This unit requires the individual to perform runs on the double backer machine, maintain production, identify and rectify problems and faults, and correctly shut down the machine.

ELEMENT

PERFORMANCE CRITERIA

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. Adjustment changes 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 double 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. Heat delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.4. Speed of machine is optimised according to running conditions

3.5. Appropriate quantity of paper is run

4. Maintain in-line process(es)

4.1. Waxing units are monitored and adjusted to suit corrugating process and according to job specifications

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

4.3. Tape dispensing units are monitored and adjusted to suit corrugating process and according to job specifications

4.4. Slitters are monitored and adjusted according to job specifications

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

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

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

6.9. Waste is sorted according to enterprise procedures

6.10. Quality checks of product are undertaken on a regular basis and adjustments made as required

7. Identify and rectify problems

7.1. Problems in corrugator operation are identified and reported according to enterprise procedures

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

7.3. 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 OHS 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 corrugator at end of run

9.1. In-line wax, coating and tape dispensing units are cleaned ready for next run

9.2. Starch delivery system is washed up 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

Required skills

OHS in relation to operating machinery such as safely switching off machinery before cleaning is started

communication skills when reading and interpreting job requirements from job documentation or production control system

planning and organising by shutting down equipment in the correct sequence

teamwork when maintaining production processes in association with colleagues

using technology by producing double-faced web on the corrugator

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

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

principle support systems on line to the corrugating machine

effective control and monitoring of the corrugator by the operator

sections of the double backer that have the higher potential for operational problems during the run

product faults that are commonly found to arise during production runs and how can they be corrected

settings monitoring and adjustment made during the run, for the following factors: : in-feed, web alignment control, adhesive application, double backer, steam delivery, heating of web and speed

product factors that can be monitored visually/manually by staff operating end stages of the corrugator machine

adjustments made in response to problems found by staff operating end stages of the corrugator machine

functions that must be attended to for the wash-up and shutdown of the single facer for an idle period of at least two days

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

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:

perform runs on the double backer machine, maintain production, identify and rectify problems and faults, and correctly shut down the machine

perform at least TWO runs on the double backer to produce TWO different types/classes of product, 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. Assessment off the job must be undertaken in a closely simulated workplace environment

in-line double backer corrugating equipment.

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:

ICPCF2106C Set up double-faced web

ICPCF220C Produce basic converted or finished product

ICPCF231C Set up machine for basic flat-bed cutting

ICPCF235C Set up machine for basic rotary cutting

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

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.

Substrate handling may include:

wide reel handling 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.

Unit sector

Converting, Binding and Finishing

This unit contains employability skills.