This unit requires the individual to maintain the operation of machinery and the production process, rectify problems and shut down the equipment.

ELEMENT

PERFORMANCE CRITERIA

1. Maintain operation of reel system (OR Element 2)

1.1. Reel stand and rewind section are monitored and adjusted to ensure efficient continuous operation to 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 operation of sheet 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 the process according to job specifications

3. Maintain operation of complex rotary die cutting or embossing process

3.1. Knife condition is 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 knife(s) is monitored and adjusted to ensure qu Packing of cutting devices is monitored and adjusted to ensure quality of product meets the standard of sample approved

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

4. Maintain production process

4.1. In-line printing/converting/binding/finishing processes 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 rotary cutting machine problems and faults

5.1. Problems in rotary cutting machine are 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. Cutting rotary machine operation is checked to ensure correct operation

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

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

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

7. Clean rotary cutting units at end of run

7.1. Knife and machine bed are cleaned ready for next run

7.2. Cutting devices are sharpened correctly according to OHS requirements and enterprise procedures

7.3. Cutting machine is disengaged and cleaned ready for next run

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

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

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

7.7. 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 by monitoring and verifying performance using process control systems

planning and organising when following the correct shutdown sequence

teamwork when conducting shutdown with fellow workers

using technology when adjusting machinery to improve performance

problem solving by 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

area of the web control system that should be adjusted to maintain correct web tension

area of the web control system that should be adjusted to maintain correct positioning of the web

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

parts of the sheet pick-up system that are to be adjusted to ensure accurate and continuous sheet handling

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

areas of the delivery system that should be observed to maintain tension

areas of the delivery system that should be observed to prevent damage to the finished product

checks to be made when substrate is removed from the machine

OHS factors that must be considered when maintaining the cutting process

items of importance to consider when maintaining rotary cutting operations

checks made on: cutting pressures, cutting registration, packing of cutting area, condition of cutting edges, the smooth running of the operation

indicators that demand the replacement of cutting edges

checks to be made when cutting accuracy is adjusted

ways in which a clean and precise result can be guaranteed

production difficulties that can be expected during production runs

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

checks to be made when packing cutting devices

procedure for correcting any machine faults

OHS factors that must be considered when conducting machine shutdown procedures

checks to be made when waste is removed from the machine and surrounding area for disposal or recycling

checks to be made when shutting down the machine

checks to be made when the 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

cleaning agents that are used in cleaning the machine

build-ups that need to be cleaned from the machine

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

steps that should be taken to ensure that important features of the production control system are followed

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

items that must be checked against the client's sample

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:

produce complex products that meet job specifications and production timeframes using rotary cutting or embossing equipment

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

competency must be demonstrated on EITHER rotary die cutting OR embossing. For either process produce TWO complex jobs (including in-line processes) with different substrates, sizes and patterns according to manufacturer's and job specifications, enterprise procedures and the listed Performance Criteria

demonstrate use of computerised control, monitoring and data entry systems if available and appropriate.

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.

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:

ICPCF327C Set up machine for complex rotary die cutting or embossing.

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, 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:

complex, multiple shapes.

Substrate types may include:

range of substrates within the major categories of paper, pressure sensitive material, board, plastics and related films, or metal.

Unit sector

Converting, Binding and Finishing

This unit contains employability skills.