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Evidence Guide: ICPPRN531 - Set up for specialised 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

 

ICPPRN531 - Set up for specialised lithographic printing

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

Confirm specialised job specifications

  1. Job requirements are read and interpreted from job documentation or production control system
  2. 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:

 

 

 

 

 

 

 

Availability of all job related components is checked

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plan and carry out specialised set-up

  1. Specialised job specifications are identified and analysed
  2. Special set-up requirements are determined
  3. Specialised set-up is completed in minimum time with minimum wastage
Specialised job specifications are identified and analysed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Special set-up requirements are determined

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Specialised set-up is completed in minimum time with minimum wastage

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 the job is considered and confirmed
  2. Inks, dyes or additives are evaluated with reference to specialised requirements
  3. Inks, dyes or additives are selected according to job specifications
  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 are mixed and prepared to match requirements of the printing process and job specifications
  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 the job is considered and confirmed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inks, dyes or additives are evaluated with reference to specialised requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inks, dyes or additives are selected according to job specifications

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 requirements of the printing process and job specifications

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 specialised lithographic printing

  1. Plate cylinder is set up, evaluated and adjusted according to job specifications
  2. Lithographic plate is selected and prepared for installation
  3. Plates are correctly mounted safely and according to job specifications
  4. Blanket and blanket cylinder are set up, evaluated and adjusted according to job specifications
  5. Impression cylinder is set up, evaluated and adjusted according to job specifications
  6. Inking system is set up, evaluated and adjusted according to the lithographic process and job specifications
  7. Dampening system is set up, evaluated and adjusted according to job specifications
  8. Drying system is set up, evaluated and adjusted according to job specifications
Plate cylinder is set up, evaluated and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Lithographic plate is selected and prepared for installation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plates are correctly mounted safely and according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Impression cylinder is set up, evaluated and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Dampening system is set up, evaluated and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Drying system is set up, evaluated and adjusted according to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct specialised proof run

  1. Material to be used for proof is organised correctly
  2. Machine is operated according to manufacturer’s specifications and enterprise procedures to produce a specified proof
  3. Specialised proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures
  4. Production does not commence without client approval or authority where appropriate
  5. Results are interpreted and evaluated with adjustments 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 specifications and enterprise procedures to produce a specified proof

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Production does not commence without client approval or authority where appropriate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

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:

 

 

 

 

 

 

 

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 specialised job specifications

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

1.2 Availability of all job related components is checked

2. Plan and carry out specialised set-up

2.1 Specialised job specifications are identified and analysed

2.2 Special set-up requirements are determined

2.3 Specialised set-up is completed in minimum time with minimum wastage

3. Set up delivery systems

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

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

4. Select and prepare inks and additives

4.1 Colour sequence for the job is considered and confirmed

4.2 Inks, dyes or additives are evaluated with reference to specialised requirements

4.3 Inks, dyes or additives are selected according to job specifications

4.4 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

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

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

4.7 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

5. Set up machine for specialised lithographic printing

5.1 Plate cylinder is set up, evaluated and adjusted according to job specifications

5.2 Lithographic plate is selected and prepared for installation

5.3 Plates are correctly mounted safely and according to job specifications

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

5.5 Impression cylinder is set up, evaluated and adjusted according to job specifications

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

5.7 Dampening system is set up, evaluated and adjusted according to job specifications

5.8 Drying system is set up, evaluated and adjusted according to job specifications

6. Conduct specialised proof run

6.1 Material to be used for proof is organised correctly

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

6.3 Specialised proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures

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

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

7. Troubleshoot machinery and material problems

7.1 Corrective or preventive action is recommended and implemented where appropriate

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

7.3 Changes are monitored to confirm improvement to production efficiency

7.4 Ongoing problems are reported according to 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. Confirm specialised job specifications

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

1.2 Availability of all job related components is checked

2. Plan and carry out specialised set-up

2.1 Specialised job specifications are identified and analysed

2.2 Special set-up requirements are determined

2.3 Specialised set-up is completed in minimum time with minimum wastage

3. Set up delivery systems

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

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

4. Select and prepare inks and additives

4.1 Colour sequence for the job is considered and confirmed

4.2 Inks, dyes or additives are evaluated with reference to specialised requirements

4.3 Inks, dyes or additives are selected according to job specifications

4.4 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

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

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

4.7 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

5. Set up machine for specialised lithographic printing

5.1 Plate cylinder is set up, evaluated and adjusted according to job specifications

5.2 Lithographic plate is selected and prepared for installation

5.3 Plates are correctly mounted safely and according to job specifications

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

5.5 Impression cylinder is set up, evaluated and adjusted according to job specifications

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

5.7 Dampening system is set up, evaluated and adjusted according to job specifications

5.8 Drying system is set up, evaluated and adjusted according to job specifications

6. Conduct specialised proof run

6.1 Material to be used for proof is organised correctly

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

6.3 Specialised proof is visually inspected and/or tested or laboratory testing is organised according to enterprise procedures

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

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

7. Troubleshoot machinery and material problems

7.1 Corrective or preventive action is recommended and implemented where appropriate

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

7.3 Changes are monitored to confirm improvement to production efficiency

7.4 Ongoing problems are reported according to enterprise procedures

Evidence of the ability to:

set up either wide or narrow reel or sheet-fed lithographic printing machines for specialised print jobs; conduct a proof run and adjust settings to ensure production speeds are attained in minimum time with minimum wastage

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

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

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 that job specifications are read and properly understood

discuss production problems that could eventuate if job specifications are not read and properly understood

identify who to discuss any production problems with

outline the problem that can result from the plate cylinder not being cleaned prior to plate fitting

describe what happens if the plate is over tensioned during fitting

list faults that can result from a plate being under tensioned

For reel systems only

describe the need for accurate plate bending on a web-fed machine

explain how to determine position of the reel

describe the effect if brake tension is not set correctly

discuss the function of the ‘dancer’ roller on a web machine

outline how to determine position of the bustle wheels

explain what happens if the web is not spliced correctly

describe the operation of the particular web viewing device

explain how the web is controlled in the rewind unit

outline the function of a slitter on a web machine

discuss what causes the web to jam up in the folder

explain the need to disengage the folder if sheeting

list problems that attributable to a blunt knife when sheeting

outline the safety feature in the delivery system for when the web jams up

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

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

outline remedial steps to take if there is a possibility of ink marking in the folder

describe the main reason for having a silicone applicator on a web machine

explain the main reason for blistering on a heat set machine

explain what the oven evaporates from the ink

discuss the function of chill rollers on a web machine

For sheet systems only

describe work health and safety (WHS) factors to consider when setting up the sheet transportation and delivery systems

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

discuss the need for accurate feeder set up

describe how to determine position of the sheet prior to transfer to the printing unit

discuss how to determine which front lays to use

explain 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 the WHS precaution to observe when setting up the delivery

list WHS precautions for removing sheets from the delivery

explain what causes incorrect sheets delivery

outline necessary adjustments when changing from lightweight to heavyweight stocks

explain what determines sheet release into the delivery

list problems caused by excessive use of anti-set off spray powder

describe what might cause printed sheets to set off in the delivery

discuss how the possibility of set off in the delivery might be reduced

explain what can happen if there is excess vacuum on the slow-down wheels

list WHS precautions that must be observed when preparing inks and additives

describe the procedure used to lengthen print length on this type of press

discuss the procedure used to shorten print length on this type of press

outline considerations of deciding colour sequence

point out the visual aid on the plate that identifies ink colour to be used

discuss all WHS precautions for webbing up the machine

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

describe what special end-use requirements might be necessary

explain the reason for mixing additives in the ink

explain how a spectrophotometer can help assess ink colour

describe the formula for calculating correct quantity of lithographic ink

discuss the print fault that occurs if excessive driers are mixed into the ink

outline precautions to minimise waste when preparing ink

explain shelf life of most inks

discuss conditions relevant to storage of inks and additives

explain conventions for labelling mixed inks

list WHS factors for setting up the machine

describe checks made on the plate prior to fitting

explain how much plate packing is required

describe normal printing pressure required between plate and blanket

explain how to determine correct printing pressure between blanket and stock

explain the ideal blanket surface condition

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

describe print faults likely if the impression cylinder is not maintained

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

explain what the width of the contact stripe between two rollers should be when setting the rollers

describe how to determine the ink duct setting

explain the ideal ink duct sweep setting

discuss recommended degrees shore hardness for bare back and conventional dampeners

describe what conductivity of the fountain solution should be

explain why it is important to constantly check conductivity of the fountain solution

explain how to change the amount of fountain solution across the plate surface

outline the need to adjust the fountain solution laterally

list reasons it might be difficult to engage the perfecting unit

list types of ink drying/curing systems

describe what the true inch function feature fitted to some machines does

list what may cause the machine to keep stopping

outline necessary checks prior to engaging the impression

describe checks performed when running the machine

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

explain how steps involved in operating the machine should be communicated to other team members

describe aids available for the testing of the machine proof

discuss where testing should take place

explain the function of a polarisation filter in a densitometer

describe ideal conditions for inspecting the proof

discuss why it is necessary to use visual aids on the printed sheets

describe the acceptable wet trap value range for lithographic inks

outline an indication of optimum solid ink density in the absence of a proof

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

describe available methods to check and adjust ink colour and consistency

list adjustments that may cause mis-register

list adjustments made to position the image laterally

list adjustments made to position the image circumferentially

list adjustments made to position the image diagonally

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

explain the difference between mechanical and optical dot gain

outline the cause of excessive mechanical dot gain

explain who has responsibility for the final say in the OK of the job

identify machine manuals, safety and other documentation relevant to this task, where they are kept, and discuss 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 up 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, control and transfer systems

set off / marking prevention devices