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Evidence Guide: ICPPRN451 - Set up for complex relief 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

 

ICPPRN451 - Set up for complex relief printing

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

Confirm non-routine job specifications

  1. Job requirements are read and interpreted from job documentation or production control system
  2. Set up is planned and carried out correctly in minimum time with minimum waste
  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:

 

 

 

 

 

 

 

Set up is planned and carried out correctly in minimum time with minimum waste

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. Inks, dyes or additives are selected according to job specifications and end-user requirements
  2. Quality and suitability of inks, dyes or additives are checked and appropriate action is taken
  3. 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
  4. Correct colour and weight/volume of ink are mixed and prepared to match the requirements of the printing process and job specifications
  5. Formulation of the ink, colour match and the approved colour are appropriately recorded
  6. 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 prolong shelf life
Inks, dyes or additives are selected according to 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 are mixed and prepared to match the requirements of the printing process and job specifications

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Formulation of the ink, colour match and the 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 prolong shelf life

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Set up machine for complex relief printing

  1. Appropriate relief plates are selected and secured to the machine
  2. Relief polymer plates/forme are set up and adjusted according to job specifications (platen)
  3. Relief polymer cylinders are set up and adjusted according to job specifications (platen)
  4. Impression is set up and adjusted according to job specifications (platen and rotary)
  5. Inking system is set up and adjusted according to the relief process and job specifications (platen and rotary)
  6. Drying system is set up and adjusted according to job specifications
Appropriate relief plates are selected and secured to the machine

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Relief polymer plates/forme are set up and adjusted according to job specifications (platen)

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Relief polymer cylinders are set up and adjusted according to job specifications (platen)

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Impression is set up and adjusted according to job specifications (platen and rotary)

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Inking system is set up and adjusted according to the relief process and job specifications (platen and rotary)

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. Proof is visually inspected and/or tested or laboratory testing organised according to enterprise procedures
  4. Production does not commence without client or relevant authority approval where appropriate
  5. Results are interpreted and adjustment changes 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:

 

 

 

 

 

 

 

Proof is visually inspected and/or tested or laboratory testing organised according to enterprise procedures

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Results are interpreted and adjustment changes 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 non-routine job specifications

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

1.2 Set up is planned and carried out correctly in minimum time with minimum waste

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

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

3.3 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

3.4 Correct colour and weight/volume of ink are mixed and prepared to match the requirements of the printing process and job specifications

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

3.6 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 prolong shelf life

4. Set up machine for complex relief printing

4.1 Appropriate relief plates are selected and secured to the machine

4.2 Relief polymer plates/forme are set up and adjusted according to job specifications (platen)

4.3 Relief polymer cylinders are set up and adjusted according to job specifications (platen)

4.4 Impression is set up and adjusted according to job specifications (platen and rotary)

4.5 Inking system is set up and adjusted according to the relief process and job specifications (platen and rotary)

4.6 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 Proof is visually inspected and/or tested or laboratory testing organised according to enterprise procedures

5.4 Production does not commence without client or relevant authority approval where appropriate

5.5 Results are interpreted and adjustment changes 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 non-routine job specifications

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

1.2 Set up is planned and carried out correctly in minimum time with minimum waste

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

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

3.3 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

3.4 Correct colour and weight/volume of ink are mixed and prepared to match the requirements of the printing process and job specifications

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

3.6 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 prolong shelf life

4. Set up machine for complex relief printing

4.1 Appropriate relief plates are selected and secured to the machine

4.2 Relief polymer plates/forme are set up and adjusted according to job specifications (platen)

4.3 Relief polymer cylinders are set up and adjusted according to job specifications (platen)

4.4 Impression is set up and adjusted according to job specifications (platen and rotary)

4.5 Inking system is set up and adjusted according to the relief process and job specifications (platen and rotary)

4.6 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 Proof is visually inspected and/or tested or laboratory testing organised according to enterprise procedures

5.4 Production does not commence without client or relevant authority approval where appropriate

5.5 Results are interpreted and adjustment changes are carried out according to product and machine specifications

Evidence of the ability to:

set up reel or sheet-fed platen, cylinder or rotary printing machines for non-routine print jobs

conduct a proof run and adjust settings to ensure production speeds are attained

correctly set up a relief printing machine for complex printing on TWO occasions (if possible using different substrates and including at least two in-line processes) according to manufacturer’s and job specifications, enterprise procedures and work health and safety (WHS) requirements.

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

Evidence of the ability to:

identify job requirements, and production problems that could eventuate by not reading and understanding job specifications

identify who to discuss any production problems with to

identify importance of relief plates, why hardness of the printing plate is important, and faults that may be detected on new plates

identify type of solvents to use on photopolymer plates

outline the purpose of binding plates after mounting, and explain V-block mounting

list checks to perform prior to cylinder installation

outline importance of machine frames, and why unit slides need to be kept clean

identify the optimum print sequence

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

For reel systems only

outline WHS precautions for installing printing cylinders in the machine

identify precautions to ensure plate/cylinders are not damaged during installation

outline the reel transportation system used on a web-fed machine, and the WHS precautions for when webbing up the machine

identify implications if the web is not spiced correctly

describe the process of determining position of the reel

outline implications if the brake tension is not set correctly

describe the function of the ‘dancer’ roller on a web machine and the function of nip rollers

outline the reel delivery system on a web-fed machine, and the WHS precautions for when setting up the reel delivery system

identify the function of web control in the rewind unit, and the slitter on a web machine

identify problems attributable to a blunt knife when sheeting

describe remedial steps if there is a possibility of ink marking in the rewind

list the main reason for blistering on a heat set machine

outline WHS precautions when slitting on the machine, and other operations that can be performed with in-line units

describe the machine position for in-line processing units and \ precautions for setting up in-line processing units

list reasons to top cut a printed product, and benefits of embossing in-line

For sheet systems only

outline the sheet transportation system on a sheet-fed machine, and WHS precautions for setting up the sheet transportation system

identify what causes more than one sheet to pick up in the feeder and describe why accurate feeder set up is essential

outline the process for determining position of the sheet prior to being transferred to the printing unit

outline the process for determining which front lays to use and the types of substrate that require additional front lays to be engaged, and why they are required

describe the sheet delivery system on a sheet-fed machine, what causes sheets to be delivered incorrectly, and WHS precautions for removing sheets from the delivery

describe adjustments needed if changing from lightweight to heavyweight stocks

identify the process for determining sheet release into the delivery

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

identify what causes printed sheets to set off in the delivery

identify how the possibility of set off in delivery can be reduced and how air blast assists sheet delivery

outline packing required in the tympan, and the ideal condition of the tympan

identify the process for determining printing pressure

outline how the correct top sheet tension is achieved when fitting a new tympan, and print faults that can occur if the tympan is not tensioned correctly

identify how to lengthen print length on this type of press, and to shorten the print length

outline WHS concerns related to preparation of inks and additives, and details required to check inks’ suitability for the printing process

outline why it might be necessary to mix an additive into ink and any special end-use requirements that may be necessary

outline how a spectrophotometer can be used to assess ink colour, and formula for calculating the correct quantity of ink in relief printing

identify print faults if excessive driers are mixed into ink, and precautions to minimise waste when preparing ink

identify the shelf life of most ink and the conditions relevant to storage of inks and additives

list conventions for labelling mixed inks

identify the process for setting up the printing machine and major WHS concerns

name the order eccentric or concentric roller adjustments should be made and the width of the contact stripe between two rollers

outline the process for determining ink duct setting, and the ideal setting

name recommended degrees shore hardness for forme rollers

describe types of ink drying/curing systems and how the drying unit cures ink

state what happens if there is excessive pressure when top cutting and excessive pressure when cutting and creasing

describe the effect of differing tooth counts on perforated products

outline problems of solving proofing and adjustment

outline the operation of the true inch function fitted to some machines, and problems that may cause the machine to keep stopping

outline checks necessary prior to engaging the impression, and checks to be performed when running the machine

describe the effect position of certain guards has on operation of the machine

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

name aids available for testing the machine proof, where testing should take place, and tests necessary for each job

name the function of a polarisation filter in a densitometer

describe ideal conditions for inspecting the proof

explain why it is necessary to use visual aids on the printed substrate

describe causes of a halo effect on the image

outline methods to check and adjust ink colour and consistency

describe adjustments that may cause mis-register

describe adjustments to position the image laterally and circumferentially

explain how changing colour sequence can effect the final colour cast

identify causes of excessive mechanical dot gain and the difference between mechanical and optical dot gain

describe the process for final approval before a print run

identify machine manuals, safety and other documentation relevant to this task, where are they kept, information included in these documents, and other sources of available information.

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 up and adjusting MUST include EITHER:

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 systems

Sheet pick-up and transportation systems

Transfer and control systems

Set off/marking prevention devices