This unit requires the individual to set up reel- or sheet-fed platen, cylinder or rotary 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 reel system (OR Element 3)

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

2.2. Webbing procedures are carried out and web-control system is set up and adjusted according to job specifications

2.3. Reels are spliced/joined according to job specifications

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

2.5. Folder and sheeters are set up and adjusted according to job specifications

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

3. Set up sheet system (OR Element 2)

3.1. Feeder and delivery sections are set up and adjusted according to job specifications

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

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

3.4. Substrate is added to and removed from process according to job instructions

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

4. Select and prepare inks and additives

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

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

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

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

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

4.6. 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

5. Set up machine for complex relief printing

5.1. Appropriate relief plates are selected and secured to the machine

5.2. Relief polymer plates/forme are set up and adjusted according to job specifications (platen)

5.3. Relief polymer cylinders are set up and adjusted according to job specifications (platen)

5.4. Impression is set up and adjusted according to job specifications (platen and rotary)

5.5. Inking system is set up and adjusted according to the relief process and job specifications (platen and rotary)

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

6. Conduct proof run

6.1. Material to be used for proof is organised correctly

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

6.3. Proof is visually inspected and/or tested or laboratory testing organised according to enterprise procedures Production does not commence without client OK or authority where appropriate

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

6.5. Results are interpreted and 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 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 substrate requirements, plate position and pressures

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

job requirements

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

with whom would you discuss any production problems

relief plates

why hardness of the printing plate is important

faults that may be detected on new plates

type of solvents that should be used on photopolymer plates

V-block mounting

purpose of binding plates after mounting

checks that need to be performed prior to cylinder installation

machine frames and unit slides to be kept cleaned

OHS precaution must be observed when installing printing cylinders in the machine

optimum print sequence

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

precautions to be taken to ensure that the plate/cylinders were not damaged during installation

reel transportation system on a web-fed machine

OHS precaution that must be observed when webbing up the machine?

determining the position of the reel

implications if the brake tension is not set correctly

function of the "Dancer" roller on a web machine

function of nip rollers

web is not spiced correctly

sheet transportation system on a sheet-fed machine

major OHS concerns when setting up the sheet transportation system

what causes more than one sheet to pick up in the feeder

accurate feeder set up is essential

determining the position of the sheet prior to being transferred to the printing unit?

determining which front lays to use

types of substrate that require additional front lays to be engaged

why additional front lays would be necessary when printing this type of substrate

reel delivery system on a web-fed machine

OHS precautions that must be observed when setting up the delivery

web controlled in the rewind unit

function of a slitter on a web machine

problems that could be attributed to a blunt knife when sheeting

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

sheet delivery system on a sheet-fed machine

OHS precautions that must be observed when removing sheets from the delivery

what causes sheets to be delivered incorrectly

what adjustments are necessary if changing from lightweight to heavyweight stocks?

determining the sheet release into the delivery

problems resulting from the excessive use of anti set off spray powder

what causes printed sheets to set off in the delivery

how the possibility of set off in the delivery can be reduced

how air blast assists sheet delivery

inks and additives

OHS concerns related to the preparation of inks and additives

details are necessary to check inks suitability for the printing process

special end-use requirements that may be necessary

why it might be necessary to mix an additive into the ink

how a spectrophotometer can be used to assess the colour of ink

the formula for calculating the correct quantity of ink in relief printing

print faults that will occur if excessive driers are mixed into the ink

precautions that are observed to minimise waste when preparing the ink

shelf life of most ink

conditions that are relevant to the storage of inks and additives

conventions should be adhered to when labelling mixed inks

machine set up

what are the Major OHS concerns when setting up the machine

packing required in the tympan

determining the amount of printing pressure

what is the ideal condition of the tympan

how the correct top sheet tension is achieved when fitting a new tympan

print faults can occur if the tympan is not tensioned correctly

order in which eccentric or concentric roller adjustments be made

when setting the rollers, the width of the contact stripe between two rollers

determining the ink duct setting

ideal ink duct sweep setting

recommended degrees shore hardness for forme rollers

main reason for blistering on a heat set machine

types of ink drying/curing systems

how the drying unit cures the ink

in-line processes

OHS precautions that must be observed when slitting on the machine

operations that can be performed with in-line units

what machine position should you engage in-line processing units

precautions that are necessary when setting up in-line processing units

reasons for a printed product to be top cut

benefits of embossing in-line

result of excessive pressure when top cutting

result of excessive pressure when cutting and creasing

effect differing tooth counts have on perforated products

problem solving proofing and adjustment

operation of the true inch function fitted to some machines

problems that may cause the machine to keep stopping

checks that are necessary prior to engaging the impression

checks to be performed when running the machine

effect the position of certain guards have on the operation of the machine

steps involved in operating the machine communicated to other team members

aids that are available for the testing of the machine proof

tests that are necessary for this job

where the testing should take place

function of a polarisation filter in a densitometer

ideal conditions for inspecting the proof

why it is necessary to use visual aids on the printed substrate

causes of a halo effect on the image

methods that are available to check and adjust ink colour and consistency

adjustments that may have caused mis-register

adjustments that are made to position the image laterally

adjustments that are made to position the image circumferentially

how changing the colour sequence can effect the final colour cast

procedure to lengthen the print length on this type of press

procedure to shorten the print length on this type of press

difference between mechanical and optical dot gain

causes of excessive mechanical dot gain

who has the final say in the "OK" of the job?Information sources

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

information that is included in these documents

other sources of information that are available

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 reel- or sheet-fed platen, cylinder or rotary 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 relief printing machine for complex printing on TWO occasions (if possible using different substrates and if possible including at least TWO in-line processes) according to manufacturer's and job 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

reel- or sheet-fed platen, cylinder or rotary 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:

ICPPR352C Produce complex relief 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.

Substrate handling may include:

wide and narrow reel, and large and small sheet handling systems.

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 densitometers and spectrophotometry.

Machines may include:

range of platen, cylinder and rotary 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.

Substratetypes may include:

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

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.

Unit sector

Printing

This unit contains employability skills.