Unit of competency details

Unit descriptor 

This unit describes the performance outcomes, skills and knowledge required to produce complex laminated product.

Application of the unit 

This unit requires the individual to monitor and adjust machinery, maintain transportation of the substrate, identify and rectify faults and correctly clean and shut down equipment.

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 operation of reel transportation system on web-fed machine

1.1. Reel stand is monitored and adjusted to ensure efficient continuous operation

1.2. Web control system is monitored and adjusted to ensure correct tension and accurate continuous positioning of the web for efficient operation

1.3. Substrate  is added to the process according to job specifications

2. Maintain operation of reel delivery system on web-fed machine

2.1. Reel rewind section is monitored and adjusted to maintain correct tension and to ensure no marks, blemishes or damage to finished product

2.2. Substrate is removed from the process according to job specifications

2.3. Sheeting section is monitored and adjusted to ensure quality and efficient product delivery

3. Maintain complex laminating process

3.1. Registration of laminating  is monitored and adjusted to ensure quality of product meets the standard of the approved sample

3.2. Pressures are monitored and adjusted to ensure quality of product meets the standard of the approved sample

3.3. Adhesion is monitored and adjusted to ensure quality of product meets the standard of the approved sample

4. Maintain production processes

4.1. In -line  printing/coating/converting/binding/finishing process(es) are monitored and adjusted to ensure the quality of product meets the standard of the approved sample

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

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

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

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

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

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

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

4.9. Waste is sorted according to enterprise procedures

5. Identify and rectify machine operating problem

5.1. Problems in laminating machine are identified and reported according to enterprise procedures

5.2. Adjustments or corrections are carried out according to specified procedures and are consistent with operator's skill level

5.3. Laminating 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 OHS requirements

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

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

6.5. Repair/adjustment is verified prior to resumption of operations

7. Clean laminating machine at end of run

7.1. Laminating machine is disengaged and cleaned ready for next run

7.2. Adhesive  system is washed up ready for next run and liquid waste is disposed of according to regulatory requirements and enterprise procedures

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

7.4. Reel feed, transportation and delivery systems are disengaged and cleaned ready for next run

7.5. Production records or other documentation are accurately completed where required by 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 skills when monitoring and verifying performance using process control systems
• planning and organising when following the correct shutdown sequence
• teamwork when conducting the shutdown with fellow workers
• using technology when adjusting machinery to improve performance and ensuring correct and continuous feeding and delivery of substrate
• problem solving when identifying problems and faults and developing solutions

Required knowledge 

• OHS factors that must be considered when operating web machine transport and delivery systems
• areas of the reel stand that should be monitored to ensure trouble-free operation
• area of the web control system that should be adjusted to maintain correct web tension
• area of the web control system that should be adjusted to maintain correct positioning of the web
• areas of the delivery system that should be observed to maintain tension
• areas of the delivery system that should be observed to prevent damage to the finished product
• checks to be made when substrate is removed from the machine
• OHS factors that must be considered when maintaining the laminating process
• ways in which registration of laminating s assured
• ways in which adjustment achieved
• ways in which the pressure can be adjusted during production
• areas of production that must be monitored to ensure trouble-free operations
• OHS factors that must be considered when maintaining the complex in-line processes
• areas of the in-line processes that should be monitored to ensure a quality product
• laminating problems that may occur during the operation of the machine
• adjustments or correction procedures that may need to be made to ensure accurate operation of the process
• OHS factors that must be considered when shutting down and cleaning the machine
• checks to be made when correctly shutting down the machine
• areas of the machine that need regular cleaning
• materials that need to be cleaned from the machine
• keeping the machine clear of surface rust (condensation)
• recommended cleaning agents
• production records that need to be kept or written up
• information that should be included in this reporting procedure
• quality aspects that should be considered in a completed laminated job
• steps that should be taken to ensure that important features of the production control system are followed
• alterations to production to meet client requirements
• items that must be checked against the client's sample
• 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 following is essential:

• produce complex laminated product that meets job specifications, production timeframes and quality standards. At least one machine used must be fully automated
• demonstrate an ability to find and use information relevant to the task from a variety of information sources
• competency must be demonstrated on any TWO of moisture, chemical and extrusion laminating. For each process operate a laminating machine (2 or more ply) to complete TWO jobs on different substrates and of different sizes (large/small formats including one in-line process) while demonstrating splicing techniques in minimum time according to manufacturer's and job specifications, enterprise procedures and the listed Performance Criteria
• demonstrate use of computerised control, monitoring and data entry systems if available and appropriate.

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.

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.

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.

Substrate delivery  may include:

• wide and narrow reel handling systems.

Laminating process  may include:

• moisture, chemical and thermal cured, and extrusion process
• thermal fastening such as high frequency and head welding.

In -line process  may include:

• minor processes that are integral to this competency can include basic in-line operations such as perforating, numbering, slitting that do not in themselves constitute another defined unit of competency. Where a major in-line process is defined as a separate competency (eg flat-bed cutting, folding) it should be assessed as such.

Adhesives  may include:

• range of one or two component adhesives used in complex laminating.

Laminating units  may include:

• range of manual, semi-automated, fully automated and computerised process control.

Substrate types  may include:

• range of absorbent, non-absorbent, transparent and non-transparent substrates within the major categories of paper, plastics and metals.

Unit sector 

Competency field 

Converting, Binding and Finishing

Co-requisite units