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Evidence Guide: ICPPR332C - Produce complex lithographic printed product

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

 

ICPPR332C - Produce complex lithographic printed product

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

Maintain non-routine operation of reel system (OR Element 2)

  1. Reel stand and rewind sections are monitored and adjusted to maintain correct tension and to ensure no marks, blemished or damage to finished product and to ensure efficient continuous operation
  2. Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web for efficient operation
  3. Substrate is added to and removed from the process according to job instructions
  4. Sheeting section is monitored and adjusted to ensure quality and efficient product delivery
  5. Set-off/marking prevention system is monitored and adjusted to ensure quality of printed product without set-off or marking meets the standard of approved proof
Reel stand and rewind sections are monitored and adjusted to maintain correct tension and to ensure no marks, blemished or damage to finished product and 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 for efficient operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Substrate is added to and removed from the process according to job instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Sheeting section is monitored and adjusted to ensure quality and efficient product delivery

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set-off/marking prevention system is monitored and adjusted to ensure quality of printed product without set-off or marking meets the standard of approved proof

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain non-routine operation of sheet system (OR Element 1)

  1. Feeder and delivery sections are monitored and adjusted to ensure continuous and efficient feeding to machine
  2. Sheet pick-up and transport system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation
  3. Transfer systems are monitored and adjusted to ensure correct and continuous sheet handling and efficient operation
  4. Substrate is added to and removed from the process according to job instructions
  5. Set-off/marking prevention system is monitored and adjusted to ensure quality of printed product without set-off or marking meets the standard of approved proof
Feeder and delivery sections are monitored and adjusted to ensure continuous and efficient feeding to machine

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Sheet pick-up and transport system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation

Completed
Date:

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Transfer systems are monitored and adjusted to ensure correct and continuous sheet handling and efficient operation

Completed
Date:

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Substrate is added to and removed from the process according to job instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set-off/marking prevention system is monitored and adjusted to ensure quality of printed product without set-off or marking meets the standard of approved proof

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain complex lithographic printing process

  1. Non-routine lithographic plate and plate cylinder condition are monitored and adjusted to ensure the quality of printed product meets the standard of the sample sheet
  2. Non-routine lithographic blanket and blanket cylinder condition are monitored and adjusted to ensure the quality of printed product meets the standard of sample sheet
  3. Non-routine lithographic impression cylinder condition is monitored and adjusted to ensure quality of printed product meets the standard of sample sheet
  4. Non-routine lithographic inking system is checked and maintained to ensure quality of printed product meets the standard of sample sheet
  5. Non-routine lithographic dampening system condition is monitored and adjusted to ensure quality of printed product meets the standard of sample sheet
  6. Set off/marking prevention and drying system is monitored and adjusted to ensure quality of printed product meets the standard of sample sheet
  7. Drying systems are monitored and adjusted to ensure quality of printed product meets the standard of approved proof
Non-routine lithographic plate and plate cylinder condition are monitored and adjusted to ensure the quality of printed product meets the standard of the sample sheet

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Non-routine lithographic blanket and blanket cylinder condition are monitored and adjusted to ensure the quality of printed product meets the standard of sample sheet

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Non-routine lithographic impression cylinder condition is monitored and adjusted to ensure quality of printed product meets the standard of sample sheet

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Non-routine lithographic inking system is checked and maintained to ensure quality of printed product meets the standard of sample sheet

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Non-routine lithographic dampening system condition is monitored and adjusted to ensure quality of printed product meets the standard of sample sheet

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set off/marking prevention and drying system is monitored and adjusted to ensure quality of printed product meets the standard of sample sheet

Completed
Date:

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Drying systems are monitored and adjusted to ensure quality of printed product meets the standard of approved proof

Completed
Date:

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Maintain production process

  1. Production process is operated in association with fellow workers and according to company specifications and planned daily schedule
  2. Production is maintained within OHS requirements and company and manufacturer's specifications
  3. Manual and/or automatic control is used as per specification
  4. Performance is monitored and verified using the process control system according to enterprise procedures
  5. Ink performance, colour, register and position of print are monitored and adjusted throughout production run
  6. Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention
  7. Process adjustments to eliminate problems are reported according to enterprise procedures
  8. Faulty performance of equipment is identified and reported according to enterprise procedures
  9. Waste is sorted according to enterprise procedures
Production process is operated in association with fellow workers and according to company specifications and planned daily schedule

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Production is maintained within OHS requirements and company and manufacturer's specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Manual and/or automatic control is used as per specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ink performance, colour, register and position of print are monitored and adjusted throughout production run

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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:

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

Completed
Date:

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Waste is sorted according to enterprise procedures

Completed
Date:

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Identify and investigate lithographic machine operating problem

  1. Problem in lithographic machine operation is investigated
  2. Problem in lithographic machine is identified and reported according to enterprise procedures
Problem in lithographic machine operation is investigated

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Problem in lithographic machine is identified and reported according to enterprise procedures

Completed
Date:

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Rectify minor lithographic machine faults

  1. Adjustments or corrections are carried out according to specified procedures and consistent with operator's skill level
  2. Lithographic machine operation is checked to ensure correct operation
Adjustments or corrections are carried out according to specified procedures and consistent with operator's skill level

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Lithographic machine operation is checked to ensure correct operation

Completed
Date:

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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 OHS requirements
  3. Unused ink is correctly labelled and stored according to manufacturer/supplier specifications and enterprise procedures
  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. All product is removed from operating area
  6. Machine faults requiring repair are identified and reported to designated person according to enterprise procedures
  7. 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 OHS requirements

Completed
Date:

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Unused ink is correctly labelled and stored according to manufacturer/supplier specifications and enterprise procedures

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:

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All product is removed from operating area

Completed
Date:

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

Completed
Date:

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Repair/adjustment is verified prior to resumption of operations

Completed
Date:

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Clean and wash up printing machine at end of print run

  1. Cylinders, plate and roller surfaces are cleaned ready for next run
  2. Inking system and dampening system are washed up ready for next run, and liquid waste is disposed of according to company and regulatory requirements
  3. In-line printing/converting/binding/finishing units are cleaned ready for next run
  4. Reel feed, transportation and delivery systems are disengaged and cleaned ready for next run
  5. Sheet feed, transport and delivery systems are disengaged and cleaned ready for next run
Cylinders, plate and roller surfaces are cleaned ready for next run

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inking system and dampening system are washed up ready for next run, and liquid waste is disposed of according to company and regulatory requirements

Completed
Date:

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In-line printing/converting/binding/finishing units are cleaned ready for next run

Completed
Date:

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

Completed
Date:

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Sheet feed, transport and delivery systems are disengaged and cleaned ready for next run

Completed
Date:

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Complete records

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

Completed
Date:

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Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of the following is essential:

Operate a lithographic press ensuring an efficient non-routine production flow that maintains product quality standards. Any production problems are anticipated and rectified with minimum downtime. The machine is correctly shut down and cleaned according to OHS guidelines

Demonstrate use of computerised control, monitoring and data entry systems if available and appropriate

Demonstrate an ability to find and use information relevant to the task from a variety of information sources

Monitor production output and make necessary adjustments to maintain print quality on a lithographic machine whilst producing a complex print on TWO occasions (if possible using different types and sizes of substrates and if possible including at least TWO in-line processes) according to job specifications, enterprise procedures and the Performance Criteria

Evidence for assessment may be gathered from assessment of the unit of competency alone or through an integrated assessment activity

Context of and specific resources for assessment

Assessment must ensure:

assessment may take place on the job, off the job or a combination of these. Off the job assessment must be undertaken in a closely simulated workplace environment

lithographic printing machine

Method of assessment

The following assessment method is appropriate for this unit:

direct questioning combined with review of portfolios of evidence and third party workplace reports of on-the-job performance by the candidate.

Guidance information for assessment

Holistic assessment with other units relevant to the industry sector, workplace and job role is recommended, for example:

ICPPR431C Set up for complex lithographic printing

Required Skills and Knowledge

Required skills

OHS in relation to operating machinery such as safely switching off machinery before cleaning is started

communication of ideas and information by interpreting the job brief and providing advice to clients about options and limitations

collecting, analysing and organising information by collecting and analysing data about printing process, machine specifications and performance to calculate appropriate adjustments for the job

planning and organising activities by providing information about time and materials requirements for production scheduling

teamwork when maintaining the production process in association with others

mathematical ideas and techniques by calculating substrate requirements, plate position and pressures

problem-solving skills by recognising proofing faults and calculating adjustments necessary to meet job specifications

use of technology by using monitoring equipment and computerised production records

Required knowledge

reel transportation and web control

OHS concerns when operating the reel transportation system

reel wander

causes of web break at the unwind unit

difference between a "flying paster" and "zero speed" type reel-stand

print fault that would result from the reel being run out of centre

faults in the unwind section that could cause a web break

sheet transportation and transfer

OHS concerns that are there when operating the sheet transportation system

result of worn suckers at the feeder suction head

type of two sheet detection on this machine

movement that the sheet should have when being registered by the side lay

causes of mis-register of the sheet at the feeder

visible signs of the sheet being registered in the feeder

gripper malfunction affecting sheet control and transfer

adjustment of sheet transfer mechanisms

causes of the feeder stack becoming uneven

result of the feeder stack not being loaded level

how unevenness of the feeder stack can be rectified

reel delivery for rewinding and sheeting

OHS risks associated with rewinding and sheeting

what safety feature is in the delivery system if the web jams up

why the sheet cut-off would wander

effect of poorly adjusted nip rollers when rewinding and sheeting

further operations that are required for printed reels upon removal from the printing machine

how the printed job should be stored after removal from the printing machine

why it is necessary to label each printed reel

sheet delivery

effect machine speed will have on sheet delivery

advantage of spraying moving sheets with anti set off powder in the delivery

items in the delivery that could cause marking of the printed image

remedial steps that may be necessary to eliminate marking of the printed image

function of a sheet decurler fitted to the delivery of some machines

faults that could result from incorrectly set grippers in the transfer section of a machine

how the printed job should be stored after removal from the printing machine

printing unit

result if the plate develops a crack at the grip edge during a print run

effect of a sticky blanket surface

print faults that would result from the blanket not being tensioned correctly

causes of blanket packing creep during printing

how a build-up of ink on the impression cylinder could affect the printed product

cause of the ink to lying back in the duct

causes of ink stripping on the inking rollers

print faults that would result from excessive use of fountain solution on the plate

recommended pH range for fountain solutions

causes of the conductivity of the fountain solution to change over an eight-hour shift

problems that can be caused by excessive conductivity of the fountain solutions

drying unit

link between driers and set off and marking

what causes UV ink to dry

what could cause the substrate to blister

effect in the chillers if the drying temperature was too low

effect of incorrect drying temperature on the finished product

in-line processes

consistency of the punching unit

result of excessive pressure on the slitters

result of a dirty former

result of defective pins in the folder

result of adjusting the rollers at the base of the former

causes of the web jamming up in the folder

maintaining production process

effect of inadequate communication within the work team on a lithographic printing machine

safety features within the organisation aid in maintaining effective production

ramifications if machine guards are removed and/or micro switches are disconnected on a machine

who would be held legally responsible for the removal of machine guards and/or disconnection of micro switches

disadvantages of using a closed looped system for automatic control of the printed product

other measurements besides optimum solid ink density can be measured to assess print quality

most accurate method of checking register during a production run

action when production problems are anticipated

action to eliminate further processing of unacceptable printed product

effect of relative humidity if increased in the press room

procedure to care for a newly delivered skid of paper to the press room

why waste should be sorted

advantage of keeping reusable waste

industry standards that can be applied to enhance effective communication with the client

necessary procedures that the client should follow to "OK" a printed product

lithographic machine operating problems

when it is necessary to call service personnel to correct a machine problem

enterprise procedures that are in place to report any machine operating problems

correct shutdown procedures

advantages that result from proper labelling and storage of excess inks and materials

why the printed product be clearly labelled prior to removal from the press room

cleaning and washing up the printing unit

OHS concerns that should be observed when handling ink

safety precautions that should be observed when cleaning the printing cylinders

washing procedure for offset rubber blanket

how plates can be stored so as to minimise damage

cleaning feed, transportation, delivery and in-line sections

OHS precautions to be observed when cleaning these sections of the machine

completing production records

completed records are used in the final analysis of the job

benefits of comprehensive records when considering the production of future jobs

machine manuals, safety and other documentation that are relevant to this task, where kept and information that is included in these documents

Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Substrate handling may include:

wide and narrow reel, and large and small sheet handling systems.

Machines may include:

range of single sheet, stream-fed or reel-fed printing machines with manual, semi-automated, fully automated or computerised process control. Includes machines with digitally imaged plates.

Non-routine may include:

non-routine within this context relates to the set up and production of print runs. The set up of equipment and production involves a significant amount of deviation from using standard equipment settings. It also involves significant problem solving and the development of new criteria and procedures for performing current practices. It does not refer to a job that an individual does only occasionally.

Inks/coatings may include:

wide range of inks commonly used in printing.

In-line processes may include:

minor processes that are integral to this competency can include basic in-line operations such as perforating, numbering, date coding, slitting that do not in themselves constitute another defined unit of competency. Where a major in-line process is defined as a separate competency (eg flat-bed cutting, folding) it should be assessed as such.

Colour matching systems may include:

use of densitometers and spectrophotometry.

Design may include:

complex graphics and text. Critical "tight" registration, fit and position, registration should be at least that required for four-colour process work.

Substrate types may include:

range of substrates within the major categories of paper, pressure sensitive material, board, plastics and related films, or metal.