Application
This unit describes the skills and knowledge required to produce non-routine gravure printed product.
It applies to individuals who operate a gravure press and maintain product quality standards. Individuals may also provide leadership and guidance to members of their team.
No licensing, legislative or certification requirements apply to this unit at the time of publication.
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
Elements describe the essential outcomes. | Performance criteria describe the performance needed to demonstrate achievement of the element. |
1. Maintain non-routine operation of reel transportation system | 1.1 Reel stand is monitored and adjusted to ensure efficient continuous operation 1.2 Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of web for efficient operation 1.3 Substrate is added to process according to job instructions |
2. Maintain non-routine operation of reel delivery system | 2.1 Reel rewind section is monitored and adjusted to maintain correct tension and to avoid marks, blemishes or damage to finished product 2.2 Substrate is removed from process according to job instructions 2.3 Sheeting section is monitored and adjusted to ensure quality and efficient product delivery 2.4 Set-off / marking prevention system is monitored and adjusted to ensure quality of printed product without set-off or marking meets the approved proof standard |
3. Maintain complex gravure printing process | 3.1 Gravure cylinder condition is monitored and adjusted to ensure quality of printed product meets the sample sheet standard 3.2 Gravure impression roller condition is monitored and maintained to ensure quality of printed product meets the sample sheet standard 3.3 Gravure inking system and doctor blade are monitored and adjusted to ensure quality of printed product meets the sample sheet standard 3.4 Drying systems are monitored and adjusted to ensure quality of printed product meets the approved proof standard |
4. Maintain operation of in-line processes | 4.1 In-line printing/converting/binding/finishing processes are monitored 4.2 In-line printing/converting/binding/finishing process are adjusted to ensure quality of product meets the approved proof standard |
5. Maintain non-routine production process | 5.1 Production process is operated in association with fellow workers and according to company specifications and planned daily schedule 5.2 Production is maintained within work health and safety (WHS) requirements and company and manufacturer’s specifications 5.3 Manual and/or automatic control is used as per specification 5.4 Performance is monitored and verified using the process control system according to enterprise procedures 5.5 Ink performance, colour, register and position of print are monitored and adjusted throughout production run 5.6 Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention 5.7 Process adjustments to eliminate problems are reported according to enterprise procedures 5.8 Waste is sorted according to enterprise procedures |
6. Identify and rectify faults | 6.1 Problems in gravure machine are identified and reported according to enterprise procedures 6.2 Adjustments or corrections are carried out according to specified procedures and consistent with operator’s skill level 6.3 Gravure machine operation is checked to ensure correct operation 6.4 Faulty performance of equipment is identified and reported according to enterprise procedures |
7. Conduct shutdown of production process | 7.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures 7.2 Shutdown is conducted in association with fellow workers and in compliance with WHS requirements 7.3 Unused ink is correctly labelled and stored according to manufacturer/supplier specifications and enterprise procedures 7.4 Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures 7.5 All product is removed from operating area 7.6 Machine faults requiring repair are identified and reported to designated person according to enterprise procedures 7.7 Repair/adjustment is verified prior to resumption of operations |
8. Clean and wash up printing machine at end of print run | 8.1 Cylinders, plate and roller surfaces are cleaned ready for next run 8.2 Inking system is washed ready for next run, and liquid waste is disposed of according to company and regulatory requirements 8.3 In-line printing/converting/binding/finishing units are cleaned ready for next run 8.4 Reel feed, transportation and delivery systems are disengaged and cleaned ready for next run 8.5 Sheet feed, transport and delivery systems are disengaged and cleaned ready for next run 8.6 Production records or other documentation are accurately completed where required by enterprise procedures |
Evidence of Performance
Evidence of the ability to:
operate a gravure press ensuring an efficient non-routine production flow that maintains product quality standards; any production problems are rectified with minimum downtime; and the machine is correctly shut down and cleaned according to work health and safety (WHS) guidelines
monitor production output and make necessary adjustments to maintain print quality on a gravure machine while producing a complex print on TWO occasions (if possible using different substrates and, if possible, including at least two in-line processes) according to job specifications and enterprise procedures.
Note: If a specific volume or frequency is not stated, then evidence must be provided at least once.
Evidence of Knowledge
To complete the unit requirements safely and effectively, the individual must:
Reel transportation and web control
identify what can cause the reel to wander
describe what can cause the web to break at the unwind unit
outline the difference between a "flying paster" and "zero speed" type reel-stand
discuss what print fault results from the reel being run out of centre
describe types of faults in the unwind section which can cause a web break
Reel delivery for rewinding and sheeting
discuss WHS risks associated with rewinding and sheeting
describe the safety feature in the delivery system for when the web jams
discuss the cause of sheet cut-off wander
outline effects of poorly adjusted nip rollers when rewinding and sheeting
Printing and drying unit
discuss how a build-up of ink on the impression cylinder can affect printed product
outline the cause of ink foaming in the ink tray
describe the effect of too much reducer in the ink
identify how to reduce doctor blade wear
describe why it is necessary to remove all solvents from the final ink film
discuss the link between driers and set-off and marking
identify what causes the substrate to distort
discuss what happens in the chillers if the drying temperature is too low
outline the effect of incorrect drying temperature on finished product
In-line processes
discuss why it is necessary to frequently examine in-line components of the job
outline how consistency of the punching unit is checked
describe the impact of excessive pressure on the slitters
discuss the benefit of identification numbers on jobs with multiple similar images
describe how the ratio of print to in-line speed is controlled
Maintaining production process
discuss possible effects of inadequate communication within the work team on a gravure printing machine
describe safety features within the organisation which aid in maintaining effective production
identify ramifications if machine guards are removed and/or micro switches are disconnected on a machine
name the person held legally responsible for the removal of machine guards and/or disconnection of micro switches
discuss the most accurate method of checking register during a production run
outline why it is necessary to take immediate action when production problems are anticipated
describe what to do to eliminate further processing of unacceptable printed product
discuss what happens to the substrate if the relative humidity increases in the press room
outline the correct procedure to care for a newly delivered substrate to the press room
discuss why waste should be sorted
describe advantages of keeping reusable waste
outline industry standards to enhance effective communication with clients
discuss procedures a client should follow to OK a printed product
Gravure machine operating problems
describe when it is necessary to call service personnel to correct a machine problem
identify enterprise procedures to report machine operating problems
Shutdown procedures
discuss what happens if correct shutdown procedures are not followed
describe why it is necessary that correct shutdown procedures are conducted with fellow workers
outline advantages of proper labelling and storage of excess inks and materials
discuss why printed product should be clearly labelled prior to removal from the press room
outline further operations required for printed reels after removal from the printing machine
describe how printed jobs should be stored after removal from the printing machine
Cleaning and washing the printing unit
list WHS concerns of handling ink
outline safety precautions for cleaning the printing cylinders
discuss why it is necessary to thoroughly clean and wash the printing unit prior to the next print run
describe why the doctor blades should be thoroughly cleaned
explain why doctor blades should be handled with extreme care
describe how to store printing cylinders to minimise damage
Cleaning feed, transportation, delivery and in-line sections
list WHS precautions for cleaning these sections of the machine
discuss why it is necessary to maintain a clean substrate handling section of the machine
Completing production records
outline how completed records are used in the final analysis of the job
describe benefits of comprehensive records when considering production of future jobs
identify what machine manuals, safety and other documentation are relevant to this task, where they are they kept and describe the information contained.
Assessment Conditions
Gather evidence to demonstrate consistent performance in conditions that are safe and replicate the workplace. Noise levels, production flow, interruptions and time variances must be typical of those experienced in the printing field of work and include access to:
special purpose tools, equipment and materials
gravure printing machines and in-line units.
Assessors must satisfy NVR/AQTF assessor requirements.
Foundation Skills
This section describes language, literacy, numeracy and employment skills incorporated in the performance criteria that are required for competent performance.
Skill | Performance Criteria | Description |
Reading | 1.3, 2.2, 5.1-5.3, 6.2, 7.1, 7.3 | Recognises and interprets text to establish job requirements from information contained within relevant procedures and specifications |
Writing | 5.7, 6.1, 6.4, 7.3, 7.6, 8.6 | Enters routine data associated with production processes and enterprise procedures |
Oral Communication | 1.3, 2.2, 5.1, 5.2, 5.7, 6.1, 6.2, 6.4, 7.1-7.3, 7.6 | Speaks clearly using appropriate vocabulary, tone and pace to report faults and discrepancies |
Numeracy | 1.3 | Interprets and analyses a range of mathematical information used in familiar and routine tasks |
Navigate the world of work | 1.1-1.3, 2.1-2.4, 3.1-3.4, 4.2, 5.1-5.4, 5.7, 5.8, 6.1-6.4, 7.1-7.4, 7.6, 8.1-8.6 | Recognises and follows explicit and implicit protocols and meets expectations associated with own role Recognises and follows all procedures for cleaning and maintenance of equipment, incorporating regulatory requirements and enterprise procedures |
Interact with others | 1.3, 2.2, 5.1-5.3, 5.7, 6.1, 6.2, 6.4, 7.1-7.3, 7.6 | Cooperates with others as part of familiar routine activities, and contributes to specific activities requiring joint responsibility and accountability Understands what to communicate, with whom and how, in routine work situations |
Get the work done | 1.1-1.3, 2.1-2.4, 3.1-3.4, 4.1, 4.2, 5.1-5.8, 6.1-6.4, 7.1-7.7, 8.1-8.6 | Determines priorities and sequences steps involved in clearly defined, familiar tasks Recognises and anticipates an increasing range of familiar problems, their symptoms and causes, actively looking for early warning signs and implementing contingency plans Follows routine procedures for using digital technology by reading data from electronic monitoring and control systems |
Sectors
Printing