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Evidence Guide: ICPCBF305 - Produce single-faced web

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

ICPCBF305 - Produce single-faced web

What evidence can you provide to prove your understanding of each of the following citeria?

Inspect and adjust quality

  1. Inspection and/or testing of sample is organised
  2. Sample is visually inspected and/or tested according to enterprise procedures
  3. Results are interpreted to determine adjustment requirements
  4. Adjustments are carried out according to product and machine specifications
Inspection and/or testing of sample is organised

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Sample is visually inspected and/or tested according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Results are interpreted to determine adjustment requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjustments are carried out according to product and machine specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain operation of reel transportation system

  1. Reel stand is monitored and adjusted to ensure efficient continuous operation
  2. Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web and efficient operation
  3. Substrate is added to the process according to job specifications
Reel stand is monitored and adjusted to ensure efficient continuous operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web and efficient operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Substrate is added to the process according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain single facing process

  1. Starch delivery system is monitored and adjusted to suit corrugating process and according to job specifications
  2. Heat delivery system is monitored and adjusted to suit corrugating process and according to job specifications
  3. Steam delivery system is monitored and adjusted to suit corrugating process and according to job specifications
  4. Corrugating roll and pressure rolls are monitored and adjusted to suit corrugating process and according to job specifications
  5. Speed of machine is optimised according to running conditions
  6. Appropriate quantity of paper is run with a minimum of wastage
Starch delivery system is monitored and adjusted to suit corrugating process and according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Heat delivery system is monitored and adjusted to suit corrugating process and according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Steam delivery system is monitored and adjusted to suit corrugating process and according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Corrugating roll and pressure rolls are monitored and adjusted to suit corrugating process and according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Speed of machine is optimised according to running conditions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Appropriate quantity of paper is run with a minimum of wastage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain in-line process(es)

  1. Coating units are monitored and adjusted to suit corrugating process and according to job specifications
  2. Waxing units are monitored and adjusted to suit corrugating process and according to job specifications
  3. Slitters are monitored and adjusted according to job specifications
  4. Cut-off knife is monitored and adjusted according to job specifications
Coating units are monitored and adjusted to suit corrugating process and according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Waxing units are monitored and adjusted to suit corrugating process and according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Slitters are monitored and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Cut-off knife is monitored and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Synchronise machine operation

  1. Machine down-time is minimised during flute, grade or deckle changes
  2. Quality of board is maintained according to enterprise procedures or client acceptance standard
  3. Machine speed is optimised and waste minimised
Machine down-time is minimised during flute, grade or deckle changes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Quality of board is maintained according to enterprise procedures or client acceptance standard

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Machine speed is optimised and waste minimised

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain production process

  1. Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule
  2. Production is maintained according to Work Health and Safety (WHS) requirements, manufacturer’s specifications and enterprise procedures
  3. Manual and/or automatic control is used according to job specifications
  4. Performance is monitored and verified using the process control system according to enterprise procedures
  5. Starch performance is monitored and adjusted throughout production run
  6. Quality checks are carried out on a regular basis and adjustments made as necessary
Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Production is maintained according to Work Health and Safety (WHS) requirements, manufacturer’s specifications and enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Manual and/or automatic control is used according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Performance is monitored and verified using the process control system according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Starch performance is monitored and adjusted throughout production run

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Quality checks are carried out on a regular basis and adjustments made as necessary

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and rectify problems

  1. Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention
  2. Process adjustments to eliminate problems are reported according to enterprise procedures
  3. Faulty performance of equipment is identified and reported according to enterprise procedures
  4. Waste is sorted according to enterprise procedures
  5. Problems in corrugator operation are identified and reported according to enterprise procedures
  6. Adjustments or corrections are carried out according to specified procedures and are consistent with operator’s skill level
  7. Corrugator operation is checked to ensure correct operation
Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Process adjustments to eliminate problems are reported according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Faulty performance of equipment is identified and reported according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Waste is sorted according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Problems in corrugator operation are identified and reported according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjustments or corrections are carried out according to specified procedures and are consistent with operator’s skill level

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Corrugator operation is checked to ensure correct operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct shutdown of production process

  1. Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures
  2. Shutdown is conducted in association with fellow workers and in compliance with WHS requirements
  3. Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures
  4. All product is removed from operating area
  5. Machine faults requiring repair are identified and reported to designated person according to enterprise procedures
  6. Repair/adjustment is verified prior to resumption of operations
Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shutdown is conducted in association with fellow workers and in compliance with WHS requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

All product is removed from operating area

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Machine faults requiring repair are identified and reported to designated person according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair/adjustment is verified prior to resumption of operations

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean and wash up

  1. In-line wax and coating units are cleaned ready for next run
  2. Starch delivery system is washed ready for next run and liquid waste is disposed of according to regulatory requirements and enterprise procedures
  3. Reel feed and transportation systems are disengaged and cleaned ready for next run
  4. Production records or other documentation are accurately completed where required by enterprise procedures
In-line wax and coating units are cleaned ready for next run

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Starch delivery system is washed ready for next run and liquid waste is disposed of according to regulatory requirements and enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Reel feed and transportation systems are disengaged and cleaned ready for next run

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Production records or other documentation are accurately completed where required by enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

ELEMENT

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1. Inspect and adjust quality

1.1 Inspection and/or testing of sample is organised

1.2 Sample is visually inspected and/or tested according to enterprise procedures

1.3 Results are interpreted to determine adjustment requirements

1.4 Adjustments are carried out according to product and machine specifications

2. Maintain operation of reel transportation system

2.1 Reel stand is monitored and adjusted to ensure efficient continuous operation

2.2 Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web and efficient operation

2.3 Substrate is added to the process according to job specifications

3. Maintain single facing process

3.1 Starch delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.2 Heat delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.3 Steam delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.4 Corrugating roll and pressure rolls are monitored and adjusted to suit corrugating process and according to job specifications

3.5 Speed of machine is optimised according to running conditions

3.6 Appropriate quantity of paper is run with a minimum of wastage

4. Maintain in-line process(es)

4.1 Coating units are monitored and adjusted to suit corrugating process and according to job specifications

4.2 Waxing units are monitored and adjusted to suit corrugating process and according to job specifications

4.3 Slitters are monitored and adjusted according to job specifications

4.4 Cut-off knife is monitored and adjusted according to job specifications

5. Synchronise machine operation

5.1 Machine down-time is minimised during flute, grade or deckle changes

5.2 Quality of board is maintained according to enterprise procedures or client acceptance standard

5.3 Machine speed is optimised and waste minimised

6. Maintain production process

6.1 Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule

6.2 Production is maintained according to Work Health and Safety (WHS) requirements, manufacturer’s specifications and enterprise procedures

6.3 Manual and/or automatic control is used according to job specifications

6.4 Performance is monitored and verified using the process control system according to enterprise procedures

6.5 Starch performance is monitored and adjusted throughout production run

6.6 Quality checks are carried out on a regular basis and adjustments made as necessary

7. Identify and rectify problems

7.1 Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention

7.2 Process adjustments to eliminate problems are reported according to enterprise procedures

7.3 Faulty performance of equipment is identified and reported according to enterprise procedures

7.4 Waste is sorted according to enterprise procedures

7.5 Problems in corrugator operation are identified and reported according to enterprise procedures

7.6 Adjustments or corrections are carried out according to specified procedures and are consistent with operator’s skill level

7.7 Corrugator operation is checked to ensure correct operation

8. Conduct shutdown of production process

8.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures

8.2 Shutdown is conducted in association with fellow workers and in compliance with WHS requirements

8.3 Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

8.4 All product is removed from operating area

8.5 Machine faults requiring repair are identified and reported to designated person according to enterprise procedures

8.6 Repair/adjustment is verified prior to resumption of operations

9. Clean and wash up

9.1 In-line wax and coating units are cleaned ready for next run

9.2 Starch delivery system is washed ready for next run and liquid waste is disposed of according to regulatory requirements and enterprise procedures

9.3 Reel feed and transportation systems are disengaged and cleaned ready for next run

9.4 Production records or other documentation are accurately completed where required by enterprise procedures

Required Skills and Knowledge

ELEMENT

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1. Inspect and adjust quality

1.1 Inspection and/or testing of sample is organised

1.2 Sample is visually inspected and/or tested according to enterprise procedures

1.3 Results are interpreted to determine adjustment requirements

1.4 Adjustments are carried out according to product and machine specifications

2. Maintain operation of reel transportation system

2.1 Reel stand is monitored and adjusted to ensure efficient continuous operation

2.2 Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web and efficient operation

2.3 Substrate is added to the process according to job specifications

3. Maintain single facing process

3.1 Starch delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.2 Heat delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.3 Steam delivery system is monitored and adjusted to suit corrugating process and according to job specifications

3.4 Corrugating roll and pressure rolls are monitored and adjusted to suit corrugating process and according to job specifications

3.5 Speed of machine is optimised according to running conditions

3.6 Appropriate quantity of paper is run with a minimum of wastage

4. Maintain in-line process(es)

4.1 Coating units are monitored and adjusted to suit corrugating process and according to job specifications

4.2 Waxing units are monitored and adjusted to suit corrugating process and according to job specifications

4.3 Slitters are monitored and adjusted according to job specifications

4.4 Cut-off knife is monitored and adjusted according to job specifications

5. Synchronise machine operation

5.1 Machine down-time is minimised during flute, grade or deckle changes

5.2 Quality of board is maintained according to enterprise procedures or client acceptance standard

5.3 Machine speed is optimised and waste minimised

6. Maintain production process

6.1 Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule

6.2 Production is maintained according to Work Health and Safety (WHS) requirements, manufacturer’s specifications and enterprise procedures

6.3 Manual and/or automatic control is used according to job specifications

6.4 Performance is monitored and verified using the process control system according to enterprise procedures

6.5 Starch performance is monitored and adjusted throughout production run

6.6 Quality checks are carried out on a regular basis and adjustments made as necessary

7. Identify and rectify problems

7.1 Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention

7.2 Process adjustments to eliminate problems are reported according to enterprise procedures

7.3 Faulty performance of equipment is identified and reported according to enterprise procedures

7.4 Waste is sorted according to enterprise procedures

7.5 Problems in corrugator operation are identified and reported according to enterprise procedures

7.6 Adjustments or corrections are carried out according to specified procedures and are consistent with operator’s skill level

7.7 Corrugator operation is checked to ensure correct operation

8. Conduct shutdown of production process

8.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures

8.2 Shutdown is conducted in association with fellow workers and in compliance with WHS requirements

8.3 Solid and liquid waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures

8.4 All product is removed from operating area

8.5 Machine faults requiring repair are identified and reported to designated person according to enterprise procedures

8.6 Repair/adjustment is verified prior to resumption of operations

9. Clean and wash up

9.1 In-line wax and coating units are cleaned ready for next run

9.2 Starch delivery system is washed ready for next run and liquid waste is disposed of according to regulatory requirements and enterprise procedures

9.3 Reel feed and transportation systems are disengaged and cleaned ready for next run

9.4 Production records or other documentation are accurately completed where required by enterprise procedures

Evidence of the ability to:

perform at least TWO runs on the single-facer to produce TWO different types of single-faced web for corrugated board manufacture, according to manufacturer’s and job specifications and enterprise procedures including inspecting the quality of the product and identifying and rectifying problems.

Note: If a specific volume or frequency is not stated, then evidence must be provided at least once.

To complete the unit requirements safely and effectively, the individual must:

explain significant work health and safety risks workers face when producing single-faced web, and measures employed to prevent injury and/or illness

identify principle support systems on line to the corrugating machine and describe how the operator can effectively control and monitor these systems

explain which sections of the single-facer have higher potential for operational problems during the run

describe product faults commonly found during production runs and explain how can they be corrected

describe how settings are monitored and adjusted during the run to cater for the following: in-feed, web alignment control, pre-conditioners, adhesive application, corrugation, single-facer, steam delivery, heating of web and speed

identify which product factors can be monitored visually/manually, and explain how these can be adjusted to respond to problems found by staff operating end stages of the corrugator machine

explain functions that must be attended to for the wash-up and shutdown of the single-facer if it will be idle for two or more days

identify machine manuals, safety and other documentation relevant to the task, where they are kept, and the information contained in them.