Application
This unit describes the skills and knowledge required to set up for specialised lithographic printing.
It applies to individuals who can problem-solve and experiment with substrate and press settings for either wide or narrow reel- or sheet-fed lithographic printing machines for specialised print jobs.
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 specialised job specifications | 1.1 Job requirements are read and interpreted from job documentation or production control system 1.2 Availability of all job related components is checked |
2. Plan and carry out specialised set-up | 2.1 Specialised job specifications are identified and analysed 2.2 Special set-up requirements are determined 2.3 Specialised set-up is completed in minimum time with minimum wastage |
3. Set up delivery systems | 3.1 Delivery systems are set up and adjusted according to job specifications 3.2 Substrate is added to and removed from process according to job specifications |
4. Select and prepare inks and additives | 4.1 Colour sequence for the job is considered and confirmed 4.2 Inks, dyes or additives are evaluated with reference to specialised requirements 4.3 Inks, dyes or additives are selected according to job specifications 4.4 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 4.5 Correct colour and weight/volume of ink are mixed and prepared to match requirements of the printing process and job specifications 4.6 Formulation of ink, colour match and approved colour are appropriately recorded 4.7 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 |
5. Set up machine for specialised lithographic printing | 5.1 Plate cylinder is set up, evaluated and adjusted according to job specifications 5.2 Lithographic plate is selected and prepared for installation 5.3 Plates are correctly mounted safely and according to job specifications 5.4 Blanket and blanket cylinder are set up, evaluated and adjusted according to job specifications 5.5 Impression cylinder is set up, evaluated and adjusted according to job specifications 5.6 Inking system is set up, evaluated and adjusted according to the lithographic process and job specifications 5.7 Dampening system is set up, evaluated and adjusted according to job specifications 5.8 Drying system is set up, evaluated and adjusted according to job specifications |
6. Conduct specialised proof run | 6.1 Material to be used for proof is organised correctly 6.2 Machine is operated according to manufacturer’s specifications and enterprise procedures to produce a specified proof 6.3 Specialised proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures 6.4 Production does not commence without client approval or authority where appropriate 6.5 Results are interpreted and evaluated with adjustments carried out according to product and machine specifications |
7. Troubleshoot machinery and material problems | 7.1 Corrective or preventive action is recommended and implemented where appropriate 7.2 Changes are communicated to relevant personnel in a logical and easily understood manner 7.3 Changes are monitored to confirm improvement to production efficiency 7.4 Ongoing problems are reported according to enterprise procedures |
Evidence of Performance
Evidence of the ability to:
set up either wide or narrow reel or sheet-fed lithographic printing machines for specialised print jobs; conduct a proof run and adjust settings to ensure production speeds are attained in minimum time with minimum wastage
set up a lithographic printing machine for a specialised job on TWO occasions using different substrates and sheet sizes if sheet-fed and including at least two in-line processes according to manufacturer’s and job specifications, enterprise procedures and the performance criteria.
find and use information relevant to the task from a variety of information sources
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 that job specifications are read and properly understood
discuss production problems that could eventuate if job specifications are not read and properly understood
identify who to discuss any production problems with
outline the problem that can result from the plate cylinder not being cleaned prior to plate fitting
describe what happens if the plate is over tensioned during fitting
list faults that can result from a plate being under tensioned
For reel systems only
describe the need for accurate plate bending on a web-fed machine
explain how to determine position of the reel
describe the effect if brake tension is not set correctly
discuss the function of the ‘dancer’ roller on a web machine
outline how to determine position of the bustle wheels
explain what happens if the web is not spliced correctly
describe the operation of the particular web viewing device
explain how the web is controlled in the rewind unit
outline the function of a slitter on a web machine
discuss what causes the web to jam up in the folder
explain the need to disengage the folder if sheeting
list problems that attributable to a blunt knife when sheeting
outline the safety feature in the delivery system for when the web jams up
describe which fold is always made with the grain of the web
explain the type of folder that folds the web in half in the direction of the web grain
outline remedial steps to take if there is a possibility of ink marking in the folder
describe the main reason for having a silicone applicator on a web machine
explain the main reason for blistering on a heat set machine
explain what the oven evaporates from the ink
discuss the function of chill rollers on a web machine
For sheet systems only
describe work health and safety (WHS) factors to consider when setting up the sheet transportation and delivery systems
explain what causes more than one sheet to be picked up in the feeder
discuss the need for accurate feeder set up
describe how to determine position of the sheet prior to transfer to the printing unit
discuss how to determine which front lays to use
explain 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 the WHS precaution to observe when setting up the delivery
list WHS precautions for removing sheets from the delivery
explain what causes incorrect sheets delivery
outline necessary adjustments when changing from lightweight to heavyweight stocks
explain what determines sheet release into the delivery
list problems caused by excessive use of anti-set off spray powder
describe what might cause printed sheets to set off in the delivery
discuss how the possibility of set off in the delivery might be reduced
explain what can happen if there is excess vacuum on the slow-down wheels
list WHS precautions that must be observed when preparing inks and additives
describe the procedure used to lengthen print length on this type of press
discuss the procedure used to shorten print length on this type of press
outline considerations of deciding colour sequence
point out the visual aid on the plate that identifies ink colour to be used
discuss all WHS precautions for webbing up the machine
outline details to check to determine an ink’s suitability for the printing process
describe what special end-use requirements might be necessary
explain the reason for mixing additives in the ink
explain how a spectrophotometer can help assess ink colour
describe the formula for calculating correct quantity of lithographic ink
discuss the print fault that occurs if excessive driers are mixed into the ink
outline precautions to minimise waste when preparing ink
explain shelf life of most inks
discuss conditions relevant to storage of inks and additives
explain conventions for labelling mixed inks
list WHS factors for setting up the machine
describe checks made on the plate prior to fitting
explain how much plate packing is required
describe normal printing pressure required between plate and blanket
explain how to determine correct printing pressure between blanket and stock
explain the ideal blanket surface condition
describe how to achieve correct blanket tension when fitting a new blanket
describe print faults likely if the impression cylinder is not maintained
explain the order eccentric or concentric roller adjustments should be made in
explain what the width of the contact stripe between two rollers should be when setting the rollers
describe how to determine the ink duct setting
explain the ideal ink duct sweep setting
discuss recommended degrees shore hardness for bare back and conventional dampeners
describe what conductivity of the fountain solution should be
explain why it is important to constantly check conductivity of the fountain solution
explain how to change the amount of fountain solution across the plate surface
outline the need to adjust the fountain solution laterally
list reasons it might be difficult to engage the perfecting unit
list types of ink drying/curing systems
describe what the true inch function feature fitted to some machines does
list what may cause the machine to keep stopping
outline necessary checks prior to engaging the impression
describe checks performed when running the machine
describe the effect position of certain guards has on operation of the machine
explain how steps involved in operating the machine should be communicated to other team members
describe aids available for the testing of the machine proof
discuss where testing should take place
explain the function of a polarisation filter in a densitometer
describe ideal conditions for inspecting the proof
discuss why it is necessary to use visual aids on the printed sheets
describe the acceptable wet trap value range for lithographic inks
outline an indication of optimum solid ink density in the absence of a proof
explain the result of low solid ink density and excessive dot gain
describe available methods to check and adjust ink colour and consistency
list adjustments that may cause mis-register
list adjustments made to position the image laterally
list adjustments made to position the image circumferentially
list adjustments made to position the image diagonally
discuss the effect of changing colour sequence on the wet trap value
explain the difference between mechanical and optical dot gain
outline the cause of excessive mechanical dot gain
explain who has responsibility for the final say in the OK of the job
identify machine manuals, safety and other documentation relevant to this task, where they are kept, and discuss 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 a lithographic 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 | 1.1, 2.1, 4.3-4.5, 4.7, 5.1, 5.3-5.8, 6.5, | Recognises and interprets text to establish job requirements from information contained within relevant procedures and specifications |
Writing | 4.6, 4.7, 6.4, 7.2, 7.4 | Completes workplace recording accurately Demonstrates sophisticated control of a broad range of text types |
Oral Communication | 1.1, 2.1, 4.3, 4.5, 5.1, 5.3-5.8, 6.4, 7.2, 7.4 | Participates effectively in spoken interactions by using strategies to confirm, clarify or repair understanding |
Numeracy | 4.5 | Interprets and analyses a range of mathematical information used in familiar and routine tasks |
Navigate the world of work | 1.2, 2.1, 2.3, 4.2-4.7, 5.1, 5.3-5.8, 6.2-6.5, 7.3, 7.4 | Recognises and follows explicit and implicit protocols and meets expectations associated with own role Complies with WHS, legislative requirements and follows organisational policies and procedures relevant to own role |
Interact with others | 1.1, 2.1, 5.3, 5.5, 6.1, 6.3-6.8, 7.4, 8.2, 8.4 | Seeks to cooperate with others to achieve results in immediate work context |
Get the work done | 1.2, 1.3, 2.1-2.3, 4.1-4.5, 4.7, 5.1, 5.3-5.8, 6.1-6.3, 6.5, 7.3, 7.4 | Plans, evaluates, identifies and assembles resources required to complete tasks Determines priorities and sequences steps involved in complex tasks with a focus on production efficiency May use formal analytical and lateral thinking techniques to identify issues, generate and evaluate possible solutions Is acutely aware of the importance of understanding, monitoring and controlling access to digitally stored and transmitted information Uses familiar digital systems and tools to access, organise, analyse and display information relevant to role 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 up 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, control and transfer systems set off / marking prevention devices |
Sectors
Printing