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Evidence Guide: ICPPRN431 - Set up for complex lithographic printing

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

 

ICPPRN431 - Set up for complex lithographic printing

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

Confirm complex job specifications

  1. Job requirements are read and interpreted from job documentation or production control system
  2. Non-routine set up is planned and carried out correctly in minimum time with minimum wastage
  3. Availability of all job related components is checked
Job requirements are read and interpreted from job documentation or production control system

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Non-routine set up is planned and carried out correctly in minimum time with minimum wastage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Availability of all job related components is checked

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up delivery systems

  1. Delivery systems are set up and adjusted according to job specifications
  2. Substrate is added to and removed from process according to job specifications
Delivery systems are set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select and prepare inks and additives

  1. Colour sequence for job is considered and confirmed
  2. Inks, dyes or additives are selected according to non-routine job specifications and end-user requirements
  3. Quality and suitability of inks, dyes or additives are checked and appropriate action is taken
  4. Inks, dyes and additives are prepared according to work health and safety (WHS) requirements, and manufacturer’s/supplier’s instructions, with suitable precautions to minimise waste
  5. Correct colour and weight/volume of ink is mixed and prepared to match requirements of the job specification and the non-routine printing process
  6. Formulation of ink, colour match and approved colour are appropriately recorded
  7. Inks, dyes and additives are appropriately labelled, handled and stored according to manufacturer’s/ supplier’s instructions to prevent damage and hazards to personnel and to prolong shelf life
Colour sequence for job is considered and confirmed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inks, dyes or additives are selected according to non-routine job specifications and end-user requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Quality and suitability of inks, dyes or additives are checked and appropriate action is taken

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inks, dyes and additives are prepared according to work health and safety (WHS) requirements, and manufacturer’s/supplier’s instructions, with suitable precautions to minimise waste

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Correct colour and weight/volume of ink is mixed and prepared to match requirements of the job specification and the non-routine printing process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Formulation of ink, colour match and approved colour are appropriately recorded

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inks, dyes and additives are appropriately labelled, handled and stored according to manufacturer’s/ supplier’s instructions to prevent damage and hazards to personnel and to prolong shelf life

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up machine for complex lithographic printing

  1. Plate cylinder is set up and adjusted according to job specifications
  2. Plates are correctly mounted according to machine specification and in a safe manner
  3. Blanket and blanket cylinder are set up and adjusted according to job specifications
  4. Impression cylinder is set up and adjusted according to job specifications
  5. Inking system is set up and adjusted according to the lithographic process and job specifications
  6. Dampening system is set up and adjusted according to job specifications
  7. Drying system is set up and adjusted according to job specifications
Plate cylinder is set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plates are correctly mounted according to machine specification and in a safe manner

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Blanket and blanket cylinder are set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Impression cylinder is set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inking system is set up and adjusted according to the lithographic process and job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Dampening system is set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Drying system is set up and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct proof run

  1. Material to be used for proof is organised correctly
  2. Machine is operated according to manufacturer’s and enterprise procedures to produce a specified proof
  3. Production does not commence without client approval or authority where appropriate
  4. Results are interpreted and adjustments are carried out according to product and machine specifications
Material to be used for proof is organised correctly

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Machine is operated according to manufacturer’s and enterprise procedures to produce a specified proof

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Production does not commence without client approval or authority where appropriate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Results are interpreted and adjustments are carried out according to product and machine specifications

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. Confirm complex job specifications

1.1 Job requirements are read and interpreted from job documentation or production control system

1.2 Non-routine set up is planned and carried out correctly in minimum time with minimum wastage

1.3 Availability of all job related components is checked

2. Set up delivery systems

2.1 Delivery systems are set up and adjusted according to job specifications

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

3. Select and prepare inks and additives

3.1 Colour sequence for job is considered and confirmed

3.2 Inks, dyes or additives are selected according to non-routine job specifications and end-user requirements

3.3 Quality and suitability of inks, dyes or additives are checked and appropriate action is taken

3.4 Inks, dyes and additives are prepared according to work health and safety (WHS) requirements, and manufacturer’s/supplier’s instructions, with suitable precautions to minimise waste

3.5 Correct colour and weight/volume of ink is mixed and prepared to match requirements of the job specification and the non-routine printing process

3.6 Formulation of ink, colour match and approved colour are appropriately recorded

3.7 Inks, dyes and additives are appropriately labelled, handled and stored according to manufacturer’s/ supplier’s instructions to prevent damage and hazards to personnel and to prolong shelf life

4. Set up machine for complex lithographic printing

4.1 Plate cylinder is set up and adjusted according to job specifications

4.2 Plates are correctly mounted according to machine specification and in a safe manner

4.3 Blanket and blanket cylinder are set up and adjusted according to job specifications

4.4 Impression cylinder is set up and adjusted according to job specifications

4.5 Inking system is set up and adjusted according to the lithographic process and job specifications

4.6 Dampening system is set up and adjusted according to job specifications

4.7 Drying system is set up and adjusted according to job specifications

5. Conduct proof run

5.1 Material to be used for proof is organised correctly

5.2 Machine is operated according to manufacturer’s and enterprise procedures to produce a specified proof

5.3 Production does not commence without client approval or authority where appropriate

5.4 Results are interpreted and adjustments are carried out according to product and machine specifications

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. Confirm complex job specifications

1.1 Job requirements are read and interpreted from job documentation or production control system

1.2 Non-routine set up is planned and carried out correctly in minimum time with minimum wastage

1.3 Availability of all job related components is checked

2. Set up delivery systems

2.1 Delivery systems are set up and adjusted according to job specifications

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

3. Select and prepare inks and additives

3.1 Colour sequence for job is considered and confirmed

3.2 Inks, dyes or additives are selected according to non-routine job specifications and end-user requirements

3.3 Quality and suitability of inks, dyes or additives are checked and appropriate action is taken

3.4 Inks, dyes and additives are prepared according to work health and safety (WHS) requirements, and manufacturer’s/supplier’s instructions, with suitable precautions to minimise waste

3.5 Correct colour and weight/volume of ink is mixed and prepared to match requirements of the job specification and the non-routine printing process

3.6 Formulation of ink, colour match and approved colour are appropriately recorded

3.7 Inks, dyes and additives are appropriately labelled, handled and stored according to manufacturer’s/ supplier’s instructions to prevent damage and hazards to personnel and to prolong shelf life

4. Set up machine for complex lithographic printing

4.1 Plate cylinder is set up and adjusted according to job specifications

4.2 Plates are correctly mounted according to machine specification and in a safe manner

4.3 Blanket and blanket cylinder are set up and adjusted according to job specifications

4.4 Impression cylinder is set up and adjusted according to job specifications

4.5 Inking system is set up and adjusted according to the lithographic process and job specifications

4.6 Dampening system is set up and adjusted according to job specifications

4.7 Drying system is set up and adjusted according to job specifications

5. Conduct proof run

5.1 Material to be used for proof is organised correctly

5.2 Machine is operated according to manufacturer’s and enterprise procedures to produce a specified proof

5.3 Production does not commence without client approval or authority where appropriate

5.4 Results are interpreted and adjustments are carried out according to product and machine specifications

Evidence of the ability to:

set up a lithographic printing machine for a complex job on TWO occasions (if possible using different substrates and sheet sizes if sheet-fed and, if possible, including at least two in-line processes) according to job and manufacturer’s specifications, and enterprise procedures

set up either wide or narrow reel or sheet-fed lithographic printing machines for non-routine print jobs

conduct proof run and adjust settings to ensure production speeds are attained in minimum time with minimum wastage

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 why it is necessary to ensure the job specifications are read and properly understood

describe production problems that can eventuate from not reading and understanding the job specifications

identify who to discuss any production problems with

describe problems that can result from the plate cylinder not being cleaned prior to plate fitting

explain what can happen if the plate is over-tensioned during fitting

explain faults that can result from a plate being under-tensioned

describe why accurate plate bending is necessary on a web-fed machine

outline considerations for deciding the colour sequence

describe the visual aid on the plate that identifies colour of ink to be used

For reel systems only

list work health and safety (WHS) precautions for webbing up the machine

explain how to determine position of the reel

describe what can happen if the brake tension is not set correctly

outline the function of the ‘Dancer’ roller on a web machine

demonstrate knowledge of how to determine the position of bustle wheels

explain what can happen if the web is not spliced correctly

demonstrate knowledge of how the particular web viewing device works

explain how to control the web in the rewind unit

describe the function of a slitter on a web machine

list possible causes of the web to jam up in the folder

explain the need to disengage folder if sheeting

describe problems that can be attributed to a blunt knife when sheeting

name a safety feature in the delivery system for when the web jams up

describe which fold is always made with the grain of the web

identify the type of folder that folds the web in half in the direction of the web grain

list remedial steps if there is a possibility of the ink marking in the folder

outline main reasons for having a silicone applicator on a web machine

list main reasons for blistering on a heat-set machine

identify substances that evaporate after ink is placed in the oven

describe the function of chill rollers on a web machine

For sheet systems only

list WHS factors to consider when setting up sheet transportation and delivery systems

explain what can cause more than one sheet to be picked up in the feeder

outline the need for accurate feeder set up

identify what determines position of the sheet prior to being transferred to the printing unit

explain how to decide which front lays to use

describe the type of substrate that requires additional front lays to be engaged

explain the need for additional front lays when printing this type of substrate

list WHS precautions for setting up the delivery

list WHS precautions for removing sheets from the delivery

explain the cause of sheets being delivered incorrectly

describe necessary adjustments if changing from lightweight to heavyweight stocks

explain what determines sheet release into the delivery

outline problems from excessive use of anti-set off spray powder

list possible causes of printed sheets to set off in the delivery

explain how to reduce possibility of set off in the delivery

identify faults that may be created by excess vacuum on the slow-down wheels

outline the procedure to lengthen print length on this type of press

outline the procedure to shorten print length on this type of press

list WHS concerns for preparation of inks and additives

identify details to check an ink’s suitability for the printing process

outline special end-use requirements that may be necessary

explain why it may be necessary to mix an additive into the ink

explain how a spectrophotometer can be used to assess colour of an ink

describe the formula for calculating correct quantity of lithographic ink

name a print fault likely if excessive driers are mixed into ink

describe precautions to minimise waste when preparing ink

describe how to determine shelf life of most inks

outline conditions relevant to storage of inks and additives

list conventions to follow when labelling mixed inks

list WHS factors to consider when setting up the machine

describe checks to be made on the plate prior to fitting

outline how much plate packing is required

explain normal printing pressure required between plate and blanket

explain how to determine correct printing pressure between blanket and stock

outline ideal blanket surface condition

explain how to achieve correct blanket tension when fitting a new blanket

identify print faults likely if the impression cylinder is not maintained

describe the order eccentric or concentric roller adjustments should be made in

list the contact stripe width required between two rollers when setting the rollers

demonstrate how to determine ink duct setting

explain the ideal ink duct sweep setting

describe recommended degrees of shore hardness for bare back and conventional dampeners

describe the best conductivity of fountain solution

explain why it is necessary to constantly check conductivity of fountain solution

demonstrate knowledge of how to change the amount of fountain solution across the plate surface

explain why it may be necessary to adjust fountain solution laterally

explain the effect of engaging the perfecting unit on the run

list WHS precautions for slitting on the machine

describe operations performed with in-line units

demonstrate knowledge of machine position used to engage in-line processing units

identify precautions for setting up in-line processing units

list reasons for a printed product to be punched

outline what to consider when setting hole punching in relation to repeat length

describe the result of excessive pressure on the slitters

describe the operation of the true inch function fitted to some machines

describe problems that may cause the machine to keep stopping

list necessary checks prior to engaging the impression

list checks performed when running the machine

explain the effect the position of certain guards have on machine operation

outline how steps involved in operating the machine are communicated to other team members

name various aids available for testing the machine proof

identify where testing should take place

explain the function of a polarisation filter in a densitometer

describe the ideal conditions for inspecting the proof

outline the need to use visual aids on the printed sheets

identify the acceptable wet trap value range for lithographic inks

explain what indicates optimum solid ink density, in the absence of a proof

describe the result of low solid ink density and excessive dot gain

list methods to check and adjust ink colour and consistency

explain adjustments that may cause mis-register

explain adjustments required to position the image laterally

list adjustments made to position the image circumferentially

list adjustments made to position the image diagonally

describe the effect of changing colour sequence on the wet trap value

explain the difference between mechanical and optical dot gain

describe factors that can cause excessive mechanical dot gain

identify who has responsibility for the final approval of the job

locate machine manuals, safety and other documentation relevant to this task and outline the information included in these documents.

Range Statement

This section specifies different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Delivery systems MUST include EITHER:

reel

OR

sheet

Setting and adjusting MUST include EITHER:

set up options for unwind and rewind reels

webbing procedures and web control system

splicing/joining reels

printed web viewing devices

folder and sheeter

set off / marking prevention devices

OR

feeder and delivery sections

sheet pick-up, transportation and control and transfer systems

set off / marking prevention devices