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Evidence Guide: ICPPR432C - Produce specialised 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

 

ICPPR432C - Produce specialised lithographic printed product

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

Maintain specialised lithographic printing process

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Lithographic blanket and blanket cylinder conditions are monitored, evaluated and adjusted to ensure the quality of the specialised printed product meets the standard of sample sheet

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Lithographic impression cylinder condition is monitored, evaluated and adjusted to ensure quality of the specialised printed product meets the standard of sample sheet

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Lithographic inking system is checked and maintained to ensure quality of the specialised printed product meets the standard of sample sheet

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Lithographic dampening system condition is monitored, evaluated and adjusted to ensure quality of the specialised printed product meets the standard of sample sheet

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain specialised 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 OHS requirements, manufacturer's specifications and enterprise procedures
  3. Manual and/or automatic control is used according to job specifications
  4. Performance is monitored, evaluated and verified using the process control system according to enterprise procedures
  5. Ink performance, colour, register and position of print are monitored, evaluated 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 enterprise procedures and planned daily schedule

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Production is maintained according to OHS 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, evaluated 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, evaluated 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:

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:

 

 

 

 

 

 

 

Tune and adjust machinery

  1. Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate or to exploit the idiosyncrasy, within manufacturer's specifications
  2. Options are assessed to determine most effective/efficient method of production, ensuring highest quality and yield from machinery
  3. A test run confirms correct options and settings or the need for further adjustment or tuning to meet quality standards
  4. Options and recommendations are documented for future reference according to enterprise procedures
  5. Instruction on new practices is provided to machine operator or finisher, if required
Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate or to exploit the idiosyncrasy, within manufacturer's specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Options are assessed to determine most effective/efficient method of production, ensuring highest quality and yield from machinery

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

A test run confirms correct options and settings or the need for further adjustment or tuning to meet quality standards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Options and recommendations are documented for future reference according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Instruction on new practices is provided to machine operator or finisher, if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Troubleshoot machinery and material problems

  1. Corrective or preventive action is recommended and implemented where appropriate
  2. Changes are communicated to relevant personnel in a logical and easily understood manner
  3. Changes are monitored to confirm improvement to production efficiency
  4. Ongoing problems are reported according to enterprise procedures
Corrective or preventive action is recommended and implemented where appropriate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Changes are communicated to relevant personnel in a logical and easily understood manner

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Changes are monitored to confirm improvement to production efficiency

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ongoing problems are reported according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct shutdown of production process

  1. Correct shutdown sequence is followed according to manufacturer's specifications and enterprise procedures
  2. Plate cylinder is set up and adjusted according to job specifications
  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:

 

 

 

 

 

 

 

Plate cylinder is set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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:

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:

 

 

 

 

 

 

 

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 ability to:

operate a lithographic press ensuring an efficient specialised 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 specialised print on TWO occasions (if possible using different types and sizes of substrates) 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

A range of assessment methods should be used to assess practical skills and knowledge. The following examples are 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:

ICPPR332C Produce complex lithographic printed product

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 providing feedback to internal and external clients about printing processes and job specifications

collecting, analysing and organising information by collating details of job and machine specifications and printing processes to ensure efficient production

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 consumables and personnel requirements to meet production schedules

problem-solving skills by identifying print problems and correcting during print run

use of technology by using monitoring systems, understanding their output and feeding into production management systems

Required knowledge

OHS concerns that are there when operating the reel transportation system

reel wander cause

cause of the web to break at the unwind unit

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

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

possible faults in the unwind section that could cause a web break

OHS concerns that are there when operating the sheet transportation system

result of worn suckers at the feeder suction head

sheet detection types that are on this machine

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

cause of mis-register of the sheet at the feeder

visible signs of the sheet being registered in the feeder

gripper malfunction affect on the sheet control and transfer

adjustment of the sheet transfer mechanisms

cause of the feeder stack to become uneven

result of the feeder stack not being loaded level

rectifying the unevenness of the feeder stack

OHS risks that are associated with rewinding and sheeting

a safety feature that is in the delivery system if the web jams up

sheet cut-off 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

storing the printed job after removal from the printing machine

need to label each printed reel

effect that 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

storing the printed job after removal from the printing machine

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

cause of blanket packing creep during printing

effect of a build-up of ink on the impression cylinder the printed product

cause of ink to lie back in the duct

cause 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

cause of change in the conductivity of the fountain solution over an eight-hour shift

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

effect of eating or drinking near the machine when using UV inks

link between driers and set off and marking

causes of UV ink to dry

cause of the substrate blistering

effect in the chillers if the drying temperature was too low

effect of incorrect drying temperature on the finished product

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

safety features within the organisation that aid in maintaining effective production

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

legally responsibility for the removal of machine guards and/or disconnection of micro switches

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

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

most accurate method of checking register during a production run

need to take immediate action when production problems are anticipated

action that is taken to eliminate further processing of unacceptable printed product

effect on a stack of paper if the relative humidity is increased in the press room

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

waste sorting

advantage of keeping reusable waste

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

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

need to call service personnel to correct a machine problem?

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

result if correct shutdown procedures were not followed

need for correct shutdown procedures that are conducted with fellow workers

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

clear labelling of the printed product prior to removal from the press room

use of completed records 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 and where they are 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.

Specialised may include:

specialised within this context relates to the set up and production of print runs that involve new products, or a new mix of substrates and inks that requires a certain amount of problem solving and experimentation with the substrate and press settings. The set up of equipment and production involves the development of new set up and production approaches based on solving technical problems arising from new product or equipment combinations.

Inks/coatings may include:

wide range of inks commonly used in printing.

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.

Colour matching systems may include:

use of densitometers and/or spectrophotometry.

Design may include:

complex graphics and text. Critical "tight" registration, fit and position, registration for quality print requirements.

Substrate types may include:

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

Substrate handling may include:

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