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. Clean collating or inserting (sheet/section/reel) machine at end of run

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 the process according to job specifications

2. Maintain sheet transportation system (OR Element 1)

2.1. Feeder is 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 end efficient operation

2.4. Substrate is added to the process according to job specifications

3. Maintain production process

3.1. Collating or inserting process is monitored and adjusted to ensure quality of product meets the standard of the approved sample

3.2. In-line printing/converting/binding/finishing processes are monitored and adjusted to ensure the quality of product meets the standard of the approved sample

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

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

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

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

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

3.8. Waste is sorted according to enterprise procedures

4. Identify and rectify problems and faults

4.1. Problems in collating or inserting (sheet/section/reel) machine are identified and reported according to enterprise procedures

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

4.3. Collating or inserting (sheet/section/reel) machine operation is checked to ensure correct operation

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

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

5. Conduct shutdown of production process

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

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

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

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. Clean collating or inserting (sheet/section/reel) machine at end of run

6.1. Collating or inserting machine is cleaned ready for next run

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

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

6.4. Sheet feed, transportation and delivery systems are disengaged and cleaned ready for next run

6.5. 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 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

areas of OHS that consideration should be given when the machine is operating

factors that govern the speed at which the machine will operate

indicators that the machine was in need of lubrication

circumstances that the machine would need to be adjusted

OHS factors that should be considered before readjusting the machine

areas of the machine that would cause sheets to crease during production

causes of the sheets misfeeding during production

correction of the creasing of sheets

method of correction that is needed to prevent double sheet feeds

adjustment that must be made to prevent "bruising" of NCR sheets

areas that are to be checked when sections are failing to open on the chain

checks to be made when correctly shutting down the machine

areas of the machine that need regular cleaning

materials that need to be cleaned from the machine

keeping the machine clear of surface rust (condensation)

recommended cleaning agents

production records that need to be kept or written up

information that should be included in this reporting procedure

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

an acceptable collating result

cause of creasing of sheets in the machine delivery

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 a complex collated product that meets job specifications, production timeframes and quality standards

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

operate machines for complex collating (at LEAST FOUR or FIVE products) including in-line processes on FOUR occasions (if possible TWO sheet jobs using different sizes and weight of substrate and TWO section jobs with and without lip/lap), 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:

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)

ICPCF342C Produce complex sequenced or multiple folded productICPCF361B Set up machine for complex adhesive, mechanical or sewn fastening.

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.

Collating process may include:

collating/inserting of sheets or book sections, or reels (may include tabs, crimping) of varied form, weight or shape.

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.

Collating units may include:

a range of machines with manual, semi-automated, fully automated or computerised process control.

Substrate types may include:

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

Unit sector

Converting, Binding and Finishing

This unit contains employability skills.