Application
This unit describes the skills and knowledge required to operate a gravure press, ensuring an efficient production flow for specialised jobs while maintaining product quality standards. Any production problems are anticipated and rectified with minimum downtime. The machine is correctly shut down and cleaned according to work health and safety (WHS) guidelines.
It applies to individuals working as print machinists in the printing and graphic arts industry. They prepare material, set up, monitor and operate equipment and machinery, apply solutions to a defined range of problems associated with the print medium, and 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 gravure printing process | 1.1 Gravure cylinder condition is monitored, evaluated and adjusted to ensure quality of printed product meets the sample sheet standard 1.2 Gravure impression roller condition is monitored, evaluated and maintained to ensure quality of the specialised printed product meets the sample sheet standard 1.3 Gravure inking system and doctor blade are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the sample sheet standard 1.4 Drying systems are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the approved proof standard 1.5 In-line printing/converting/binding/finishing processes are monitored, evaluated and adjusted to ensure quality of specialised product meets the approved proof standard |
2. Maintain specialised production process | 2.1 Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule 2.2 Production is maintained according to 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 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 2.6 Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention 2.7 Process adjustments to eliminate problems are reported according to enterprise procedures 2.8 Waste is sorted according to enterprise procedures |
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 Test run confirms correct options and settings or need for further adjustment or tuning to meet quality standards 3.3 Options and recommendations are documented for future reference according to enterprise procedures 3.4 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 Unused ink is correctly labelled and stored according to manufacturer’s/supplier’s specifications and enterprise procedures 5.4 Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures 5.5 All product is removed from operating area 5.6 Machine faults requiring repair are identified and reported to designated person according to enterprise procedures |
Evidence of Performance
Evidence of the ability to:
operate a gravure press ensuring production flow that maintains product quality standards and minimises downtime from production problems
shut down and clean a gravure press 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, 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:
describe what can cause reel to wander
outline what can cause the web to break at the unwind unit
explain the difference between a ‘flying paster’ and ‘zero speed’ type reel-stand
outline the print fault that results from the reel being run out of centre
list possible faults in the unwind section that can cause a web break
identify WHS risks associated with rewinding and sheeting
identify the safety feature in the delivery system for when the web jams up
explain why the sheet cut-off might wander
describe the effect of poorly adjusted nip rollers when rewinding and sheeting
explain the effect of a build-up of ink on the impression cylinder on printed product
list causes of ink foaming in the ink tray
outline the effect of too much reducer in ink
describe what action can reduce wear of the doctor blade
explain why all solvents need to be removed from the final ink film
describe link between driers and set off and marking
explain the cause of substrate distortion
describe the effect in the chillers, if the drying temperature was too low
identify the effect of incorrect drying temperature on the finished product
outline the effect of inadequate communication within the work team on a gravure printing machine
list safety features within the organisation that aid in maintaining effective production
describe ramifications if machine guards are removed and/or micro switches are disconnected on a machine
identify who is legally responsibility for the removal of machine guards and/or disconnection of micro switches
demonstrate knowledge of the most accurate method of checking register during a production run
explain 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
explain what happens to the substrate if relative humidity is increased in the press room
list procedures to care for a newly delivered substrate to the press room
demonstrate knowledge of how to correctly sort waste
outline advantages of keeping reusable waste
identify industry standards to enhance effective communication with clients
list necessary procedures clients should follow to approve a printed product
explain when to call service personnel to correct a machine problem
outline enterprise procedures to report any machine operating problems
describe consequences if correct shutdown procedures are not followed
explain why it is necessary for correct shutdown procedures to be conducted with fellow workers
list advantages of proper labelling and storage of excess inks and materials
explain why printed product should be clearly labelled prior to removal from the press room
outline any additional operations required for printed reels after they are removed from the printing machine
describe how the printed job should be stored after it is removed from the printing machine
explain how completed records are used in final analysis of the job
describe benefits of comprehensive records when considering production of future jobs
locate machine manuals, safety and other documentation relevant to this task and outline 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 gravure printing machine.
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, 3.2, 5.1, 5.3 | Recognises and interprets text to establish job requirements from information contained within relevant procedures and specifications |
Writing | 2.7, 3.3, 4.4, 5.3, 5.6, | Completes records, forms and other documents accurately and according to workplace requirements |
Oral Communication | 2.1, 2.7, 3.4, 4.1, 4.2, 4.4, 5.2, 5.6, | Participates effectively in discussions using appropriate vocabulary, and questioning and listening skills |
Navigate the world of work | 2.1, 2.2, 2.4, 2.5, 2.7, 2.8, 3.3, 4.4, 5.1-5.4, 5.6, | Complies with legislative requirements and follows organisational policies and procedures relevant to own role |
Interact with others | 2.1, 2.7, 3.4, 4.1, 4.4, 5.2, 5.6, | Collaborates and cooperates with others to achieve joint outcomes Contributes to work group discussions using accepted conventions |
Get the work done | 1.1-1.5, 2.-2.8, 3.1, 3.2, 5.1- | 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 decision-making experience Responds to predictable problems and implements standard or logical solutions related to role in immediate work environment Reads data from electronic monitoring and control systems |
Sectors
Printing