This unit requires the individual to set up gravure printing machines for non-routine print jobs. The individual will conduct a proof run and adjust settings to ensure production speeds are attained.

ELEMENT

PERFORMANCE CRITERIA

1. Confirm non-routine job specifications

1.1. Job requirements 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 reels

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

2.2. Webbing procedures are carried out according to non-routine job specifications

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

2.4. Reels are spliced/joined according to job specifications

2.5. Printed web viewing devices are set up and adjusted according to job specifications

2.6. The folder and sheeter is are set up and adjusted according to job specifications

2.7. Set off/marking prevention devices are set up and adjusted according to job specifications

3. Select and prepare inks and additives

3.1. Inks, dyes or additives are selected according to job specifications and end-user requirements

3.2. Quality and suitability of inks, dyes or additives are checked and appropriate action is taken

3.3. Inks, dyes and additives are prepared according to OHS requirements, and manufacturer's/supplier's instructions with suitable precautions to minimise waste

3.4. Correct colour and weight/volume of ink are mixed and prepared to match the requirements of the printing process and job specifications

3.5. Formulation of the ink, colour match and the approved colour are appropriately recorded

3.6. Inks, dyes and additives are appropriately labelled, handled and stored according to manufacturer's/supplier's instructions to prevent damage and hazards to personnel and prolong shelf life

4. Set up machine for complex gravure printing

4.1. Gravure cylinders are selected, installed, set up and adjusted according to job specifications

4.2. Impression roller is set up and adjusted according to job specifications

4.3. Inking system/doctor blade is set up and adjusted according to the gravure process and job specifications

4.4. Drying system is set up and adjusted according to job specifications

5. Conduct proof run

5.1. Material to be used for proof is organised correctly

5.2. Machine is operated according to manufacturer's and enterprise procedures to produce a specified proof

5.3. Machine is operated according to manufacturer's and enterprise procedures to produce a specified proof

5.4. Production does not commence without client OK or authority where appropriate

5.5. Results are interpreted and adjustments are carried out according to product and machine specifications to determine adjustment requirements

Required skills

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

communication of ideas and information by interpreting the job brief and providing advice to internal or external clients about options and limitations

collecting, analysing and organising information by collecting and analysing data about printing process, machine specifications and performance to calculate appropriate adjustments for the job

planning and organising activities by providing information about time and materials requirements for production scheduling

teamwork when cooperating with other workers and coordinating the production unit to ensure efficient operation

mathematical ideas and techniques by calculating cylinder position, pressures and substrate requirements

problem-solving skills by recognising proofing faults and calculating adjustments necessary to meet job specifications

use of technology by using monitoring equipment and computerised production records

Required knowledge

need to ensure that the job specifications are read and properly understood

production problems that could eventuate by not reading and understanding the job specifications

person / people any production problems should be discussed with

OHS precaution that must be observed when installing printing cylinders on the machine

determining the optimum print sequence

visual aid on the cylinder that identifies the colour of ink to be used

precautions that are taken to ensure that the cylinders are not damaged during installation

OHS precautions that must be observed when webbing up the machine

determining the position of the reel

effect if the brake tension is not set correctly

function of the "Dancer" roller on a web machine

effect if the web is not spliced correctly

workings of the particular web viewing device

principle of ESA roller operation on the gravure printing machine

type of substrate that should be used on the ESA roller

OHS precautions that must be observed when setting up the delivery

controlling of the web in the rewind unit

result of incorrect rewind tension

remedial steps that can be taken if there is a possibility of the ink marking in the rewind

problems that could be attributed to a blunt knife when sheeting

use of air blast play in the delivery of sheets

OHS precautions that must be observed when preparing inks and additives

details that are necessary to check an ink's suitability for the printing process

special end-use requirements that may be necessary

additives used in gravure inks

range in seconds for zahn cup measurements

effect foaming has in a zahn cup when measuring the ink viscosity

bringing pigmented ink to operating temperature before correcting the viscosity

essential checks to be made

advantage of using automatic viscosity controllers

precautions that you observe to minimise waste when preparing the ink

shelf life of most inks

conditions that are relevant to the storage of inks and additives

conventions that should be adhered to when labelling mixed inks

advantage of using automatic viscosity controllers

precautions that you observe to minimise waste when preparing the ink

shelf life of most inks

conditions that are relevant to the storage of inks and additives

conventions that should be adhered to when labelling mixed inks

OHS factors that need to be considered when setting up the machine

function of chill rollers on a machine

main advantage of gauging up and dry register prior to printing a job

result of excess printing pressure

determining the pressure to be applied to the doctor blade

print faults that could be caused by excessive overspill of air from the inter-colour drier

recommended air ratio for efficient inter-colour drying

advantages of using high velocity air in the drying system

OHS precautions that must be observed when slitting on the machine

pre-heat web temperature required for lamination

reasons for a printed product to be punched

considerations when setting hole punching in relation to repeat length

purpose of the dwell when cutting and creasing in-line

controlling the ratio of print to in-line speed controlled

result of excessive pressure on the slitters

cause of the doctor blade to wear on a gravure printing unit

reducing the wear of the doctor blade

determining the optimum make ready speed for the job

communicating the steps involved in make ready to other team members

need to grade the drying speeds of each progressive colour, so that first-down colours dry faster the subsequent colours

causes of a decrease in web tension

result of increasing rewind tension after the roll has been partially rewound

major cause of a telescopic roll

testing metallised film to find out which is the correct side on which to print

measuringthe metallised surface for coating thickness

effect of annealing on aluminium foil

purpose of using thermal imaging face stocks

metallising substrates

client requirements for bar codes

print characteristics that are related to excessive printing pressure

causes of picking when printing multicoloured work

print faults resulting from using an over-reduced ink

causes of moire patterns when printing by the gravure process

instrument used to identify retained solvent trapped in the print

purpose of taking Dyne readings

purpose of the crinkle test when testing an ink

print faults resulting from a worn doctor blade

use of ink returning from the ink fountain when checking the viscosity of ink whilst using ink pumps

problems that result from the excessive use of slow solvents

reason why laminating inks once printed appear dull and easy to scratch

result of excessive print area tension

problems which the printer may associate with cold seals

responsibility for the final say in the "OK" of the job

machine manuals, safety and other documentation that are relevant to this task and where are they 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 ability to:

set up gravure printing machines for non-routine print jobs. The individual will conduct a proof run and adjust settings to ensure production speeds are attained

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

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

set up a gravure printing machine for a complex job on TWO occasions (if possible using different substrates and if possible including at least TWO in-line processes) according to manufacturer's specifications, enterprise procedures and the 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. Off the job assessment must be undertaken in a closely simulated workplace environment

gravure printing machine.

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:

ICPPR422C Produce complex gravure printed product.

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.

Non-routine may include:

non-routine within this context relates to the set up and production of print runs. The set up of equipment and production involves a significant amount of deviation from using standard equipment settings. It also involves significant problem solving and the development of new criteria and procedures for performing current practices. It does not refer to a job that an individual does only occasionally.

Inks/coatings may include:

range of inks commonly used in 3 or more colour printing, including standard and special colours.

Colour matching systems may include:

use of viscosity controls, densitometers and spectrophotometry.

Machines may include:

range of stack, in-line and central impression printing machines with manual, semi-automated, fully automated or computerised process control.

Design may include:

3 or more colours, complex graphics and text. Critical "tight" registration, fit and position, registration should be at least that required for four-colour process work.

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.

Substrate types may include:

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

Substrate handling may include:

wide and narrow reel handling systems.

Unit sector

Printing

This unit contains employability skills.