This unit requires the individual to set up for complex adhesive, mechanical or sewn fastening.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare for job

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

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

1.3. Availability of all job related components is checked

2. Set up sheet/section system

2.1. Feeder and delivery systems are set up and adjusted according to job specifications

2.2. Sheet/section pick-up and transportation system is set up and adjusted according to job specifications

2.3. Transfer systems are set up and adjusted according to job specifications

2.4. Substrate is removed from the process according to job specifications

2.5. Sheet/section transfer and control system is set up and adjusted according to job specifications

3. Set up machine and in-line units

3.1. Fastening system is set up and adjusted according to job specifications

3.2. Minor in-line printing/converting/binding units are set up for basic processes and adjusted according to machine requirements and job specifications

3.3. Assistance is given in set up of major in-line printing/converting/binding units (NOTE: if entire set up is completed, refer to appropriate competency standards)

4. Conduct sample run

4.1. Material to be used for sample is organised correctly

4.2. Machine is set up and operated to produce a specified sample according to OHS requirements, manufacturer's specifications and enterprise procedures

4.3. Sample is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures

4.4. Results are interpreted to determine adjustment requirements

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

Required skills

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

communication skills when organising a laboratory test and reading and interpreting job specifications

planning and organising when conducting a sample run

teamwork when giving assistance with setting up in-line units

using technology when setting up and adjusting the fastening system according to job specifications

problem solving when interpreting sample results to determine adjustment requirements

Required knowledge

information concerning binding requirements that would you expect to find in the job documentation or production control system

interpretation of information to ensure smooth workflow throughout the factory

elements that must be considered when planning a collated sample

OHS concerns that are there when setting up transportation systems

special delivery problems that are associated with adhesive machines

overcoming these problems

different section feeding systems

monitoring the delivery systems present on the various machines

ways in which the completed work can be secured for dispatch

largest/smallest size sheet that can be processed on this machine

ways that the machine can be adapted to facilitate smaller/larger stock

OHS areas that must be addressed when setting up fastening equipment on the machine

a jobs correct binding technique

OHS safeguards that are necessary with hot melt adhesives

methods of adhesive metering present on the machine

care that should be taken to ensure a neat and clean adhesive binding job

expectations if sewing is not in the right position

parts of the wire stitcher that would need to be adjusted to process books of different thicknesses

position of the wire stitches on the book

difference between a staple and a wire stitch

appropriate wire calliper for a particular job

largest/smallest size sheet that can be processed on each machine

machines be adaption to facilitate smaller/larger stock

OHS areas that must be addressed when setting up these areas of the machine

in-line units that are available for these binding processes

OHS factors that should be considered before readjusting the machine

circumstances that the machine would need to be adjusted

quality aspects that should be considered in the completed binding job

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

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:

correctly set up machines for complex adhesive, mechanical or section fastening according to job specifications and within the production timeframe

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

demonstrate all safety devices on the machine

competency must be demonstrated in any ONE of adhesive, thermal, mechanical or section sewing. For each process set up (including replacing adhesive, thread, wire) TWO complex jobs using different sizes and weights of substrate 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:

ICPCF220C Produce basic converted or finished product.

Depending on the configuration of equipment and types of jobs, virtually any other converting and finishing set up unit can be assessed at the same time.

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:

large or small sheet/section handling systems.

Fastening processes may include:

adhesive fastening such as cold and hot melt gluing, taping of substrates of varied form, weight or shape, eg hard case making, casing in, spine lining, multiple head and complex pattern gluing

mechanical fastening such as wire stitching, loop stitching of substrates of varied form, weight or shape

section sewing.

In-line processes may include:

minor processes that are integral to this competency can include basic in-line operations such as perforating, numbering, date coding, 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.

Fastening units may include:

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

Complexity may include:

complex refers to use of automatic adhesive and thermal machines, multiple head mechanical machines, section sewers.

Substrate types may include:

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

Unit sector

Converting, Binding and Finishing

This unit contains employability skills.