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Evidence Guide: ICPPRN332 - 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

 

ICPPRN332 - 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 delivery system

  1. Delivery systems are monitored and adjusted to ensure efficient and continuous operation and ensure no damage to finished product
  2. Substrate is added to and removed from process according to job specifications
Delivery systems are monitored and adjusted to ensure efficient and continuous operation and ensure no damage to finished product

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Substrate is added to and removed from process according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain complex lithographic printing process

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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 work health and safety (WHS) 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 work health and safety (WHS) 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:

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:

 

 

 

 

 

 

 

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:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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:

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. Unused ink is correctly labelled and stored according to manufacturer’s/supplier’s 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 WHS requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Unused ink is correctly labelled and stored according to manufacturer’s/supplier’s 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:

 

 

 

 

 

 

 

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 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. Transportation 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 ready for next run, and liquid waste is disposed of according to company and regulatory requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Transportation and delivery systems are disengaged and cleaned ready for next run

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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:

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. Maintain non-routine operation of delivery system

1.1 Delivery systems are monitored and adjusted to ensure efficient and continuous operation and ensure no damage to finished product

1.2 Substrate is added to and removed from process according to job specifications

2. Maintain complex lithographic printing process

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

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

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

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

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

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

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

3. Maintain production process

3.1 Production process is operated in association with fellow workers and according to company specifications and planned daily schedule

3.2 Production is maintained within work health and safety (WHS) requirements and company and manufacturer’s specifications

3.3 Manual and/or automatic control is used as per specification

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

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

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

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

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

3.9 Waste is sorted according to enterprise procedures

4. Identify and investigate lithographic machine operating problem

4.1 Problem in lithographic machine operation is investigated

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

5. Rectify minor lithographic machine faults

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

5.2 Lithographic machine operation is checked to ensure correct operation

6. Conduct shutdown of production process

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

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

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

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

6.5 All product is removed from operating area

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

6.7 Repair/adjustment is verified prior to resumption of operations

7. Clean and wash up printing machine at end of print run

7.1 Cylinders, plate and roller surfaces are cleaned ready for next run

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

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

7.4 Transportation and delivery systems are disengaged and cleaned ready for next run

8. Complete records

8.1 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. Maintain non-routine operation of delivery system

1.1 Delivery systems are monitored and adjusted to ensure efficient and continuous operation and ensure no damage to finished product

1.2 Substrate is added to and removed from process according to job specifications

2. Maintain complex lithographic printing process

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

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

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

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

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

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

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

3. Maintain production process

3.1 Production process is operated in association with fellow workers and according to company specifications and planned daily schedule

3.2 Production is maintained within work health and safety (WHS) requirements and company and manufacturer’s specifications

3.3 Manual and/or automatic control is used as per specification

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

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

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

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

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

3.9 Waste is sorted according to enterprise procedures

4. Identify and investigate lithographic machine operating problem

4.1 Problem in lithographic machine operation is investigated

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

5. Rectify minor lithographic machine faults

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

5.2 Lithographic machine operation is checked to ensure correct operation

6. Conduct shutdown of production process

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

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

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

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

6.5 All product is removed from operating area

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

6.7 Repair/adjustment is verified prior to resumption of operations

7. Clean and wash up printing machine at end of print run

7.1 Cylinders, plate and roller surfaces are cleaned ready for next run

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

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

7.4 Transportation and delivery systems are disengaged and cleaned ready for next run

8. Complete records

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

Evidence of the ability to:

operate a lithographic press ensuring an efficient non-routine production flow that maintains product quality standards; production problems are anticipated and rectified with minimum downtime; and the machine is correctly shut down and cleaned according to work health and safety (WHS) guidelines

demonstrate use of control, monitoring and data entry systems

monitor production output and make necessary adjustments to maintain print quality on a lithographic machine while 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 and enterprise procedures.

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:

For reel systems only

Reel transportation and web control

explain WHS requirements for operating the reel transportation system

explain what can cause the reel to wander

describe what can cause the web to break at the unwind unit

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

identify the print fault that results from the reel being run out of centre

list faults in the unwind section that can cause a web break

Reel delivery for rewinding and sheeting

explain WHS risks associated with rewinding

identify what safety feature is in the delivery system for when the web jams

explain why the sheet cut-off wanders

describe the effect of poorly adjusted nip rollers when rewinding and sheeting

outline further operations required for printed reels after removal from the printing machine

explain how to store the printed job after removal from the printing machine

explain why it is necessary to label each printed reel

For Sheet Systems Only

Sheet transportation and transfer system

explain WHS requirements associated with operating the sheet transportation system

explain the result of worn suckers at the feeder suction head

identify the type of two sheet detection on this machine

discuss how much movement the sheet should have when being registered by the side lay

explain possible causes of mis-register of the sheet at the feeder

explain visible signs of the sheet being registered in the feeder

explain how gripper malfunction can affect sheet control and transfer

explain when to adjust sheet transfer mechanisms

list causes of the feeder stack becoming uneven

explain what happens if the feeder stack is not loaded levelly

explain how unevenness of the feeder stack can be rectified

In-line processes

explain how consistency of the punching unit is checked

describe the outcome of excessive pressure on the slitters

describe the outcome of a dirty former

describe the outcome of defective pins in the folder

describe the outcome of adjusting rollers at the base of the former

list causes of the web jamming up in the folder

Sheet delivery

explain WHS risks associated with sheeting

describe the effect machine speed has on sheet delivery

explain advantages of spraying moving sheets with anti-set-off powder in the delivery

name items in the delivery that can mark the printed image

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

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

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

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

Printing unit

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

explain the effect of a sticky blanket surface

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

outline causes of blanket packing-creep during printing

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

describe the cause of ink lying back in the duct

list causes of ink stripping on the inking rollers

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

describe the recommended pH range for fountain solutions

list causes of conductivity of the fountain solution changing over an eight-hour shift

outline problems caused by excessive conductivity of the fountain solutions

Drying unit

explain the link between driers and set-off and marking

identify what causes UV ink to dry

identify what causes the substrate to blister

describe what happens in the chillers if the drying temperature was too low

outline the effect of incorrect drying temperature on the finished product

Maintaining production process

explain the effect of inadequate communication within the work team

identify safety features within the organisation that help maintain effective production

explain ramifications of machine guards being removed and/or micro switches being disconnected on a machine

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

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

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

outline the most accurate method of checking register during a production run

explain why it is important to take immediate action when production problems are anticipated

explain what action is taken to eliminate further processing of unacceptable printed product

outline the effect of increases in relative humidity in the press room

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

explain why waste should be sorted and the advantages of keeping reusable waste

explain industry standards to enhance effective communication with the client

discuss necessary procedures the client should follow to OK a printed product

Lithographic machine operating problems

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

identify enterprise procedures in place to report any machine operating problems

Shutdown procedures

list advantages of proper labelling and storage of excess inks and materials

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

Cleaning and washing the printing unit

explain work health and safety (WHS) requirements for handling ink

explain safety precautions for cleaning the printing cylinders

describe the washing procedure for offset rubber blanket

determine how plates can be stored to minimise damage

Cleaning feed, transportation, delivery and in line sections

explain WHS precautions for cleaning these sections of the machine

Completing production records

explain how completed records are used in the final analysis of the job

outline benefits of comprehensive records when considering the production of future jobs

Information sources

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

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

Monitoring and adjusting MUST include EITHER:

reel stand and rewind sections

web control system

sheeting section

set off / marking prevention systems

OR

feeder and delivery systems

sheet pick-up and transportation system

transfer systems

set/ off/marking prevention system