operation

areas of the sheet-fed feeder that should be monitored to ensure trouble-free operation

OHS factors that must be considered when setting up and/or operating machine delivery systems

checks needed when substrate is removed from the machine

OHS factors that must be considered when maintaining the cutting process

important points to monitor when maintaining the rotary cutting process

sectors of the basic in-line printing/converting/binding/finishing process that may need to be monitored and adjusted to meet the approved standards

production difficulties that can be expected during production runs

OHS factors that must be considered when problem solving on the rotary machine cutting process

the procedure for correcting common machine faults

OHS factors that must be considered when conducting machine shutdown procedures

checks needed when waste is removed from the machine and surrounding area for disposal or recycling

checks needed when cutting devices or knives are cleaned, stored or replaced ready for the next run

areas of the machine that require cleaning at the end of the run

production records that need to be kept or written up

information that should be included in this reporting procedure

quality aspects that should be considered in a completed rotary cutting job

production areas that may have to be adjusted to meet client requirements

machine manuals, safety and other documentation that are relevant to this task and where they are kept

information that is included in these documents

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:

produce rotary cut products that meet the job specifications, production time frames and quality requirements

demonstrate an ability to find and use information relevant to the task from a variety of information sources

competency must be demonstrated on any THREE different processes. For each process produce TWO jobs with different types and sizes of substrate and design of finished patterns, according to manufacturer's and job specifications, enterprise procedures and the listed Performance Criteria.

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

assessment off the job must be undertaken in a closely simulated workplace environment.

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:

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

ICPSU202C Prepare, load and unload product on and off machine

ICPSU208C Operate and monitor machines (basic).

Since the component processes often occur as in-line processes they may also be assessed at the same time as virtually any printing, converting, binding and finishing or corrugating process.

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.

Substrate handling may include:

wide or narrow reel or large or small sheet handling systems

Cutting process may include:

rotary die and forme cutting, kiss cutting, perforating, sprocket hole punching, slotting, slitting, sheeting, creasing, scoring and embossing

In-line processes may include:

minor processes that are integral to this competency can include basic in-line operations such as perforating, numbering, slitting that do not in themselves constitute another defined unit of competency. Where a major in-line process is defined as a separate competency (eg flat-bed cutting, folding) it should be assessed as such

Rotary cutting units may include:

a range of machines with dies or cutting formes and manual, semi-automated, fully automated or computerised process control

Shapes may include:

simple or single shapes

Substrate types may include:

range of substrates within the major categories of:

paper

pressure sensitive material

board

plastics and related films

metal.

Unit sector

Converting, Binding and Finishing

This unit contains employability skills.