Application
This unit describes the skills and knowledge required to set up options, and then set up either wide or narrow reel or sheet-fed lithographic printing machines for non-routine print jobs. It includes the ability to conduct a proof run and adjust settings to ensure production speeds are attained in minimum time with minimum wastage.
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. Confirm complex job specifications | 1.1 Job requirements are read and interpreted from job documentation or production control system 1.2 Non-routine 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 delivery systems | 2.1 Delivery systems are set up and adjusted according to job specifications 2.2 Substrate is added to and removed from process according to job specifications |
3. Select and prepare inks and additives | 3.1 Colour sequence for job is considered and confirmed 3.2 Inks, dyes or additives are selected according to non-routine job specifications and end-user requirements 3.3 Quality and suitability of inks, dyes or additives are checked and appropriate action is taken 3.4 Inks, dyes and additives are prepared according to work health and safety (WHS) requirements, and manufacturer’s/supplier’s instructions, with suitable precautions to minimise waste 3.5 Correct colour and weight/volume of ink is mixed and prepared to match requirements of the job specification and the non-routine printing process 3.6 Formulation of ink, colour match and approved colour are appropriately recorded 3.7 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 to prolong shelf life |
4. Set up machine for complex lithographic printing | 4.1 Plate cylinder is set up and adjusted according to job specifications 4.2 Plates are correctly mounted according to machine specification and in a safe manner 4.3 Blanket and blanket cylinder are set up and adjusted according to job specifications 4.4 Impression cylinder is set up and adjusted according to job specifications 4.5 Inking system is set up and adjusted according to the lithographic process and job specifications 4.6 Dampening system is set up and adjusted according to job specifications 4.7 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 Production does not commence without client approval or authority where appropriate 5.4 Results are interpreted and adjustments are carried out according to product and machine specifications |
Evidence of Performance
Evidence of the ability to:
set up a lithographic printing machine for a complex job on TWO occasions (if possible using different substrates and sheet sizes if sheet-fed and, if possible, including at least two in-line processes) according to job and manufacturer’s specifications, and enterprise procedures
set up either wide or narrow reel or sheet-fed lithographic printing machines for non-routine print jobs
conduct proof run and adjust settings to ensure production speeds are attained in minimum time with minimum wastage
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:
explain why it is necessary to ensure the job specifications are read and properly understood
describe production problems that can eventuate from not reading and understanding the job specifications
identify who to discuss any production problems with
describe problems that can result from the plate cylinder not being cleaned prior to plate fitting
explain what can happen if the plate is over-tensioned during fitting
explain faults that can result from a plate being under-tensioned
describe why accurate plate bending is necessary on a web-fed machine
outline considerations for deciding the colour sequence
describe the visual aid on the plate that identifies colour of ink to be used
For reel systems only
list work health and safety (WHS) precautions for webbing up the machine
explain how to determine position of the reel
describe what can happen if the brake tension is not set correctly
outline the function of the ‘Dancer’ roller on a web machine
demonstrate knowledge of how to determine the position of bustle wheels
explain what can happen if the web is not spliced correctly
demonstrate knowledge of how the particular web viewing device works
explain how to control the web in the rewind unit
describe the function of a slitter on a web machine
list possible causes of the web to jam up in the folder
explain the need to disengage folder if sheeting
describe problems that can be attributed to a blunt knife when sheeting
name a safety feature in the delivery system for when the web jams up
describe which fold is always made with the grain of the web
identify the type of folder that folds the web in half in the direction of the web grain
list remedial steps if there is a possibility of the ink marking in the folder
outline main reasons for having a silicone applicator on a web machine
list main reasons for blistering on a heat-set machine
identify substances that evaporate after ink is placed in the oven
describe the function of chill rollers on a web machine
For sheet systems only
list WHS factors to consider when setting up sheet transportation and delivery systems
explain what can cause more than one sheet to be picked up in the feeder
outline the need for accurate feeder set up
identify what determines position of the sheet prior to being transferred to the printing unit
explain how to decide which front lays to use
describe the type of substrate that requires additional front lays to be engaged
explain the need for additional front lays when printing this type of substrate
list WHS precautions for setting up the delivery
list WHS precautions for removing sheets from the delivery
explain the cause of sheets being delivered incorrectly
describe necessary adjustments if changing from lightweight to heavyweight stocks
explain what determines sheet release into the delivery
outline problems from excessive use of anti-set off spray powder
list possible causes of printed sheets to set off in the delivery
explain how to reduce possibility of set off in the delivery
identify faults that may be created by excess vacuum on the slow-down wheels
outline the procedure to lengthen print length on this type of press
outline the procedure to shorten print length on this type of press
list WHS concerns for preparation of inks and additives
identify details to check an ink’s suitability for the printing process
outline special end-use requirements that may be necessary
explain why it may be necessary to mix an additive into the ink
explain how a spectrophotometer can be used to assess colour of an ink
describe the formula for calculating correct quantity of lithographic ink
name a print fault likely if excessive driers are mixed into ink
describe precautions to minimise waste when preparing ink
describe how to determine shelf life of most inks
outline conditions relevant to storage of inks and additives
list conventions to follow when labelling mixed inks
list WHS factors to consider when setting up the machine
describe checks to be made on the plate prior to fitting
outline how much plate packing is required
explain normal printing pressure required between plate and blanket
explain how to determine correct printing pressure between blanket and stock
outline ideal blanket surface condition
explain how to achieve correct blanket tension when fitting a new blanket
identify print faults likely if the impression cylinder is not maintained
describe the order eccentric or concentric roller adjustments should be made in
list the contact stripe width required between two rollers when setting the rollers
demonstrate how to determine ink duct setting
explain the ideal ink duct sweep setting
describe recommended degrees of shore hardness for bare back and conventional dampeners
describe the best conductivity of fountain solution
explain why it is necessary to constantly check conductivity of fountain solution
demonstrate knowledge of how to change the amount of fountain solution across the plate surface
explain why it may be necessary to adjust fountain solution laterally
explain the effect of engaging the perfecting unit on the run
list WHS precautions for slitting on the machine
describe operations performed with in-line units
demonstrate knowledge of machine position used to engage in-line processing units
identify precautions for setting up in-line processing units
list reasons for a printed product to be punched
outline what to consider when setting hole punching in relation to repeat length
describe the result of excessive pressure on the slitters
describe the operation of the true inch function fitted to some machines
describe problems that may cause the machine to keep stopping
list necessary checks prior to engaging the impression
list checks performed when running the machine
explain the effect the position of certain guards have on machine operation
outline how steps involved in operating the machine are communicated to other team members
name various aids available for testing the machine proof
identify where testing should take place
explain the function of a polarisation filter in a densitometer
describe the ideal conditions for inspecting the proof
outline the need to use visual aids on the printed sheets
identify the acceptable wet trap value range for lithographic inks
explain what indicates optimum solid ink density, in the absence of a proof
describe the result of low solid ink density and excessive dot gain
list methods to check and adjust ink colour and consistency
explain adjustments that may cause mis-register
explain adjustments required to position the image laterally
list adjustments made to position the image circumferentially
list adjustments made to position the image diagonally
describe the effect of changing colour sequence on the wet trap value
explain the difference between mechanical and optical dot gain
describe factors that can cause excessive mechanical dot gain
identify who has responsibility for the final approval of the job
locate machine manuals, safety and other documentation relevant to this task and outline the 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 lithographic printing machine with 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 | 1.1, 3.2, 3.4, 3.7, 4.1-4.8, 5.4 | Recognises and interprets text to establish job requirements from information contained within relevant instructions, procedures and specifications |
Writing | 5.7, 5.3 | Completes forms and labels accurately and according to workplace requirements |
Oral Communication | 5.3 | Participates effectively in spoken interactions using appropriate vocabulary, and employs questioning and listening techniques to gain approvals |
Navigate the world of work | 3.4, 3.6, 3.7, 4.3, 5.2, 5.3, | Complies with legislative requirements and follows organisational policies and procedures relevant to own role |
Interact with others | 5.3 | Follows accepted communication practices and protocols when seeking approval |
Get the work done | 1.1-1.3, 2.1, 2.2, 3.1, 3.2-3.5, 3.7, 4.1-4.8, 5,1, 52, 5.4 | With assistance, determines priorities and sequences steps involved in clearly defined, familiar tasks and identifies and assembles required resources 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 |
Range Statement
This section specifies different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Delivery systems MUST include EITHER: | reel OR sheet |
Setting and adjusting MUST include EITHER: | set up options for unwind and rewind reels webbing procedures and web control system splicing/joining reels printed web viewing devices folder and sheeter set off / marking prevention devices OR feeder and delivery sections sheet pick-up, transportation and control and transfer systems set off / marking prevention devices |
Sectors
Printing