Application
This unit describes the skills and knowledge required to produce specialised flexographic printing that needs a certain amount of problem-solving and experimentation with the substrate and press settings.
It applies to skilled individuals working as print machinists in the printing and graphic arts industry who prepare material, set up, monitor, operate and clean equipment and machinery, problem-solve, analyse and evaluate information from a variety of sources. They may also provide leadership and guidance to others with some limited responsibility for the output of others.
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 specialised flexographic printing process | 1.1 Flexographic plate and plate cylinder or sleeve condition is monitored, evaluated and adjusted to ensure quality of printed product meets the approved proof standard 1.2 Flexographic impression roller condition is monitored and evaluated to ensure the quality of printed product meets the approved proof standard 1.3 Flexographic inking system and doctor blade condition is monitored, evaluated and adjusted to ensure quality of specialised printed product meets the approved proof standard 1.4 Drying systems are monitored, evaluated and adjusted to ensure quality of the specialised printed product meets the approved proof standard |
2. Maintain specialised production process | 2.1 Production process is maintained in association with fellow workers and according to enterprise procedures and planned daily schedule 2.2 Production is maintained according to work health and safety (WHS) requirements, manufacturer’s specifications and enterprise procedures 2.3 Manual and/or automatic control is used according to job specifications 2.4 Performance is monitored, adjusted and verified using the process control system according to enterprise procedures 2.5 Ink performance, colour, register and position of print are monitored, evaluated and adjusted throughout production run |
3. Tune and adjust machinery | 3.1 Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate, or exploit the idiosyncrasy, within manufacturer’s specifications 3.2 Options are assessed to determine most effective/efficient method of production, ensuring highest quality and yield from machinery 3.3 Test run confirms correct options and settings or the need for further adjustment or tuning to meet quality standards 3.4 Options and recommendations are documented for future reference according to enterprise procedures 3.5 Instruction on new practices is provided to machine operator or finisher, if required |
4. Troubleshoot machinery and material problems | 4.1 Corrective or preventive action is recommended and implemented where appropriate 4.2 Changes are communicated to relevant personnel in a logical and easily understood manner 4.3 Changes are monitored to confirm improvement to production efficiency 4.4 Ongoing problems are reported according to enterprise procedures |
5. Conduct shutdown of production process | 5.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures 5.2 Shutdown is conducted in association with fellow workers and in compliance with WHS requirements 5.3 Reels and cores are removed from press 5.4 Unused ink is drained back into containers and correctly labelled and stored according to manufacturer’s/supplier’s specifications and enterprise procedures 5.5 Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures 5.6 Product is removed from operating area |
Evidence of Performance
Evidence of the ability to:
safely monitor production output and make necessary adjustments to maintain print quality on a flexographic 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, enterprise procedures and work health and safety (WHS) guidelines.
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:
identify causes of reel wander and the print fault that results from the reel being run out of centre
identify causes of web breaking at the unwind unit, and possible faults in the unwind section that cause a web break
outline the difference between a ‘flying paster’ and ‘zero speed’ type reel-stand
outline WHS risks associated with rewinding and sheeting, and identify the safety feature in the delivery system for when the web jams up
identify causes of sheet cut-off wander
outline the effect of poorly adjusted nip rollers when rewinding and sheeting, and what happens if the plate lifts on the leading edge during a print run
describe the effect on printed product of a build-up of ink on the impression cylinder, and the cause of ink foaming in the ink tray
identify the effect of too much reducer in the ink
name the action that reduces doctor blade wear
describe why all solvents need to be removed from the final ink film
identify link between driers and set off and marking and the causes of UV ink drying
describe faults that cause substrate distortion
outline the effect in the chillers if the drying temperature is too low, and the effect of incorrect drying temperature on the finished product
describe the effect of eating or drinking near the machine when using UV inks
describe the need to frequently examine in-line components of the job
outline consistency checks for the punching unit
describe the result of excessive pressure on the slitters
outline safety features within the organisation that aid in maintaining effective production
outline the legal responsibility for removal of machine guards and/or disconnection of micro switches
describe the effect of inadequate communication within the work team on a flexographic printing machine
describe ramifications if machine guards are removed and/or micro switches are disconnected on a machine
outline other measurement, besides optimum solid ink density, to assess print quality
describe the most accurate method of checking register during a production run
outline the need to take immediate action when production problems are anticipated, and action taken to eliminate further processing of unacceptable printed product
outline the result to the substrate if relative humidity is increased in the press room, and how to care for a newly delivered substrate to the press room
describe the process for waste sorting and the advantage of keeping reusable waste
list industry standards to enhance effective communication with clients, and procedures clients should follow to approve a printed product
identify times when it is necessary to call service personnel to correct a machine problem
outline enterprise procedures in place to report any machine operating problems, and what happens if correct shutdown procedures are not followed with fellow workers
describe advantages of proper labelling and storage of excess inks and materials
describe the process for clear labelling of printed product prior to removal from the press room
outline operations required for printed reels after they are removed from the printing machine, and how to store printed jobs after they are removed from the printing machine
outline use of completed records in the final analysis of the job, and benefits of comprehensive records when considering production of future jobs
identify machine manuals, safety and other documentation relevant to this task, where are they kept and information included in these documents.
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, including a reel-fed flexographic press.
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 | 2.2, 2.3, 3.1, 5.1, 5.4 | Recognises and interprets text to establish job requirements from information contained within relevant instructions, procedures and specifications |
Writing | 3.4, 3.5, 4.1, 4.4, 5.4 | Completes records, forms and other documents accurately and according to workplace requirements |
Oral Communication | 2.1, 3.5, 4.1, 4.2, 4.4, 5.2 | Participates effectively in discussions using appropriate vocabulary, questioning and listening skills |
Navigate the world of work | 2.1, 2.2, 3.4, 4.4, 5.1, 5.2, 5.4, 5.5 | Complies with legislative requirements and follows organisational policies and procedures relevant to own role |
Interact with others | 2.1, 3.5, 4.1, 4.2, 4.4, 5.2 | Collaborates and cooperates with others to achieve joint outcomes Contributes to workgroup discussions using accepted conventions Selects and uses appropriate communication practices when reporting issues |
Get the work done | 1.1-1.4, 2.1-2.5, 3.1, 3.4, 4.1-4.4, 5.1-5.6 | Determines priorities and sequences steps involved in clearly defined, familiar tasks and identifies and assembles required resources Makes rapid decisions when required, drawing on in-depth understanding of a situation and experience of decision-making Responds to predictable problems and implements standard or logical solutions related to role in the immediate work environment Reads data from electronic monitoring and control systems |
Sectors
Printing