This unit requires the individual to set up a machine for complex flat-bed die cutting or embossing.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare 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. Prepare flat-bed die cutting or embossing devices

2.1. Appropriate cutting devices or dies are selected and secured to machine according to job specifications

2.2. Cutting devices or dies are registered and proofed according to job specifications

2.3. Cutting devices or dies are correctly mounted

3. Set up reel system (OR Element 4 )

3.1. Unwind and rewind reels are set up and adjusted according to job specifications

3.2. Webbing procedures are carried out according to job specifications

3.3. Web control system is set up and adjusted according to job specifications

3.4. Reels are spliced/joined according to job specifications

4. Set up sheet system (OR Element 3)

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

4.2. Sheet pick-up and transportation system is set up and adjusted according to job specifications

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

4.4. Folder and sheeter are set up and adjusted according to job specifications

4.5. Substrate is removed from process according to job specifications

5. Set up machine for complex flat-bed die cutting or embossing

5.1. Flat-bed cutting devices are set up and adjusted according to job specifications

5.2. Cutting pressures are set up and adjusted according to job specifications

5.3. Machine lays are set to correct position to register

6. Set up in-line units

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

6.2. Assistance is given in set up of major in-line printing/converting/binding units

7. Conduct sample run

7.1. Material to be used for sample is organised correctly

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

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

7.4. Results are interpreted to determine adjustment requirements

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

Required skills

OHS when ensuring that the work area is safe and ready for production according to safety requirements

communication skills when reading and interpreting job requirements from the job documentation

planning and organising when setting up the machine for operation

teamwork when confirming the sample with the supervisor

applying mathematical ideas and techniques when positioning the forme and counters

using technology by using machines

problem solving by interpreting results to determine adjustment requirements

Required knowledge

information concerning flat-bed die cutting or embossing

information to ensure smooth workflow throughout the factory

factors that must be considered when deciding on a cutting system

methods for registering and proofing the cutting devices

checked when the cutting devices are secured to the machine

criteria for determining the selection of particular cutting devices

OHS concerns when setting up reel transportation systems

adjustments to the unwind reel may be needed to suit various jobs

important areas to be considered during webbing procedures

adjustments available to the web

splicing/joining the web

areas of the reel delivery system that may need to be adjusted according to job specifications

steps that should be taken to ensure that the delivery system operates effectively

adjustment to the sheeter during production

adjustment to the folder during production

adjustment to the rewind wheel during production

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

important areas of the feeder unit set up

accurate sheet pick-up and transportation

areas of the delivery system that should be observed to maintain neat delivery of finished work

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

securing finished product for dispatch

OHS factors that must be considered when setting up cutting devices

setting up, adjusting and operating flat-bed cutting devices

machine pressure

machine cutting depths

adjusting in-line units

suitability of in-line processes

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

conformance with the client's requirements

product testing procedures

common faults with the flat-bed cutting process

replacement of knives/blades/cutting edges

storage of cutting edges to guard against damage and deterioration

machine manuals, safety and other documentation are relevant to this task and where are they kept and information 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 flat-bed die cutting or embossing 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 on EITHER flat-bed die cutting OR embossing. For either process set up TWO jobs changing the type and size of substrates and design of finished 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

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. 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

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.

Cutting process may include:

flat-bed die and forme cutting and embossing.

Substrate handling may include:

wide or narrow reel or large or small sheet handling systems.

Flat-bed cutting units may include:

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

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.

Shapes may include:

simple or multiple shapes.

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.