Unit of competency details

Unit descriptor 

This unit describes the performance outcomes, skills and knowledge required to produce specialised gravure printed product that requires a certain amount of problem solving and experimentation with the substrate and press settings.

Application of the unit 

This unit requires the individual to operate a gravure press ensuring an efficient production flow for specialised jobs that maintains product quality standards. Any production problems are anticipated and rectified with minimum downtime. The machine is correctly shut down and cleaned according to OHS guidelines.

Prerequisite units 

Employability skills 

This unit contains employability skills.

Elements describe the essential outcomes of a unit of competency.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge section and the range statement. Assessment of performance is to be consistent with the evidence guide.

ELEMENT 

PERFORMANCE CRITERIA 

1. Maintain specialised gravure printing process

1.1. Gravure cylinder condition is monitored, evaluated and adjusted to ensure the quality of printed product meets the standard of the sample sheet

1.2. Gravure impression roller condition is monitored, evaluated and maintained to ensure that the quality of the specialised  printed product meets the standard of the sample sheet

1.3. Gravure inking system and doctor blade are monitored, evaluated and adjusted to ensure quality of specialised printed product meets the standard of sample sheet

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

1.5. In-line printing/converting/binding/finishing processes are monitored, evaluated and adjusted to ensure quality of specialised product meets the standard of the approved proof

2. Maintain specialised production process

2.1. Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule

2.2. Production is maintained according to OHS requirements, manufacturer's specifications and enterprise procedures

2.3. Manual and/or automatic control is used according to job specifications

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

2.5. Ink  performance, colour, register and position of print are monitored, evaluated and adjusted throughout production run

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

2.7. Process adjustments to eliminate problems are reported according to enterprise procedures

2.8. Waste is sorted according to enterprise procedures

3. Tune and adjust machinery

3.1. Idiosyncrasies of machines  are reviewed and adjustments or tuning undertaken to compensate or to exploit the idiosyncrasy, within manufacturer's specifications

3.2. Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate or to exploit the idiosyncrasy, within manufacturer's specifications

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

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

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

4. Troubleshoot machinery and material problems

4.1. Corrective or preventive action is recommended and implemented where appropriate

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

4.3. Changes are monitored to confirm improvement to production efficiency

4.4. Ongoing problems are reported according to enterprise procedures

5. Conduct shutdown of production process

5.1. Correct shutdown sequence is followed according to manufacturer's specifications and enterprise procedures

5.2. Shutdown is conducted in association with fellow workers and in compliance with OHS requirements

5.3. Unused ink is correctly labelled and stored according to manufacturer's/supplier's specifications and enterprise procedures

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

5.5. All product is removed from operating area

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

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

REQUIRED SKILLS AND KNOWLEDGE 

This section describes the skills and knowledge required for this unit.

Required skills 

• OHS in relation to operating machinery such as safely switching off machinery before cleaning is started
• communication of ideas and information by providing feedback to internal and external clients about printing, in-line processes and job specifications
• collecting, analysing and organising information by collating details of job and machine specifications and printing processes to ensure efficient production
• planning and organising activities by providing information about time and materials requirements for production scheduling
• teamwork when maintaining the production process in association with others
• mathematical ideas and techniques by calculating consumables and personnel requirements to meet production schedules
• problem-solving skills by identifying print problems and correcting during print run
• use of technology by using monitoring systems, understanding their output and feeding into production management systems

Required knowledge 

• reel to wander causes
• web break causes at the unwind unit
• difference between a "flying paster" and "zero speed" type reel-stand
• a Print fault that would result from the reel being run out of centre
• possible faults in the unwind section that could cause a web break
• OHS risks associated with rewinding and sheeting
• safety feature that is in the delivery system if the web jams up
• sheet cut-off wandering
• effect of poorly adjusted nip rollers when rewinding and sheeting
• effect of a build-up of ink on the impression cylinder on the printed product
• cause of the ink to foam in the ink tray
• effect of too much reducer in the ink
• an action that reduces wear of the doctor blade
• need for all solvents be removed from the final ink film
• link between driers and set off and marking
• cause substrate distortion
• effect in the chillers if the drying temperature was too low
• effect of incorrect drying temperature on the finished product
• effect of inadequate communication within the work team on a gravure printing machine
• safety features within the organisation that aid in maintaining effective production
• ramifications if machine guards are removed and/or micro switches are disconnected on a machine
• legally responsibility for the removal of machine guards and/or disconnection of micro switches
• most accurate method of checking register during a production run
• need to take immediate action when production problems are anticipated
• action that is taken to eliminate further processing of unacceptable printed product
• result to the substrate if the relative humidity is increased in the press room
• procedure to care for a newly delivered substrate to the press room
• waste sorting
• advantage of keeping reusable waste
• industry standards that can be applied to enhance effective communication with the client
• necessary procedures that the client should follow to "OK" a printed product
• need to call service personnel to correct a machine problem
• enterprise procedures that are in place to report any machine operating problems
• result if correct shutdown procedures were not followed
• need for correct shutdown procedures to be conducted with fellow workers
• advantages that result from proper labelling and storage of excess inks and materials
• clear labelling of the printed product prior to removal from the press room
• further operations that are required for printed reels upon removal from the printing machine
• storing the printed job after removal from the printing machine
• use of completed records in the final analysis of the job
• benefits of comprehensive records when considering the production of future jobs
• machine manuals, safety and other documentation that are relevant to this task and where they are kept and information that is included in these documents

EVIDENCE GUIDE 

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment 

Critical aspects for assessment and evidence required to demonstrate competency in this unit 

Evidence of the ability to:

• operate a gravure press ensuring an efficient specialised production flow that maintains product quality standards. Any production problems are rectified with minimum downtime. The machine is correctly shut down and cleaned according to OHS guidelines
• demonstrate use of computerised control, monitoring and data entry systems if available and appropriate
• demonstrate an ability to find and use information relevant to the task from a variety of information sources
• monitor production output and make necessary adjustments to maintain print quality on a gravure machine whilst producing a complex print on TWO occasions (if possible using different substrates and if possible including at least TWO in-line processes) according to job specifications, enterprise procedures and the Performance Criteria
• evidence for assessment may be gathered from assessment of the unit of competency alone or through an integrated assessment activity.

Context of and specific resources for assessment 

Assessment must ensure:

• assessment may take place on the job, off the job or a combination of these. Off the job assessment must be undertaken in a closely simulated workplace environment
• gravure printing machine.

Method of assessment 

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

• direct questioning combined with review of portfolios of evidence and third party workplace reports of on-the-job performance by the candidate.

Guidance information for assessment 

Holistic assessment with other units relevant to the industry sector, workplace and job role is recommended, for example:

• ICPPR421C Set up for complex gravure printing
• ICPPR322C Produce complex gravure printed product.

RANGE STATEMENT 

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Specialised  may include:

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

Inks /coatings  may include:

• range of inks commonly used in 3 or more colour printing, including standard and special colours.

Machines  may include:

• range of stack, in-line and central impression printing machines with manual, semi-automated, fully automated or computerised process control.

Colour matching systems  may include:

• use of viscosity controls, densitometers and spectrophotometry.

Design  may include:

• complex graphics and text. Critical "tight" registration, fit and position, registration should be at least that required for four-colour process work.

Substrate types  may include:

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

Substrate handling  may include:

• wide and narrow reel handling systems.

Unit sector 

Competency field 

Printing

Co-requisite units