ICP30503 Certificate III in Printing and Graphic Arts …1).doc · Web viewrelief printing does not necessarily create relief or raised lettering such as found in embossing and thermography

RPL Assessor KitICP30505Certificate III in Printing and Graphic Arts (Printing)Editable version

Skills First RPL Assessor Kits are developed by the State of Queensland (Department of Education, Training and the Arts) and are based on the Skills First philosophy of providing client focussed, streamlined, and flexible RPL.

The State of Queensland (Department of Education, Training and the Arts) is the copyright owner of material contained within the original RPL Assessor Kit.

Permission is given to Registered Training Organisations to use, reproduce and adapt this RPL Assessor Kit for their organisation’s RPL assessment purposes, provided such use, reproduction or adaptation is for non-commercial purposes.

The State of Queensland (Department of Education, Training and the Arts) disclaims any liability for any damage resulting from the use of the material (in either original or modified format) and will not be responsible for any loss, howsoever arising, from use of, or reliance on this material.

The original version of this RPL Assessor Kit is available free of charge at http://www.vetpd.qld.gov.au/teaching_learning_and_assessment/resources/index.html

If you would like any further information, please email [email protected]

mailto:[email protected]

http://www.vetpd.qld.gov.au/teaching_learning_and_assessment/resources/index.html

RPL Assessor KitICP30505 Certificate III in Printing and Graphic Arts (Printing)

HOW TO USE THIS RPL ASSESSOR KIT

This RPL Assessor Kit is divided into sections to allow you to easily access only those sections you require at any given time. These sections are:

SECTION A – Assessor Information

You need to read this information before conducting an assessment. It outlines the intent and processes surrounding this RPL assessment and how it differs from assessment undertaken following formal training.

SECTION B – Candidate Information and Application Forms

You give this information to the candidate. It tells them about the assessment process as well as containing simple forms for the applicant to fill out. From the information provided by the candidate on these forms, you will be able to gain a general understanding of the skills and experience the candidate may have, as well as potential referee contacts.

SECTION C – Competency Conversation

You use this section to determine and record candidate competence via a competency conversation. In other words, these questions guide your conversation with the applicant and assist in your assessment of their competence. The notes you take about this conversation are important evidence for assessment.

SECTION D – Practical Tasks and Observation Recording Sheets

You use this section to assess competencies through a practical demonstration of the candidate’s skills. It contains practical tasks/scenarios on the outcomes required to determine competency and a place to record your observation. The notes you take are important evidence for assessment.

SECTION E – Resources for Practical Tasks

You use this section to access required resources for performing practical tasks and scenarios.

SECTION F – Third Party Verification

You give this section to the referees to confirm the candidate’s skills and experience in this qualification/occupation. The referees may fill out the appropriate form and return to you to confirm your judgement. You may be able to complete this part of evidence gathering in person while at the workplace.

SECTION G – Assessment Tables

You use this table as a reference tool to see at a glance how units/elements of competency are assessed within the tool. All the elements and performance criteria within the competency units are cross-matched in this table with a corresponding assessment question/task/scenario. This allows you to validate the assessment process against the qualification.

Editable version Page 2 of 149




SECTION AAssessor Information

It is VITAL you read this information prior to commencing your RPL assessment. It provides generic information on assessment, as well as an overview of this streamlined RPL assessment process.



ADVICE FOR ASSESSORS

This RPL Assessor Kit streamlines the RPL assessment process for ICP30505 Certificate III in Printing and Graphic Arts (Printing) by taking a practical approach to RPL and increasing the use of on-site questioning and observation. This will assist in developing a “picture of the candidate’s skills and knowledge”. This picture can then be compared with industry standards enabling a determination of whether the candidate has achieved the required outcomes.

IMPORTANT ASPECTS TO REMEMBER:

A sound knowledge of assessment and the qualification is essential

It is important to have a good understanding of the competencies and qualification/s appropriate to the candidate’s goals.

Assessing a single unit of competency is rarely cost or time effective. Where possible, effort should be made to assess several units at the same time taking advantage of any commonality in content. This means looking at the whole picture of a particular job role as it happens in industry and assessing holistically. This saves valuable time in the assessment process.

Assessment involves judgement

This tool encourages the use of a “competency conversation” to maximise the candidate’s opportunities to demonstrate competence. This is NOT an oral exam. It is about using the two or three holistic questions provided to start a conversation with the candidate which draws out their actual individual experiences and relevant skills. In other words, it is about the assessor probing the candidate through a conversation to draw out further information on the candidate’s experience which may not be forthcoming due to nerves or confusion over technical terminology.

The tool also provides observable tasks to allow candidates to demonstrate skills.

Authentication/verification is integral to RPL assessment

It is critical information gleaned from the interview and observation be confirmed with those who can vouch for the candidate’s skill over time. Supervisors would generally perform this role. Authentication may also be done through conversation but it cannot be stressed enough that it is essential assessors take careful notes to back up and record their judgement.

Recording assessment is critical

Keep careful records of all aspects of conversations, skills demonstration or documentation viewed that support the claim of prior learning. Remember – the record is the document that makes sense of the assessment and why a particular judgment was made. Keeping detailed notes about the candidate’s response is vital, as is the rationale for judgement.

The assessment record is a legal document and must be signed, dated and stored according to requirements of the State Training Authority and the AQTF Standards for Registered Training Organisations.

Assessor summaries and other quality assurance documentation from your own Registered Training Organisation will also be required. For examples of assessment summary documentation, please see Assessment Guide Number 1: Training Package Assessment Materials Kit:http://resourcegenerator.gov.au/loadpage.asp?page=TPAGGuide01.htm


http://resourcegenerator.gov.au/loadpage.asp?page=TPAGGuide01.htm



To access further information on the principles assessment and dimensions of competency, you can visit Assessment Guide Number 1: Training Package Assessment Materials Kit.http://resourcegenerator.gov.au/loadpage.asp?page=TPAGGuide01.htm

To access further information on the Australian Qualifications Framework, you can visit:http://www.aqf.edu.au/


http://www.aqf.edu.au/




COMPETENCIES IN THIS RPL ASSESSMENT TOOL

ICP30505 CERTIFICATE III IN PRINTING AND GRAPHIC ARTS (PRINTING)

For this qualification 20 units must be completed comprising of 13 core units; and 7 elective units.

CORE UNITS

All core units must be undertaken, but in exceptional circumstances, up to two of the core units of competency can be exchanged with competency standards from the elective list below, except for the following three compulsory units:

ICPSU216A Inspect quality against required standards

ICPSU261A Follow OHS practices and identify environmental hazards

ICPSU262A Communicate in the workplace

Unit Code Unit Title Questions Practical




ICPKN312A Apply knowledge of printing machining

ICPSU201A Prepare, load and unload reels and cores on and off machine

ICPSU202A Prepare, load and unload product on and off machine

ICPSU203A Prepare and maintain the work area

ICPSU207A Prepare machine for operation (basic)

ICPSU208A Operate and monitor machines (basic)

ICPSU211A Prepare ink and additives

ICPSU224A Perform basic machine maintenance

ICPSU263A Perform basic industry calculations

ICPSU281A Use computer systems

ICPSU357A Apply quick changeover procedures



ELECTIVES (7 units required from the list below including one print process stream, one complex set up unit and three further electives)

Two elective units may be selected from other qualifications in the Printing and Graphics Training Package or from any other nationally endorsed Training Package, provided that the selected units are at the Certificate III or higher level.

Print process streams (3 units from one print process stream required)


ICPPR214A Produce basic flexographic printed product

ICPPR313A Set up for basic flexographic printing

ICPPR314A Produce complex flexographic printed product

ICPPR232A Produce basic lithographic printed product

ICPPR331A Set up for basic lithographic printing

ICPPR332A Produce complex lithographic printed product

ICPPR252A Produce basic relief printed product

ICPPR351A Set up for basic relief printing

ICPPR352A Produce complex relief printed product

Complex set up units (one of the following)


ICPPR413A Set up for complex flexographic printing

ICPPR431A Set up for complex lithographic printing

Further electives (three required)


ICPPP266A Make and proof relief plates

ICPPP268A Make photopolymer plates (flexographic)

ICPPP267A Produce offset lithographic plates



OVERVIEW OF RECOGNITION PROCESS

This kit has been developed to streamline the application for recognition of prior learning.


GAP TRAINING (ONLY IF

REQUIRED)

APPLICATION

PRACTICAL ASSESSMENT

COMPETENCY CONVERSATION

INTERVIEW and DOCUMENT REVIEW

ISSUE QUALIFICATION- RTO


RPL ASSESSMENT PROCESS FLOWCHART FOR ASSESSORS


Step 1:Analyse the application.

Identify links between any documents applicant provides

and competency units.Identify any key questions for

competency conversation.

Step 5:Identify any practical activities required to confirm competency

Observe practical activity

Step 7:Identify areas where 3rd party

verification is needed and inform candidate.

Confirm / Verify 3rd party reports

Step 3:Conduct competency

conversation

Step 2:Record results of analysis in table

at end of application

Step 4:Complete the Record of

Conversation sheets during the competency conversation

Step 6:Complete Practical Assessment

Tasks Observation Sheets

Step 8:Receive completed Third party

reports

* Remember RPL assessment is an accumulative process of collecting evidence.

Complete assessment sign off & file documentation.

Issue qualification / advise of gap training as appropriate

Assessment Activity Record keeping Activity


STEPS IN THE RPL PROCESS

1. Complete application

The candidate completes the application forms in SECTION B. It is important candidates provide as much information of their previous experience in the printing and graphic arts industry as is available.

Documents that may be available include but are not limited to:

any licences brief CV or work history certificates/results of assessment certificates – vendor training courses, in house courses, workshops, seminars certificates – club courses e.g. first aid, officials, surf life saving, etc photographs of work undertaken sample print work/products diaries/task sheets/job sheets/log books site training records site competencies held record membership of relevant professional associations hobbies/interests/special skills outside work references/letters from previous employers/supervisors industry awards any other documentation that may demonstrate industry experience

Candidates also need to provide contact details for one or two referees who can confirm their industry skills in context and over time.

To have skills formally recognised under the Australian Qualifications Framework, you must ensure the candidate’s skills meet industry standards.

2. Interview about candidate’s documentary information

Review the information provided by the candidate and arrange a time for both you and the candidate to discuss. Begin alignment of documentation and skills to the following qualification:

ICP30505 Certificate III in Printing and Graphic Arts (Printing)

The candidate will have the opportunity to discuss and identify previous experience with you. The available documents are step one in collecting information and you will need to determine which units of competency, if any, are fully covered at this stage. You use your own or your RTO’s assessment recording forms to record this stage of the assessment.

There may be instances where the candidate has little, or no, documentary information of industry experience. This is not a barrier to gaining recognition. This will just require you to rely on the questioning, practical assessment and referee validation phases of the RPL process.



3. Questions for the Competency Conversation

The bank of questions in SECTION C is the next phase in collecting evidence for the RPL process. The questions are designed to enable you to have a “competency conversation” with the candidate to further gain evidence of their past experience. REMEMBER, the primary focus is on the candidate’s experience.

Each question has “key points” to look for in responses. You may use the list of key points to formulate questions of your own if you wish, or contextualise the question to the candidate’s particular work situation. The Record of Conversation sheets indicate relevant content that should be sought. Place a tick next to each key point as you hear this topic being discussed during the conversation. You should read the “industry requirements” of each competency before the candidate answers the questions posed. You may also target the assessment to those aspects that present the greatest risk in the industry. Questions are aligned with the relevant unit/s of competency in SECTION G.

It is not intended every question for all competencies is asked, only those competencies the initial interview about the candidate’s documentary evidence has failed to fully address. The question bank covers most but not all units in the kit. Units without questions are covered in the practical assessment/scenario section.

4. Practical assessment tasks

It is important that you use both Steps 3 (Questioning) and 4 (Practical Assessment) in doing this assessment. The RPL process is a streamlined RPL process which does not rely solely on practical assessment but uses a combination of questioning and practical to provide evidence of candidate competence.

This is the third phase in collecting evidence. A practical skills test is then conducted by you at the candidate’s workplace or another suitable venue. Appropriate permission must be sought before entering workplaces.

This is a further opportunity for candidate to demonstrate competence. It is expected the practical assessment will comprise only those competencies the candidate is still unable to demonstrate knowledge/experience in after documentary review and questioning have been applied. These assessments contain the practical skills and application of knowledge for the qualification. A number of holistic practical assessments are included in this kit (SECTION D) to assist you with tasks suitable for observation on the job.

You decide if the response to questions and practical assessment tasks fulfils the requirements of the standard and may choose to pursue the issue further for a determination to be made. The assessment is a conversation/observation, not an exam, and you are encouraged to assist candidates to focus responses toward relevant issues.

Assessing through observation and questioning, particularly on the job, will speed up and streamline the RPL assessment process.

NOTE: Where candidate’s documentation and questions meet the assessment requirement, it is still strongly recommended the candidate undertake one practical assessment so you are confident in making a judgement of “competent”. The practical assessment selection should be negotiated between you and the candidate.

Recording sheets for candidate information, questioning and the practical assessments have been included in SECTION D. You may use other recording mechanisms provided these also keep a



complete record of assessment and justification of judgement. Candidate responses, observations of skills demonstrated and documents presented as evidence must be noted in enough detail so anyone external to the process (e.g. a fellow assessor, auditor, lawyer, etc) can read the record and retrace your judgement.

5. Gap training

RPL is an assessment process designed to show areas of competence and to identify IF a candidate has gaps in skills and knowledge against a whole qualification.

Not all candidates will have skill/knowledge gaps.

If a candidate has skills gaps, a pathway to complete training in the outstanding units can be negotiated to assist the client to gain the full qualification.



EVIDENCE REVIEW

Recognition of prior learning outcomes (both Granted and Not Granted) are now funded nationally and as such will be included in National AVETMISS audits. NCVER have stipulated evidence recording requirements for RPL assessments as a minimum requirement for passing an AVETMISS audit. The following “Evidence Review” proforma has been approved by NCVER as covering AVETMISS audit requirements for RPL recorded outcomes. It also gives you an opportunity to track a student’s assessment progress at a glance.

It is expected that this “Evidence Review” summary sheet (or similar) would be attached to each participant’s evidence compiled during the RPL assessment process.

(Place a tick in the appropriate evidence collection method column for each unit of competency. Place a line through those units not examined as part of this RPL assessment.)

Unit Code Unit Title

Que

stio

ns

Prac

tical

Doc

umen

ts

3rd P

arty

R

epor

t

Oth

er

evid

ence


























Unit Code Unit Title

Que

stio

ns

Prac

tical

Doc

umen

ts

3rd P

arty

R

epor

t

Oth

er

evid

ence






Assessor’s Name:

Assessor’s Signature:

Date:



SECTION BCandidate Information and

Application Forms

You give this information to the candidate for them to read about the RPL process and to complete the appropriate forms.



WHAT DOES IT MEAN TO BE A PRINTING MACHINIST?

Certificate III in Printing and Graphic Arts (Printing) is the primary qualification for a person wishing to be recognised as a printing machinist.

The printing and graphic arts industry is a major manufacturing industry in Australia and its products are used by every other industry sector. A large number of employees in the industry work in small to medium enterprises with less than 20 employees. A qualification in printing allows a person to work in a variety of roles in the printing sector of the industry.

The Certificate III in Printing and Graphic Arts (Printing) is made up of 7 compulsory units and 13 elective units – a total of 20 units of competency. Upon completion of the Certificate III a person may progress to a Certificate IV in Printing and Graphic Arts with a focus on management/sales, printing or process leadership.

To gain the core units of competency for the Certificate III you will be required to demonstrate that you can currently do all or some of the following:

inspect the quality of products

follow OHS practices

communicate in the workplace

prepare and operate printing machines

prepare and select inks and additives

perform basic machine maintenance

perform basic industry calculations

use a computer

You may have other printing skills that can also be used to get recognition in additional units towards a Certificate III.

“If you are doing these roles in your job, then don’t write off your skills – consider getting them recognised.”



TIPS AND HINTS TO HELP YOU PREPARE FOR RECOGNITION

To have skills formally recognised in the national system, assessors must make sure you have the skills and knowledge to meet the industry standard. This means you must be involved in a careful and comprehensive process that covers the content of all unit/s or qualification/s you can be recognised for.

Assessment happens in a variety of ways. Being prepared can save you valuable time and hassle and make the recognition process stress-free for you.

Here are some tips and hints for you:

1. Be prepared to talk about your job roles and your work history. Bring a resume or jot down a few points about where you have worked, either paid or unpaid, and what you did there.

2. Bring your position description and any performance appraisals you have from any printing and graphic arts shops or facilities you have worked in.

3. Consider the possibilities for workplace contact. Are you in a workplace that is supporting your goals to get qualified? Would you feel comfortable to have the assessor contact your workplace or previous workplaces so your skills can be validated?

4. Think about who can confirm your skill level. Think about current or recent supervisors who have seen you work in the past 18 months and will be able to confirm your skills. The assessor will need to contact them. You may also have community contacts or even clients themselves who can vouch for your skills level.

5. Collect any certificates from in-house training or formal training you have done in the past.

6. You can speak with training organisation about other ways you can show your skills in the printing and graphic arts. These could be letters from employers, records of your professional development sessions, employers or clients in related industries or government agencies, acknowledgements, workplace forms (as long as they don’t show client details) or other relevant documents.



STEPS IN THE RPL PROCESS

Step 1 – Provide information of your skills and experience

Complete the attached forms and provide as much information of your previous experience in the printing and graphic arts industry as you can. This is your first opportunity (and not the last) to provide proof of your variety of experience in the industry. Here you can supply examples of your work history which could include:

any licences brief CV or work history certificates/results of assessment certificates – vendor training courses, in house courses, workshops, seminars certificates – club courses e.g. first aid, officials, surf life saving, etc photographs of work undertaken sample print work/products diaries/task sheets/job sheets/log books site training records site competencies held record membership of relevant professional associations references/letters from previous employers/supervisors industry awards any other documentation that may demonstrate industry experience

Depending on the industry you have worked in, you may or may not have documentary evidence available. This should not deter you from seeking RPL as the Assessor will work with you during the RPL process.

You will also need to supply contact details of one or two work referees who can confirm your skills in the industry.

Step 2 – Conversation with Assessor

An assessor will review the information you have provided (usually with you) and begin to match up your skills to the units/subjects in the qualification. At this point, you will have the opportunity to discuss and identify your previous experience with the assessor who will understand your industry experience and conduct a competency conversation with you. You will be required to answer printing and graphic arts industry related questions to identify your current skills.

Step 3 – Practical demonstration of your skills

The assessor will conduct a practical skills test at your workplace (if appropriate) or at another suitable venue. This, again, is an opportunity to demonstrate your level of competence. This assessment will be focussed on skills that are required in the qualification. Your assessor will identify the skills that he/she will want you to demonstrate.

Further steps

After the assessment, your assessor will give you information about the skills that have been recognised and whether you have gained the full qualification. If you do have skill gaps, these may be addressed through flexible training.



APPLICATION – Self Assessment QuestionnaireICP30505 Certificate III in Printing and Graphic Arts (Printing)

Candidate Name: Date Completed:

Please identify your level of experience in each competency.

Unit Code Unit Title I have performed these tasksFrequently Sometimes Never

CORE/COMPULSORY UNITS




CORE UNITS













ELECTIVE UNITS















Unit Code Unit Title I have performed these tasksFrequently Sometimes Never



Candidate Signature: Date:



RPL APPLICATION FORM

Applicant Details:

1. Occupation you are seeking recognition in

2 Personal Details

Surname

Preferred Title (Mr, Mrs, Ms, Miss)

First Name/s

Any other name used

Home Address

Postal address if different from above

Telephone Numbers Home: Work:

Mobile: Fax:

Date of Birth / /

Gender MALE / FEMALE Age

Are you a permanent Resident of Australia

YES / NO

3 Current Employment

Are you currently employed?

If Yes, in which occupation are you currently employed?

Who is your current employer?

YES / NO

………………………………………………………

……………………………………………………….

4. Armed Forces details (If Applicable)

Branch of Service

Trade classification on discharge



5. Further Training

Have you undertaken any training courses related to the occupation applied for?

YES / NO

If Yes

What occupation were you trained in?

Training completion Date (month, year)

Country where you trained

Name of course and institution (if applicable)

6. Is there any further information you wish to give in support of your application

7. Professional Referees (relevant to work situation)

Name

Position

Organisation

Phone Number

Mobile Number

Email Address

……………………………………………………………………

……………………………………………………………………

……………………………………………………………………

……………………………………………………………………

……………………………………………………………………

……………………………………………………………………

Name

Position

Organisation

Phone Number

Mobile Number

Email Address

……………………………………………………………………

……………………………………………………………………

……………………………………………………………………

……………………………………………………………………

……………………………………………………………………

……………………………………………………………………



APPLICANT EMPLOYMENT HISTORY FORM

Name, Address and Phone number of

Employers

Period of Employment(DD/MM/YYYY)

Position Held Full Time Part-time Casual

Description of Major Duties

From To

1.

2.

3.

4.

Attach additional sheet if required

If you are including documents in your application, please provide a brief description below

Document Description(e.g. resume, photos, awards etc)

Office Use Only – Assessor to use this section to align documents to specific units of competency and identify key questions for competency conversation

Declaration

I declare that the information contained in this application is true and correct and that all documents are genuine.

Candidate Signature: Date



SECTION CCompetency Conversation

This section assists the assessor in documenting the competency conversation.

Do NOT give this section to the candidate.

Once you have assessed the candidate’s documentary information and determined which competencies you still require more information/evidence on, you use the question bank and Record of Conversation sheets in this section to document evidence of past experience. It is not intended that every question for all competencies be discussed during the conversation, only those competencies the initial documentary review has failed to fully address.

Each question has “key points” to look for in responses. You may use the list of key points to formulate questions of your own if you wish, or contextualise or rephrase the suggested question to the candidate’s particular work situation. The questions are not intended to be a formal ‘script’ for the assessor to follow, but to provide guidance in exploring the range of the candidate’s skills, knowledge and experience in performing a particular task or function.

The Record of Conversation sheets indicate relevant content that should be sought. Place a tick next to each key point as you hear this topic being discussed during the conversation. In doing so, you are making a statement of fact about what you hear the candidate say during the competency conversation. Use the Comments section to provide further detail about the context of the discussion or briefly outline any examples discussed by the candidate. You may also use the Comments section to make a brief analysis of the responses or summary judgements about the quality of the candidate’s responses in relation to the requirements of the competency standard.

Remember, the notes you take about this conversation are important evidence and should be retained in the candidate’s assessment record.



QUESTION BANK

Note to Assessors: Refer to “Record of Conversation” sheets

Unit of Competency

Question

GenericComponent Plan and prepare

A: When you receive a new work order, how do you identify what will be required for the job?

B: Explain how you have sequenced your work effectively to complete your work in a timely manner.

GenericComponent Proof run

C: When conducting proof runs, what quality control measures do you routinely apply to test against approved standards?

D: Outline how you have run a print proof prior to a full production run.

E: How did you determine what adjustments needed to be made after inspection of the initial proof? What did you look for?

GenericComponent Production records

F: What types of forms/documents have you completed as part of the production process?

G: What statistics/data have been produced from production documents in your workplace?

H: Explain the importance of having a client history for repeat jobs.

GenericComponent Shutdown and clean

I: Using an example of a production process in your workplace, outline the steps you have taken to shutdown production and prepare a machine for the next run.

J: How do you ensure a machine is safely shutdown?

K: After shutting down the production process, what cleaning was necessary to prepare the machine for the next run?

GenericComponent Waste management

L: What are the reuse and recycling practices with respect to ink, paper?,

M: Describe other operations procedures around waste management?

ICPSU216AInspect quality against required standards

1: Provide an example and describe the process of a quality inspection you have carried out for a particular job.

2: How were quality requirements checked before the job commenced?

3: Using an example of two production jobs, identify what quality checks are made at various control points

4: What did you do when you detected a fault?


5: Discuss the types of hazards that can occur in your work place and how they are controlled/managed.

6: How do you contribute to OHS in your workplace?



Unit of Competency

Question


7: Describe a time you have taken a message in your workplace and the information you passed on.

8: Give an example of a situation in which you provided instructions on how to carry out an activity (eg operation of a machine) to a fellow worker. (Assessor prompt – How did you know they understood your instructions?)

9: How have you ensured that you actively contributed to the objectives of a work group?

10: What sort of information do you regularly exchange with your supervisor or the floor manager?


11: In developing general printing and production strategies and making print set up decisions there are many issues to consider. Briefly discuss each of the following:

a) relevant lawsb) pre-press functionsc) types of printing processesd) types of converting and finishing processe) substrate and inks considerations in print set up decisionsf) colour theory and production costs.

12: How have you applied your knowledge in one or more of these areas when discussing a print job with a customer or your production manager?

13: What are some of the recent technology advances in the printing industry?


14: Describe what steps you have taken to load and unload reels and cores on and off machines.

15: What has been the main fault to a reel or core you have recognised and how did you correct the fault?

16: How do you identify the stop and safety controls of a machine?


17: Name some machines/equipment in your workplace required to complete job orders.

18: How do you load and unload product on and off machines with minimum downtime?

19: How have you avoided stacks distorting during loading?

20: What are the correct procedures for turning substrates?

ICPSSU203A Prepare and maintain the work area

21: Discuss the types of cleaning duties you have carried out in your workplace and the health and environmental issues relevant to performing these duties.

22: Describe the system your workplace has for maintaining and storing supplies of materials and equipment.

23: What systems are used in your workplace to store and retrieve information artwork?


24: Discuss how you prepare and set up either a web fed or sheet fed printing machine.

25: How did you avoid damaging the finished product?

26: What problems could interrupt the running cycle of the machine?


27: Using an example of a production process you have monitored in your workplace, discuss the operation and monitoring of the machine during production. (Assessor prompt - Indicate the purpose of monitoring those parts of the machine)

28: What are the main differences between a reel system and a sheet or product system?

29: What basic criteria have you applied in monitoring the quality of the finished product?



Unit of Competency

Question


30: Outline the steps you have taken to prepare ink and additives for a job.

31: How have you ensured the suitability of the ink selected and how have you checked the selected ink matched the job requirements?

32: What are the main functions of additives?

33: How did you determine that the inks being mixed were compatible?

34: What procedures have you followed to store and handle ink?


35: Taking one type of printing and converting equipment in your workplace as an example, what checks do you complete as part of your routine maintenance?

36: Why is routine maintenance so important?

37: What are the main precautions to observe when maintaining and cleaning a reel handling system?

38: What common faults have you identified that cause breakdown or failure of a printing unit?


39: Using examples from your workplace, describe the types of trade calculations and measurements you carry out. (Assessor prompt - What equipment or tools did you use for these calculations and measurements?)

40: What is parallax error and how does it occur?

ICPSU 281A Use computer system

41: What are the key health and safety issues to consider in using a computer in the workplace?

42: Explain the uses of a software program you frequently use in the workplace. (Assessor prompts – How did you access the program? How did you input, retrieve and save information?)


43: What does ‘quick changeover’ refer to and how is it carried out in your workplace?

44: Explain an improvement you have recommended or implemented that improved changeover.

45: Describe Single Minute Exchange of Die (SMED) and the variations that occur in your workplace.

ICPPP266A Produce relief plates

46: Describe the steps you have taken to produce relief plates from film input for letterpress or label printing.

47: What did you do to prepare the film for plate production?

48: How did you establish conditions for plate exposure?


49: Explain the steps you have taken to make flexographic plates from film input.

50: How did you determine exposure time for the plate?

51: Why is it important to have the correct shoulder angle?

52: Discuss your experience with dimensional printing techniques such as engraving, thermography and letterpress.

53: Discuss the following properties of plate making:

a) plasticity b) resilience c) shelf life

54: Explain the terms ‘dot’, ‘dot gain’ and ‘dot growth’ in relation to photopolymer plates.



Unit of Competency

Question

ICPPR214A Produce basic flexographic printed productICPPR314A Produce complex flexographic printed product

55: Describe how you have operated either a reel or sheet fed flexographic press to maintain production efficiency and product quality.

56: Describe an in-line press.

57: Describe the main principles of felxographic printing.

58: Outline your experience in work-and-turn and work-and-tumble printing.

59: Outline your experience in four-color printing and spot colour ink.

60: Discuss the advantages and disadvantages of flexograhic printing



61: Outline the steps you have taken when setting up either a reel or sheet fed flexographic printing machine for a routine print job.

62: Give an example of a complex or non-routine flexographic printing job you have carried out

63: Identify and describe the techniques you have used to minimise scuffing

64: Discuss techniques you have used to prevent leaching.

65: What print characteristics are related to excessive printing pressure? How do you ensure even pressure during the production phase?

66: Discuss some issues around the operation, preventative maintenance and cleaning of anilox rollers.



67: When operating either a reel or sheet fed lithographic press, what do you monitor and adjust to maintain production efficiency and product quality.

68: Describe four common offset printing errors you have come across and discuss how they can be corrected.

69: Describe the difference between a ‘flying paster’ and a ‘zero speed’ splicer.

ICPPR 331A Set up for basic lithographic printing

ICPPR 431A Set up for complex lithographic printing

70: Outline the steps you have taken to set up either a reel or sheet fed lithographic printing machine for a routine print job.

71: Give an example of a complex or non-routine printing job you have carried out. What additional matters did you consider in the set up of the machine for that print job?

72: Outline your experience in regulating the blanket?. How have you determined the correct printing pressure between blanket and stock? How do you achieve the correct blanket tension when fitting a new blanket?

ICPPR 252A Produce basic relief printed product

ICPPR 352A Produce complex relief printed product

73: Describe how you have operated either a reel or sheet fed a platen, cylinder or rotary printing machine to maintain production efficiency and product quality standards.

74: Discuss your experience using fountain solutions – what is their purpose, and what they are made of.

75: Explain relief printing and the techniques you have used.

76: Explain the ink drying principles of absorption, evaporation and oxidation.


77: Describe a basic relief printing job and how you set up the reel system or sheet system?

78: How do you correctly handle, position and adjust relief plates?

79: What are some of the adjustments you have had to make to a sheet delivery system to ensure correct operation?



Unit of Competency

Question


80: Outline the steps you have taken to prepare, expose and process a lithographic plate.

81: How did you post-treat the plate?

82: Explain the difference between ‘negative’ working and ‘positive’ working lithographic plates.



RECORD OF CONVERSATIONGeneric component: Plan and Prepare

CANDIDATE’S NAME: ASSESSOR’S NAME: DATE:

Question A: When you receive a new work order, how do you identify what will be required for the job?

Question B: Explain how you have sequenced your work effectively to complete your work in a timely manner.

KEY POINTSThe candidate’s response should evidence the following

INDUSTRY REQUIREMENTS

These must be evidenced in the candidate’s response

Indicate if response addresses KP and IR

COMMENTSRecord other key points and examples from conversation.

Identify whether a practical assessment is warranted.

Question ACodes of practice

Workplace hazard policies and procedures

Standard operating procedures

Machine manuals

Safe working loads

Material safety sheets

Good housekeeping

Assesses job requirement

Reads work instructions or job order, plans, drawings or designs

Prepares materials lists

Identifies relevant workplace procedures

Identifies processing techniques, time and safety requirements

Selects and checks tools and tests equipment

Selects appropriate PPE

Measures for materials, checks for faults, damage, quality, suitability

Sets-up work area, prepares surfaces

Question B

Plans and sequences:

Materials preparation

Loading and unloading equipment/components

Preparation of product/substrate

Positioning product/substrates









Operations

Proof run

Colours/ink and consumables

Production

Shutdown



RECORD OF CONVERSATIONGeneric component: Proof runs


Question C: When conducting proof runs, what quality control measures do you routinely apply to test against approved standards?

Question D: Outline how you have run a print proof prior to a full production run.

Question E: How did you determine what adjustments needed to be made after inspection of the initial proof? What did you look for?







Question CCodes of practice



Machine manuals

Safe working loads


Visual inspection

Laboratory testing

100%, random inspection

Periodic or continuous in-line inspection

Question D

Organise materials for use

Operates machine to suit print run

Carries out inspections/tests in sequence or as required

Interprets results

Makes necessary adjustments

Seeks OK for print production

Question E

Checks product match to job requirements - colour, print, ink drying, substrate

Laboratory tests

Checks production speed meets job requirements









Look



RECORD OF CONVERSATIONGeneric component: Production records


Question F: What types of forms/documents have you completed as part of the production process?

Question G: What statistics/data have been produced from production documents in your workplace?

Question H: Explain the importance of having a client history for repeat jobs.







Question FWorkplace hazard policies and procedures


Machine manuals


Chemical register

Materials data sheet

Job sheet

Ink formulas

Job schedule

Work order

Faults report

Inventory control forms/document

Machine cleaning register

Customer chart/form

Proof run approval form

Question G

Ink/materials usage

Colour charts/formulas

Print run times

Number of correct proof runs









Waste – ink, additives

Machine usage and wear

Drying times

Number of tests run with suitable outcomes

Number of adjustments

Question H

Customer history outlines

Previous problems and suggestions for improvement

Variations required

Preparation – job sequence, production plan

Ink formulas and additives preparation

Substrate positioning

Machine settings

Inspections and testing

Adjustment requirements

Production outcomes



RECORD OF CONVERSATIONGeneric component: Shutdown and clean


Question I: Using an example of a production process in your workplace, outline the steps you have taken to shutdown production and prepare a machine for the next run.

Question J: How do you ensure a machine is safely shutdown?

Question K: After shutting down the production process, what cleaning was necessary to prepare the machine for the next run?







Question ISafe work practices



Machine manuals

Safe working loads


Waste management

Good housekeeping

Follows manufacturer’s and workplace shutdown sequence

Stores unused materials

Removes and stores plates, cutting and other devices

Removes product

Identifies and reports machine faults and ensures repair before recommencing

Cleans and washes machine: machine sections used; inking/gluing/coating system; in-line printing/converting/binding/finishing/coating units; and feed, transportation and delivery systems after disengaged.

Question J

Follows manufacturer’s and workplace shutdown sequence

Stores unused materials

Removes and stores plates, cutting and other devices









Removes product and other hazards

Identifies and reports machine faults and ensures repair before recommencing

Question K

Uses personal safety equipment

Cleans and washes - cylinders or sleeves, plate and roller surfaces, inking rollers, blade systems, ink pumps, tanks and hoses, rollers, in-line printing/converting/binding/finishing units

Uses correct solvents and disposes of liquid waste

Checks and lubricate machine parts

Removes, labels and stores inks

Removes and recycles or disposes of wastes

Removes product

Tidies work area

Wipes down and dries machine

Disengages and cleans transportation and delivery systems



RECORD OF CONVERSATIONGeneric component: Waste management


Question L: What are the reuse and recycling practices with respect to ink, paper, and other printing materials?

Question M: Describe other operations procedures around waste management?







Question LMaterial safety sheets

Waste management


Environmental regulations and guidelines

Minimise waste – only dispose of waste as a last option

Extend life of resources – recovery, reuse, recycle

Implement waste recycle (reuse) system for non-hazardous solid waste

Reuse paper – note pads, poster paper or create other products

Donate paper to schools etc

Recycle aluminium plates, negatives and any other silver laden paper

Use lids to keep products fresh

Fill ink fountains with only enough ink for one run

Donate emulsified inks to trade schools for use

Question M

Monitor press performance to minimise bad runs and waste

Clearly label waste containers

Do not mix waste in one container

Dispose of waste by use of licensed waste removalist









Silver – recover from bath and have chemical recycler pick it up

Use water based solution rather than chemical

Run similar jobs simultaneously to reduce waste

Use water based inks to cut down on solvents

Dedicate one press for inks with hazardous pigments and solvents

Use alternatives to solvents where possible



RECORD OF CONVERSATIONICPSU216A Inspect quality against required standards


Question 1: Provide an example and describe the process of a quality inspection you have carried out for a particular job.

Question 2: How were quality requirements established before the job commenced?

Question 3: Using an example of two production jobs, identify what quality checks are made at various control points

Question 4: What did you do when you detected a fault?







Question 1Workplace procedures and standards

Quality specifications and tolerances

Customer requirements

Waste minimisation

Machine manuals

Manufacturer’s specifications

Identifies the type of inspection and testing technique (100%, random, periodic and continuous in-line)

Collects job and inspects against job specifications

Understands quality specifications and tolerances

Applies inspection and testing procedures at regular intervals eg uses colour bars

Identifies unsatisfactory work (eg hickey)

Takes appropriate measure to address quality problems (eg remove material)

Completes documentation

Gives suggestion for improvement of quality/procedures

Question 2

Checks against customer requirements/job specifications

Checks against workplace procedures

Checks against industry standards

Question 3









Ensures product quality meets proof standard by monitoring and adjusting - flexographic plate and plate cylinder or sleeve condition, flexographic impression roller condition, flexographic inking system and doctor blade, drying systems and basic in-line printing/converting/binding/finishing processes

Monitors and adjusts operation of reel system - reel stand, rewind sections, web control system, sheeting section, set off/marking prevention system and substrate

Monitors and adjusts operation of sheet system - feeder and delivery, sheet pick-up and transport system, transfer system, set-off/marking prevention system and substrate

Question 4

Identifies fault and cause

Reports fault to supervisor/manager

Stops press

Receifies according to skills level

Records fault and rectification



RECORD OF CONVERSATIONICPSU261A Follow OHS practices and identify environmental hazards


Question 5: Discuss the types of hazards that can occur in your work place and how they are controlled/managed.

Question 6: How do you contribute to OHS in your workplace?







Question 5Safe work practices

Codes of practice



Machine manuals

Safe working loads


Environmental regulations and guidelines

Waste management

Good housekeeping

Hazards - noise, light, gas, smoke, odour, vapour, liquids/solids, particulates, fumes; other workers and people; electrical hazards; dust; heat; chemicals; walkways, stairs and ladders; tools and equipment; waste and rubbish; manual handling; vehicles; operation of machines

Workplace policies and procedures


Incident reporting procedures

Lockout procedures – danger and warning tags and isolation

Guards on machinery and use of emergency stops

Regular maintenance and inspection of machinery

Training on safety and use of machines

Clean and adequate workspace and lighting

Ventilation of work areas

Correct materials handling, storage, disposal (esp. solvents)

Emergency procedures in event of fire and accident and regular training









Fire fighting equipment, exits marked

Easily locatable first aid kit and trained first aiders

Manual handling procedures

Use of personal safety equipment

Ladders and stairways clean and maintained

Use of material data safety sheet

Hazardous substances identified and recorded in register

Risk assessments

Containment and disposal procedures for spills

Labelling of containers

Signage of hazards eg Forklifts in use

Question 6

Raises OHS issues with designated personnel

Contributes to management of OHS

Uses chemical data sheets

Uses personal protective equipment

Ensures OHS is observed while undertaking work practices

Identifies and reports hazards

Reads labels, instructions and manuals



RECORD OF CONVERSATIONICPSU262A Communicate in the workplace


Question 7: Describe a time you have taken a message in your workplace and the information you passed on.

Question 8: Give an example of a situation in which you provided instructions on how to carry out an activity (eg operation of a machine) to a fellow worker. (Assessor prompt – How did you know they understood your instructions?)

Question 9: How have you ensured that you actively contributed to the objectives of a work group?

Question 10: What sort of information do you regularly exchange with your supervisor or the floor manager?









Question 7Customer requirements

Industry terminology

Workplace policies and procedures

Communicates in a professional and friendly manner

Communication is customer focused

Uses appropriate greetings

Clarifies information received or given

Names and phone number

Purpose of call

Job details

Availability, timeframes and any urgency

Date and time of call

Information provided to the client

Response required

Any other relevant information

Question 8

Provides relevant information

Explains information clearly to the person

Clarifies objectives and purpose of activity

Gives demonstrations and/or examples (if necessary)

Uses appropriate industry terminology

Encourages questions

Monitors and supports the person and gives feedback

Question 9

Cooperates with fellow workers to monitor production









Follows production schedule

Monitors product quality

Identifies and reports faults and problems

Seeks approval as required

Understands the goals of the work group

Attends meetings, participates in discussions and provides support to other team members

Performs agreed or allocated tasks

Encourages and supports the resolution of outstanding issues and implements agreed actions

Question 10

Job requirements

Customer information

Proof run outcomes

Machine faults

Seeking approval on proof

Job schedule and planning

Ink, additives and paper requirements

Cleaning and maintenance issues

Modifications to work

Product quality



RECORD OF CONVERSATIONICPKN312A Apply knowledge of printing machining


Question 11: In developing general printing and production strategies and making print set up decisions there are many issues to consider. Briefly discuss each of the following:

a) relevant lawsb) pre-press functionsc) types of printing processesd) types of converting and finishing processe) substrate and inks considerations in print set up decisionsf) colour theory and production costs.

Question 12: How have you applied your knowledge in one or more of these areas when discussing a print job with a customer or your production manager?

Question 13: What are some of the recent technology advances in the printing industry?









Question 11Knowledge of laws, acts and regulations


Industry practices

Production processes Technology

Laws: Copyright, OHS, Environmental, Access and equity and Industrial awards

Prepress functions: image setting, image combining, image output and digital workflow

Printing processes: lithography, relief, flexography, gravure, pad printing, screen printing and digital/electronic printing

Finishing and converting processes: guillotining, flat-bed and rotary cutting, collating, folding, adhesive and thermal fastening

Print set up: range of substrates, different paper sizes, weights and callipers of substrates, paper grain, different properties of inks for finishing processes

Colour theory: additives colours (RGB), subtractive colours (pigments) (CMYK), relationship between colours and hue, greyness and tone; colour matching systems

Production costs: fixed, capital, variable; collection of information to cost jobs; minimise materials use; efficient use of resources

Question 12

Discussed job procedures

Discusses job requirements – functions and processes

Discusses modification throughout the process

Discusses colour requirements

Discuses cost

Gives routine instructions during production









Question 13

Describes recent advancements in: inkjet printing laser printing image processing developing film transferring toner fusing elements or image fixing process cleaning – electrically neutral rubber blade pad printing cliché phase, transfer phase, print phase



RECORD OF CONVERSATIONICPSU201A – Prepare, load and unload reels and cores on and off machine


Question 14: Describe what steps you have taken to load and unload reels and cores on and off machines.

Question 15: What has been the main fault to a reel or core you have recognised and how did you correct the fault?

Question 16: How do you identify the stop and safety controls of a machine?







Question 14Job specifications

Quality control

Safe work practices


Manufacturer’s instructions

Machine manuals

Product labels

Manual handling

Good housekeeping

Selects reels and cores

Identifies faulty reels and cores

Loads and unloads reels using correct manual handling or appropriate machinery (eg forklift)

Correctly positions substrate (noting unwind direction) and splices/joins substrate

Ensures guards and safety devices in place and clear of nip points

Cleans area around machine

Strips, stacks, wraps and labels unloaded reels

Stores reels

Question 15

Describes distortion/s to reel or core

Repairs/replaces reel or core

Question 16

Refers to machine manual

Refers to safety manuals









Checks machine for safety labels, stop buttons, tags



RECORD OF CONVERSATIONICPSU202A Prepare, load and unload product on and off machine


Question 17: Name some machines/equipment in your workplace required to complete job orders.

Question 18: How do you load and unload product on and off machines with minimum downtime?

Question 19: How have you avoided stacks distorting during loading?

Question 20: What are the correct procedures for turning substrates?








Quality control

Safe work practices



Machine manuals

Product labels

Manual handling

Good housekeeping

Printing

Screen printing

Converting

Binding and finishing

Corrugating

Coating

Laminating

Question 18

Identifies and removes faulty product

Positions product to machine

Prepares substrate: fanning, turning and jogging (manual and machine)

Loads and unloads using safe practices

Cleans area around machine

Prepares product for next process: stripped, stacked,









wrapped and labelled

Stores product appropriately

Question 19

‘Set’ each image quickly

Uses flat stackable printing blades

Uses pile height governor for a feeder

Adjusts feed and tension controls

Watches and monitors feeders

Checks correct positioning of materials

Question 20

Describes manual turning and machine turning

Cleans surfaces before turning



RECORD OF CONVERSATIONICPSU203A Prepare and maintain the work area


Question 21: Discuss the types of cleaning duties you have carried out in your workplace and the health and environmental issues relevant to performing these duties.

Question 22: Describe the system your workplace has for maintaining and storing supplies of materials and equipment.

Question 23: What systems are used in your workplace to store and retrieve information artwork?







Question 21Safe work practices

Workplace procedures

Material data safety sheets

Manufacturer’s recommendations

Environmental regulations

Waste management

Good housekeeping

Use of personal protection equipment where necessary

Selecting appropriate cleaning equipment

Determining appropriate cleaning agents

Preparation and mixing of chemicals to manufacturer’s specifications

Use of material safety sheets to identify safe chemical handling procedures

Chemicals and liquid waste are handled appropriately

Cleaning liquids and chemicals appropriately stored and disposed of

Question 22

Requests/orders for supplies recorded and processed

Supplies and equipment appropriately stored and handled (manual and machine eg forklift)

Type of media storage (hard copy, electronic, plates, films)

System for retrieval of information (eg indexing, cross









indexing)

Proper equipment for storage and retrieval

Information located in appropriate place to ensure preservation and security

Question 23

Uses inventory control system to file and retrieve artwork, information, used plates, film

Files and stores according to information system (e.g. alpha, numerical, subject, chronological, job no.)



RECORD OF CONVERSATIONICPSU207A Prepare machine for operation (basic)


Question 24: Discuss how you prepare and set up either a web fed or sheet fed printing machine.

Question 25: How did you avoid damaging the finished product?

Question 26: What problems could interrupt the running cycle of the machine?








standard operating procedures


Manufacturer’s/supplier’s instructions

Safe work practices

Good housekeeping

Reel system (web fed): sets up and/or adjusts unwind reel, web control system, rewind reel, folder , sheeter and transport and delivery systems

Carries out webbing procedures

Splices/joins reels

Sheet or product system: Sets up and adjusts feeder, sheet/product pick-up and transportation system, transfer systems, delivery, sheet/product transfer and control system

Removes product from process

Reports readiness of transport and delivery systems for final adjustments

Loads inks, glues, liquid and/or other materials

Installs plates, cutting or other devices

Confirms registration, alignment or centring

Runs machine through cycle to ensure substrate/product is positioned properly

Question 25









Removes from print machine with care

Removes from print area

Hangs or puts aside finished product for drying

Stacks product correctly

Wraps product correctly

Question 26

Incorrect set up of machine

Incorrect adjustments to machine when setting up

Plates, cutting devise move

Ink, glue or liquid is incorrect for print job

Centring or alignment is incorrect

Product is not in correct position



RECORD OF CONVERSATIONICPSU208A Operate and monitor machines (basic)


Question 27: Using an example of a production process you have monitored in your workplace, discuss the operation and monitoring of the machine during production. (Assessor prompt - Indicate the purpose of monitoring those parts of the machine)

Question 28: What are the main differences between a reel system and a sheet or product system?

Question 29: What basic criteria have you applied in monitoring the quality of the finished product?











Safe work practices

Good housekeeping

Reel system: monitors and adjusts reel stand, web control system, reel rewind and sheeting section

Monitoring and adjustment ensures continuous operation (reel stand) and correct tension and product quality (web control system, reel rewind and sheeting section)

Sheet or product system: monitors and adjusts feeder, sheet or product pick-up and transport system, transfer systems and delivery

Monitoring and adjustments ensure continuous and efficient feeding to the machine (feeder, sheet or product pickup, transport and transfer systems) and quality and efficient product delivery (delivery)

Question 28

Reel system features: reel stand, web control system, reel rewind and sheeting section

Sheet or product system features: feeder, sheet or product pick-up and transport system, transfer systems and delivery

Question 29









Makes minor adjustments to ensure quality of product

Identifies faulty performance of equipment

Monitors production process

Monitors product as it is produced/printed



RECORD OF CONVERSATIONICPSU211A Prepare ink and additives


Question 30: Outline the steps you have taken to prepare ink and additives for a job. Question 31: How have you ensured the suitability of the ink selected and how have you checked the selected ink matched the job requirements?

Question 32: What are the main functions of additives?

Question 33: How did you determine that the inks being mixed were compatible?

Question 34: What procedures have you followed to store and handle ink?








Safe work practices



Material Safety Data Sheet (MSDS)

Product labels

Ink management plan

Good housekeeping

Selects inks and additives to suit job

Considers substrates, adhesion, physical and chemical resistance, light fastness, drying method and print process in selection of inks and additives

Mixes and prepares colour and weight/volume of ink to match job

Uses measuring equipment (eg scales)

Records ink formula and approved colour

Handles, stores and labels inks and dyes appropriately

Question 31

Checks ink selected matches job requirements

Checks quality of ink

Checks suitability to substrate, adhesion, physical and chemical resistance

Chooses ink for desired finish- matt, gloss, embossing,









foils, wax

Chooses ink characteristics to suit substrate

Chooses ink to adhere to substrate

Determines light or colour fastness of ink

Question 32

Additives support: thickness of ink thinness of ink colour and consistency of ink

Question 33

Manufacturer’s/suppliers instructions

Weight and volume

Colour matching

Printing press requirements

Ink formula

Question 34

Material Safety Data Sheet

Avoid eyes, skin, clothing

Storage conditions – temperature, light

Environmental conditions and hazards

Labelling per suppliers instructions, use and volume

Correct disposal of inks, solvents and solvent rags



RECORD OF CONVERSATIONICPSU224A Perform basic machine maintenance


Question 35: Taking one type of printing and converting equipment in your workplace as an example, what checks do you complete as part of your routine maintenance?

Question 36: Why is routine maintenance so important?

Question 37: What are the main precautions to observe when maintaining and cleaning a reel handling system?

Question 38: What common faults have you identified that cause breakdown or failure of a printing unit?













Safe work practices

Good housekeeping

Reel handling system: cleanliness, check lubricants, unwind unit, web control devices, rewind unit, folding unit and sheeting unit, electronic sensors

Sheet or object handling system: cleanliness, check and lubricate feeder, lays and transfer gripper system and delivery

Printing units: cleanliness, check and lubricate cylinder / screen / plate and roller surfaces, safety devices, gears and bearings, ink distribution system components and various print control devices

Cutting units: cleanliness, check and lubricate cutting devices and knives, and machine bed check

Folding/collating units: cleanliness, check and lubricate folding/collating system components and machine bed check

Fastening units: cleanliness, check and lubricate adhesive and mechanical fastening units and machine bed check

Question 36

Ensure safety of machine

Check all components are working and replace parts as required

Check lubricants

Prevent failure and/or breakdown

Keep machine in use longer

Machine runs better

Question 37









Dealing with air compression

Lubricating the unwind unit, web control and rewind unit

Cleaning electronic sensors

Checking the folding unit

Machine checks

Chemicals used for cleaning

Question 38

Parts fail due to ineffective cleaning

Worn rollers

Worn bearers in cylinders

Damages cylinder/screen/plate

Dirty cylinder body

Poor lubrication of components

Damaged gears or bearings

Damaged ink distribution systems



RECORD OF CONVERSATIONICPSU263A Perform basic industry calculations


Question 39: Using examples from your workplace, describe the types of trade calculations and measurements you carry out. (Assessor prompt - What equipment or tools did you use for these calculations and measurements?)

Question 40: What is parallax error and how does it occur?










Numeracy skills

Uses math (add, subtract, divide, multiply and percentages) to calculate costs and dimensions

Uses appropriate equipment (calculators and computers)

Records results of calculations

Correctly calculates density and/or volumes of fluids and colours

Selects and uses basic measuring tools: micrometers, scales, humidity meters, pH meters, screen angle and screen ruling gauges, dot gain scales and pantone colour matching

Question 40

Reading the dial on measuring equipment incorrectly due to standing position

Line of sight in not perpendicular to the face of the dial



RECORD OF CONVERSATIONICPSU281A Use computer systems


Question 41: What are the key health and safety issues to consider in using a computer in the workplace?

Question 42: Explain the uses of a software program you frequently use in the workplace. (Assessor prompts – How did you access the program? How did you input, retrieve and save information?)











Safe work practices

Operator manuals

Correct posture at keyboard

Computer set up appropriately (ie monitor and keyboard levels)

Safe keyboard technique

Regular breaks

Cables appropriately hidden

Question 42

Software applications used for: typesetting; image manipulation; page layout; word processing; database; spreadsheet; production control and monitoring

Turns computer on

Ensures physical set up (location of mouse, keyboard, chair etc) safe

Uses keyboard and mouse to select and access program and files

Carries out search where necessary to locate program/file

Selects templates









Names and saves files in appropriate format and location

Turns off computer (if appropriate) when task completed



RECORD OF CONVERSATIONICPSU357A Apply quick changeover procedures


Question 43: What does ‘quick changeover’ refer to and how is it carried out in your workplace?

Question 44: Explain an improvement you have recommended or implemented that improved changeover.

Question 45: Describe Single Minute Exchange of Die (SMED) and the variations that occur in your workplace.









Question 43Job instructions

Production schedule



Machine manuals

Good housekeeping

Quick changeover: exchange of dies or tools; change between batches, or equipment/process change to produce a different product (eg plate changeover, stock changeover)

Follows quick changeover principles

Determines timing of changeover (refers to production schedule)

Liaises with fellow workers

Checks output

Notes problems and recommends changes

Hazards: machine operation (nip points); manual handling; slips trips and falls

Question 44

Improvement to exchange dies/tools, change between batches, quantum equipment/process change producing a better product, plate changeover, stock changeover

Question 45

SMED – changing a die on a forming or stamping machine in a minute or less

Variations – Single-digit set-up – performing a set-up activity in a single-digit number of minutes (fewer than ten)OTED (One Touch Exchange of Die) – changing a die with one physical motion such as pushing a button



RECORD OF CONVERSATIONICPPP266A Produce relief plates


Question 46: Describe the steps you have taken to produce relief plates from film input for letterpress or label printing.

Question 47: What did you do to prepare the film for plate production?

Question 48: How did you establish conditions for plate exposure?







Question 46Plate processor Manufacturer’s specifications


Job specifications

Quality standards

Good housekeeping

Prepares and maintains plate processor

Establishes and maintains plate processor (using vacuum frames)

Produces plates that meet job requirements

Proofs plates

Question 47

Consider plate requirements

Check accuracy and repeatability

Complete quality control

Use problem solving device if required

Question 48

Conduct exposure tests

Check continuity

Ensure control of plate exposure



RECORD OF CONVERSATIONICPPP268A Make photopolymer plates (flexographic)


Question 49: Explain the steps you have taken to make flexographic plates from film input.

Question 50: How did you determine exposure time for the plate?

Question 51: Why is it important to have the correct shoulder angle?

Question 52: Discuss your experience with dimensional printing techniques such as engraving, thermography and letterpress.

Question 53: Discuss the following properties of plate making: Plasticity; Resilience; Shelf life.

Question 54: Explain the terms ‘dot’, ‘dot gain’ and ‘dot growth’ in relation to photopolymer plates.








Plate manufacturer’s specifications

Safe work practices



Good housekeeping

Selects plate to accord with printing requirements and job

Plans the process: checks negatives, cuts exposure masks; calculates amount of plate material required

Establishes exposure time

Exposes the plate

Maintains chemistry balance and washout unit

Washes out plate

Finishes plate (dried, cleaned, post-exposed and light finished)

Uses chemicals safely

Question 50

Uses a step wedge and depth gauge

Determines copy requirements









Identifies plate thickness

Determines front, back and post exposure times

Question 51

To prevent elements coming off the plate

Question 52

Engraving delicate line work sharpest image of any print method requires a metal plate or dye in to which a design is

cut by hand, chemically etched or photoengraved

Thermography creates raised affects much like engraving adds dimension and colour to type, line work, solids

and screens a process that combines offset printing ink with a

powdered resin which is baked so that the resin rises to give the ink a textured effect

Letterpress much like embossing or engraving a relief process whereby a raised image is inked and

then pressed in to the paper, essentially making an indentation

Question 53

Plasticity – also called viscosity is a measure of flow of an uncured material under heat and pressure prior to the start of cure

Resilience – a measure of the recovery (rebound) of a cured material to its original thickness after impact









Shelf life – indicates the expected useful life of unprocessed (before curing) plate material

Question 54

Dot - An element of halftones. Using a loupe you will see that printed pictures are made up of many dots.

Dot gain - A term used to explain the difference in size between the dot on film versus on paper.Alt: A phenomenon, which occurs when wet ink comes in contact with paper. As the halftone dots are applied to the paper, the wet ink spreads, causing the dots to increase in size and halftones to appear darker. A number of factors affect dot gain.

Dot growth - The enlargement of a halftone dot from the printing plate to the printed image as a result of pressure needed to transfer the ink onto the substrate.



RECORD OF CONVERSATIONICPPR214A Produce basic flexographic printed product



Note: To assess competency in these units the same questions may be used. To demonstrate competency, for example in ICPPR314A Produce complex flexographic printed product (reel-fed flexographic press only), the individual must provide their response in relation to complex or non-routine flexographic printing as defined by the range statement.

Question 55: Describe how you have operated either a reel or sheet fed flexographic press to maintain production efficiency and product quality.

Question 56: Describe an in-line press.

Question 57: Describe the main principle of flexographic printing.

Question 58: Outline your experience in work-and-turn and work-and-tumble printing.

Question 59: Outline your experience in four-color printing and spot colour ink.

Question 60: Discuss the advantages and disadvantages of flexograhic printing









Question 55 Work procedures

Job specifications

Approved proofs

Production schedules


Safe work practices

Good housekeeping

Ensures product quality meets proof standard by monitoring and adjusting - flexographic plate and plate cylinder or sleeve condition, flexographic impression roller condition, flexographic inking system and doctor blade, drying systems and basic in-line printing/converting/binding/finishing processes

Monitors and adjusts ink performance, colour, register and position of print

Rectifies faults where appropriate

Question 56

A press coupled to another operation such as bag-making, sheeting, die-cutting, creasing, etc. A multi-color press in which the color stations are mounted horizontally in a line

Question 57

All original text, pictures, and illustrations are photographed to convert them into the proper positive or negative films to make the plate which reproduces the image on the substrate

Question 58

Work and tumble: Printing one side of a sheet and turning it over from the gripper to the tail to print the second side using the same side guide and plate for the second side

Work and turn: Printing one side of a sheet and running it over from left to right using the same side guides and plate for the second side

Question 59









Uses three primary ink colours -- cyan, magenta, and yellow, plus black

Uses "spot colour" inks, alone or in combination with the four-color process method

Uses specific formulations that are printed alone, rather than mixed to produce various hues and shades

Question 60

Advantages

More suited to printing solid colours than waterless printing

Allows for greater ink quantities to be applied to the medium (six grams per square metre as opposed to one gram per square meter in the case of waterless printing)

Less expensive printing plates

Faster set-up time

Capable of printing long or short runs at high production rates

Disadvantages

Reproduction of original graphic materials may suffer loss of definition

Does not offer the advantage of zero percent vignettes

Uses larger dot-sizes (40 micron) as opposed to the much smaller dot-size offered by waterless printing (four micron).

Can only print on certain substrates – plastic, cereal boxes



RECORD OF CONVERSATIONICPPR313A Set up for basic flexographic printing



Question 61: Outline the steps you have taken when setting up either a reel or sheet fed flexographic printing machine for a routine print job.

Question 62: ICPPR413A only: Give an example of a complex or non-routine flexographic printing job you have carried out.

Question 63: Identify and describe the techniques you have used to minimise scuffing.

Question 64: Discuss techniques you have used to prevent leaching.

Question 65: What print characteristics are related to excessive printing pressure? How do you ensure even pressure during the production phase?

Question 66: Discuss some issues around the operation, preventative maintenance and cleaning of anilox rollers.










Australian standards for storage of hazardous liquids

Safe work practices



Good housekeeping

Reel system: checks and positions reels and cores; secures unwind reels; webs press; sets edge guide, unwind tension, rewind tension, nip rollers and Positively Infinitely Variable (PIV)

Sheet system: removes substrate from stacker and sets and adjusts feeder, sheet pick-up and transportation system, transfer systems, delivery, sheet transfer and control system and set off / marking prevention devices

Introduces inks

Installs/mounts flexographic plate cylinders, sleeves or mounting sheets

Sets plate cylinders, inking system and roller nips/blades and ink circulation

Adjust viscosities and selects air volume and drier temperature

Registers adjustments

Sets up in-line printing/converting/binding units for basic processes

Applies proofing process

Question 62

Complex job involves 4 or more colours, complex graphics and text, tight registration, fit and position

Set up of additional process units and machinery

Deviation from standard settings

Question 63

Consults ink manufacturer









Reduces level of ink

Reduces ink film or has ink made stronger

Remove ink and replace with fresh

Slow down press or change ink type

Question 64

The monomer and other migratable components in the photopolymerizable layer should be insoluble in the solvent or solution utilized to apply the powder material.

To prevent migration or leaching of the ink printed data toward the substrate is to provide a specific ink-receiving formulation below the printed data

The ink-receiving formulation is selected such that the ink from the ink-jet defining the lottery data is substantially absorbed in the formulation

Question 65

Too much pressure from roller to plate, plate to blanket or blanket to substrate causes halftone dots

Lifting-off of coating from coated stock and pulling paper fibres from uncoated stock (picking)

Excessive plate to blanket pressure – part or all of image does not take ink, resulting in loss of image (plate binding)

The non-image area of the plate accepts ink in random areas (scumming)

Dots or image appear elongated or smeared (slurring)

Ensures even pressure packs plate and blanket properly









sets pressure correctly

Question 66

Planning: specifies ink formulations that will “stay open” and not

dry too rapidly, plugging the anilox roll cells uses preventive measures to keep ink flowing in the

system makes sure that all inks have used compatible resins

so that the same clean-up procedure can be used

Operation: keeps rollers clean while they are on the press uses spray bottles and cleaning solutions that

penetrate and remove wet ink from plates and anilox rollers

Preventive maintenance: periodically removes rollers from the press and do a

deep clean selects an option that matches both the quality

requirements of your customers and the technical level of personnel

Cleaning: baking soda blast – uses air pressure to deliver

baking soda media to the anilox roll plastic bead systems use air and plastic bead media

to impact upon anilox surfaces at an air pressure of 35-70 PSI

ultrasonic is sound energy that creates cavitation when introduced into a liquid. The cavitation is caused by pressure differentials, providing the cleaning action of this process









chemical cleaners are used daily in the flexo printing industry and for the most part they work. Many of these cleaners are caustic, permitting a fast and thorough cleaning

a stainless steel brush should be used with chemical cleaners on ceramic anilox rolls, and a brass brush should be used for chrome rolls



RECORD OF CONVERSATIONICPPR232A Produce basic lithographic printed product



Note: To assess competency in these units the same questions may be used. To demonstrate competency, for example in ICPPR332A Produce complex lithographic printed product, the individual must provide their response in relation to complex or non-routine lithographic printing as defined by the range statement.

Question 67: When operating either a reel or sheet fed lithographic press, what do you monitor and adjust to maintain production efficiency and product quality.

Question 68: Describe four common offset printing errors you have come across and discuss how they can be corrected.

Question 69: Describe the difference between a ‘flying paster’ and ‘zero speed’ splicer.









Question 67Work procedures

Job specifications

Approved proofs



Safe work practices

Good housekeeping



Ensures product quality meets proof standard by monitoring and adjusting: lithographic plate and plate cylinder condition; lithographic blanket and blanket cylinder; lithographic impression cylinder condition; lithographic inking condition and lithographic dampening system

Non-routine/complex printing: monitors and adjusts set off/marking prevention and drying system



Question 68

Uneven colour: make sure that the colour is the same on both sides

of the sheet by rolling the sheet up so that you can look at opposite edges of the sheet side by side

Ghosts: images formed in areas where they should not

appear, or formation of lighter areas where there should be even inking.

occasionally it can be eliminated by changing the color sequence, the inks, the paper, changing to a press with a drier, printing the problem area in a









separate pass through the press or changing the racking (reducing the number of sheets on the drying racks)

Hickies (aka Fish-Eyes): non-inked circles created by lint on the plate or

blanket generally something that can be cleaned up when

appearing on several sheets in a row never be able to eliminate every single hickie,

especially if you have large solids in your printing piece and have to print thousands of sheets

Picking: non-inked areas that look like snow created in areas

where the ink and some of the paper has been lifted off the sheet when the ink is too tacky

picking can occur due to a paper related problem

Muddy or Uneven Screens: occur as a result of dot gain. In the worst case

scenario caused by a muddy or uneven screen, you may need to remake a plate using a coarser screen

some dot gain can be alleviated by running the ink a little lighter and by ensuring that the gradients on your piece, if any, look even

Offsetting: appearance created on the back of a sheet by an

image present on the sheet touching it offsetting happens as a result of too much ink

insufficient driers in the ink or trimming of the job done when the ink is too wet

Question 69









Flying paster is an automatic pasting device that splices a new roll of paper onto an expiring roll, without stopping the press.

Zero speed splicers are used for splicing of pre-printed rolls in register



RECORD OF CONVERSATIONICPPR331A Set up for basic lithographic printing



Note: To determine competency for ICPPR 431A Set up for complex lithographic printing all questions should be used.

Question 70: Outline the steps you have taken to set up either a reel or sheet fed lithographic printing machine for a routine print job.

Question 71: Give an example of a complex or non-routine lithographic printing job you have carried out. What additional matters did you consider in the set up of the machine for that print job?

Question 72: Outline your experience in regulating the blanket? How have you determined the correct printing pressure between blanket and stock? How do you achieve the correct blanket tension when fitting a new blanket?









Safe work practices




Good housekeeping

Reel system: sets up unwind and rewind reels, web control systems, printed web viewing devices and folder and sheeter

Splices/joins reels


Sheet system: sets up feeder and delivery sections, registration system, sheet pick-up, and transportation, control and transfer systems

Removes substrate from process

Introduces inks

Sets and adjusts plate cylinder and installs lithographic plates

Sets up and adjustment blanket and blanket cyclinder, impression cylinder, inking system and dampening system










Question 71

Non-routine/complex set up involves a significant amount of deviation from standard settings

Use of wide range of inks (four or more)

Complex graphics and texts require critical tight registration and fit and position

Additional steps: (reel system) close analysis and scrutiny of unwind and reel set up options and web-control system options or (sheet system) close analysis and scrutiny of feeder and delivery section set up options; set up and adjustment of set off/marking prevention devices

Question 72

Three critical areas on the blanket that determine if installed properly and whether the correct height has been obtained to achieve the correct pressure lead edge of the blanket at the gap trail edge of the blanket at the gap half gap or 180° from the gap

If these above measurements have a greater range then the blanket is egg shaped (due to over tightening)

Poor register, feed, release, susceptibility to smashes and on-press damage result from incorrect tension

Insert same length of blanket in both ends and tighten both ends at the same time to ensure the blanket is stable and square on the cylinder

Easy to over tighten one end and create a ‘step’ from the edge to the trail edge resulting in gear streaking or cylinder bounce



RECORD OF CONVERSATIONICPPR252A Produce basic relief printed product



Note: To assess competency in these units the same questions may be used. To demonstrate competency, for example in ICPPR352A Produce complex relief printed product, the individual must provide their response in relation to complex or non-routine relief printing as defined by the range statement.

Question 73: Describe how you have operated either a reel or a sheet fed platen, cylinder or rotary printing machine to maintain production efficiency and product quality standards.

Question 74: Discuss your experience using fountain solutions – what is their purpose, and what are the made of?

Question 75: Explain relief printing and the techniques you have used.

Question 76: Explain the ink drying principles of absorption, evaporation and oxidation.









Question 73Work procedures

Job specifications

Approved proofs



Safe work practices

Good housekeeping



Non-routine/complex printing: monitors and adjusts drying systems



Question 74

Key functions of fountain solutions: keeps ink off the background with a film of water maintains the hydrophilic nature of the background quickly cleans ink off the background during press

starts promotes fast spreading of water over the plate

surface helps the water flow evenly through the dampening

rollers lubricates the plate and blanket controls emulsify cation of ink and water

Made of water, acid, plate conditioners/additives, wetting agents and gum arabic

Question 75

Relief printing:









the image to be transferred to paper (or other surface) is raised above the surface of the printing plate

Ink is applied to the raised surface then rolled or stamped onto the substrate

printing process is similar to using an inkpad and stamp

relief printing does not necessarily create relief or raised lettering such as found in embossing and thermography

flexography and letterpress are forms of relief printing

Techniques include woodcuts, linoleum cuts and acrylic plates for plaster relief. These techniques involve the cutting away of plate areas that are not to be printed

Question 76

AbsorptionThe ink used is usually quite thin, and the vehicle, which is non-drying, is absorbed by the inner fibres of the paper, where it stays damp for some time. Meanwhile, the pigment remains on the surface

EvaporationThe ink is dried principally by the evaporation of the vehicle from the ink, leaving behind a solid film of pigment. The evaporation drying process is used with or without heat

Oxidation/PolymerizationA two-step ink-drying method used for most offset and letterpress inks. Oxygen is absorbed by the drying, oil, portion of the vehicle (oxidation), followed by a cross-linking of molecules (polymerization), causing the ink film to gel and then harden



RECORD OF CONVERSATIONICPPR351A Set up for basic relief printing


Question 77: Describe a basic relief printing job and how you set up the reel system or sheet system?

Question 78: How do you correctly handle, position and adjust relief plates?

Question 79: What are some of the adjustments you have had to make to a sheet delivery system to ensure correct operation?









Safe work practices




Good housekeeping

Reel system: sets up unwind and rewind reels, web control systems, printed web viewing devices and folder and sheeter

Splices/joins reels


Sheet system: sets up feeder and delivery sections, registration system, sheet pick-up, and transportation, control and transfer systems

Removes substrate from process

Introduces inks

Question 78

Selects and secures relief plates

Sets and adjusts relief plates or formes or cylinders, impression, inking system and drying system

Sets up and adjustment blanket and blanket cyclinder, impression cylinder, inking system and dampening system










Question 79

Feeder and delivery section

Sheet pick-up and transportation system

Transfer and control system

Set off/marking prevention devices



RECORD OF CONVERSATIONICPPP267A Produce offset lithographic plates


Question 80: Outline the steps you have taken to prepare, expose and process a lithographic plate.

Question 81: How did you post-treat the plate?

Question 82: Explain the difference between ‘negative’ working and ‘positive’ working lithographic plates.












Standard operating procedures and machine manuals

Quality standards

Good housekeeping

Selects type of plate to suit job

Prepares plate to accommodate printing machine plate positioning

Positions film correctly on the plate

Selects exposure unit

Established exposure control using step wedges

Maintains exposure and vacuum frame

Uses plate processing unit to process plate

Question 81

Checks plate for quality of outcome

Checks plate meets job requirements

Adds and deletes to plate image to ensure plate delivers standards output for the job

Bakes and/or chemically treats plate

Question 82

Negative working are exposed through photographic negatives

Positive working are exposed through photographic positives



SECTION DPractical Tasks and

Observation Recording Sheets

You use this section to assist you in determining a candidate’s competency in those areas where they have not yet successfully demonstrated their skills, knowledge and prior experience. Therefore, candidates are not required to complete all tasks. You select tasks after considering available evidence collected through previous phases and according to context and needs of each candidate.



PRACTICAL TASKS

Candidates are not required to complete all tasks. The Assessor is to select tasks after considering available evidence collected through previous phases and according to the context and needs of each candidate.

Task 1 ICPSU262A Communicate in the workplaceICPKN312A Apply knowledge of printing machiningICPSU263A Perform basic industry calculationsICPSU281A Use computer system

Read the instructions and complete parts A & B below.

Use a print job sourced in your workplace or use the following scenario to complete this task.

You are meeting with Mr David, the manager of a local financial planning business. Mr David wants to produce 1000 copies of a 5 page newsletter which he intends to send out to his clients four times a year.

Mr David arrives at your workplace to inspect the proof on the machine. He decides after seeing the proof that he wants to increase the number of colours used in the product and increase the page sizes to A4.

Part A:

You are required to:

a) discuss with your Assessor the proposed changes;

b) describe the types of calculations you would need to carry out to determine the additional costs involved with Mr David’s request (and any equipment such as a computer or calculator you would use)

c) consider how you would communicate with Mr David and other staff about the matter

d) record details of the proposed job alteration

Part B:

Using a computer write a brief one or two paragraph memorandum to your supervisor summarising your discussions with your Assessor (or customer), and how you would estimate the additional costs. Demonstrate how you would access the appropriate computer program and create and save the document.



Task 2 ICPPP268A Make photopolymer plates (flexographic)ICPSU203A Prepare and maintain the work areaICPSU261A Follow OHS practices and identify environmental hazardsICPSU216A Inspect quality against required standardsICPKN312A Apply knowledge of printing machining

Demonstrate how to prepare a photopolymer (flexographic) plate from film input for an existing job brief in your work place or alternatively a brief agreed with your assessor.

Task 3 ICPPP266A Make and proof relief platesICPSU203A Prepare and maintain the work areaICPSU261A Follow OHS practices and identify environmental hazardsICPKN312A Apply knowledge of printing machining

Demonstrate how to prepare and proof a relief plate from film input suitable for letterpress or label printing for an existing job brief in your workplace or alternatively a brief agreed with your assessor.

Task 4 ICPPP267A Produce offset lithographic platesICPSU203A Prepare and maintain the work areaICPSU261A Follow OHS practices and identify environmental hazardsICPSU216A Inspect quality against required standardsICPKN312A Apply knowledge of printing machining

Demonstrate how to prepare, expose and process a lithographic plate from film input for an existing job brief in your work place or alternatively a brief agreed with your assessor.

Task 5 ICPSU207A Prepare machine for operation (basic)ICPSU208A Operate and monitor machines (basic)ICPSU202A Prepare, load and unload product on and off machineICPSU201A Prepare, load and unload reels and cores on and off machineICPSU211A Prepare ink and additivesICPSU216A Inspect quality against required standardsICPSU224A Perform basic machine maintenanceICPSU261A Follow OHS practices and identify environmental hazardsICPKN312A Apply knowledge of printing machining

In this task you are required to demonstrate your skills in relation to the set up and operation of a printing machine utilising one of the following printing processes:

a) flexographic printing (flexographic press)

b) lithographic printing (lithographic press) or

c) relief printing (platen, cyclinder or rotary printing machine)

With your assessor you need to:

a) select one of the above printing processes

b) agree upon the specifications of a routine or basic job that you will use to demonstrate your skills and knowledge.

The job specifications may be based on an existing job brief within your workplace or alternatively a job specification agreed with your assessor.

(cont…)



Using the job specification you are required to:

a) prepare, load and unload product on and off the machine

b) prepare, load and unload reels and cores on and off the machine

c) prepare ink and additives for the particular job

d) set up the printing machine, conduct a proof run and adjust settings

e) operate and monitor the machine during the production process

f) inspect the quality of the product

g) shutdown the printing process

h) demonstrate how you would carry out basic maintenance and cleaning of the machine

[Note: A complex job description may be chosen where considered appropriate]

Task 6 – Complex printing

ICPPR413A Set up for complex flexographic printingICPPR314A Produce complex flexographic printed product

orICPPR431A Set up for complex lithographic printingICPPR332A Produce complex lithographic printed product

plusICPPR352A Produce complex relief printed productICPSU261A Follow OHS practices and identify environmental hazards

You are required to demonstrate your skills in relation to complex machine set ups and the operation of the machine to produce complex printed product. You may choose one type of printing process for both stages.

Set-up:

You are required to set-up a printing machine, conduct a proof run and adjust settings for a complex or non-routine print job. You may choose to carry out this task using either a flexographic (reel fed) or lithographic printing machine. With your assessor you are required to select an appropriate complex job specification. The job specifications may be based on an existing job brief within your workplace or alternatively a job specification agreed with your assessor.

Operation:You are required to demonstrate your skills in the operation of a printing machine for a non-routine or complex job specification using the same printing process as that selected for Task 5 (a - h) above.

Task 7 ICPSU261A Follow OHS practices and identify environmental hazardsICPKN312A Apply knowledge of printing machiningICPSU203A Prepare and maintain the work areaICPSU357A Apply quick changeover procedures

SCENARIO:

The following scenario will require you to demonstrate your knowledge and understanding of quick changeover procedures, OHS issues and the preparation and maintenance of the work area.



You are operating a printing machine with a fellow worker, Tom, a young school leaver who has only recently commenced working with your enterprise. The particular print job requires you, as the machine operator, to carrying out quick changeover procedures with minimum down time.

During the quick changeover you realise there is inadequate ink to continue the print run. Tom a willing assistant, conscious of the need to minimise production down time, rushes to the storeroom to get more ink. Shortly after you hear a crashing sound in the store area and rush over to see Tom lying on the floor injured having tripped over a number of boxes blocking the doorway to the store room. Almost all the contents of the last 30kg container of blue ink in the store have spilled on the floor.

You are required to discuss how you would respond to the incident. With reference to relevant enterprise procedures you should consider:

a) your immediate response to the situation

b) the OHS issues raised by the incident

c) cleaning of the work place and removal of wastes

d) changes you would recommend (including to quick changeover procedures) to ensure such an incident does not occur again

e) how you would complete the changeover to complete the job



OBSERVATION RECORDING SHEETPractical Tasks

CANDIDATE’S NAME: SIGNATURE: DATE:

ASSESSOR’S NAME: SIGNATURE: DATE:

LOCATION:

NB: The skills listed below must be verified by a competent assessor through observed demonstration either in the candidate’s workplace as part of the candidate’s normal work duty OR as part of a practical assessment/demonstration set by the assessor.



Unit and element

covered in task

Task No.

Observable behaviours in task Industry requirements Assessor’s comments Indicate if behaviour observed

Date assessed

ICPSU262A1, 2, 3, 4

ICPKN312A1, 3, 4, 5, 7, 9

ICPSU263A1, 2, 3

1A Communication:

Interacts with client in professional and courteous manner

Seeks and records relevant information

Clarifies client needs

Demonstrates understanding

Provides clear, logical and concise explanation

Industry knowledge:

Uses appropriate industry terminology

Understands pre-press functions and printing processes

Applies knowledge of printing process

Understands costs elements of production

Calculations:

Applies industry calculations accurately

Uses appropriate equipment – calculator and/or computer, tools for measuring

Customer requirements



Knowledge of laws and regulations


ICPSU281A1, 2

1B Uses computer system safely

Chooses appropriate program

Creates and saves document in appropriate

Format and file location

Safe work practices


ICPPP268A1, 2, 3, 4, 5

2 Follows job specifications

Selects and retrieves appropriate plate

Safe work practices

Standard operating



Unit and element

covered in task

Task No.


Date assessed

ICPSU203A1, 2, 3, 4

ICPSU261A1, 2, 3

ICPSU216A1, 2

ICPKN312A3

Checks film negatives and plans the process

Exposes the plate correctly

Washes out plate

Dries, cleans plate

Post exposes and finishes plate

Establishes/uses chemical register

Cleans work area

Applies basic principles of pre-press processes

Follows OHS:

identifies hazards while working

controls discharges and emissions

handles chemical and liquid waste

reports and records OHS issues

cleans work area

maintains supply of materials

Ensures quality

checks quality during job

completes required documentation

procedures

Job specifications

Quality standards



Industry terminology & practices

Good housekeeping

ICPPP266A1, 2

ICPSU203A3

3 Prepares the work area for job


Prepares and maintains plate processor

Establishes and maintains exposure

Plate processor manufacturer’s specifications




Unit and element

covered in task

Task No.


Date assessed

ICPSU2161, 2

ICPKN312A3

control

Uses vacuum frames and plate processors as required

Produces plates

Proofs relief plates

Checks quality during job

Stores plate correctly

Completes required documentation

Follows worksafe practices during plate preparation

Correctly handles chemical and liquid waste

Cleans and maintains work area

Job specifications

Quality standards

Safe work practices

Industry terminology and practices

Good housekeeping

ICPPP267A1, 2, 3, 4

ICPSU261A1, 2, 3

ICPSU203A1, 2, 3, 4

ICPSU216A1, 2

ICPKN312A3

4 Selects and retrieves appropriate plate and film

Prepares plate to accommodate printing machine plate positioning

Positions film correctly

Selects correct exposure unit

Exposes plate

Processes plate

Checks plate for quality and conformance

Treats plate with correct chemical and/or bakes plate

Prepares and stores plate prior to printing

Follows safe work practices throughout

Job specifications



Machine manuals

Quality standards

Environmental hazards procedures

Safe work practices

Good housekeeping



Unit and element

covered in task

Task No.


Date assessed

job

Checks quality during job

Completes required documentation


ICPSU207A1, 2, 3, 4, 5, 6

ICPSU208A1, 2, 3, 4, 5

ICPSU202A1, 2, 3

ICPSU201A 1, 2, 3

ICPSU211A1, 2, 3

ICPSU216A 1, 2

ICPSU224A1, 2, 3, 4, 5, 6

ICPSU261A1, 2, 3

ICPKN312A4, 6, 8, 10

5 APPLICABLE TO ALL MACHINESPrepares machine:

sets up and prepares substrates

sets up reel or sheet system to suit

sets up machine

Operate and monitor machines

operates and monitors reel system OR

operates and monitors sheet system

adds substrate/product to process

makes major adjustment to the process as required

reports adjustments

operates and monitors production

monitors product for quality

notices and reports faulty performance of equipment

Loads product onto machines

locates and prepares product

positions product on the machine

Job specifications



Safe work practices

Product labels

Waste minimisation

Good housekeeping



Unit and element

covered in task

Task No.


Date assessed

loads and unloads product

prepares and stores product ready for next process

Loads/unloads reels and cores

prepares and selects reels and cores

loads reels

unloads and stores reels

Prepare inks and additives

selects inks, dyes and additives

prepares inks, dyes and additives

records ink formulation and correct colour

stores, handles and labels inks, dyes and additives appropriately

Inspects quality

inspects job/product is inspected against job specifications

inspects and tests regularly to determine conformity with specifications

notices and corrects unsatisfactory work

completes relevant documentation

Performs basic machine maintenance

Carries out routine maintenance and cleaning:



Unit and element

covered in task

Task No.


Date assessed

reel handling system

sheet or object handling system

printing units

cutting / folding / collating units

fastening units

Shuts down machine:

shuts down machine

removes and stores used plates, cutting and other devices

removes product from the operating areas

repairs and records machine faults

cleans and washes machine at the end of run

disengages and cleans feed, transportation and delivery systems for next run

Follows OHS practices

identifies hazards while working

controls discharges and emissions

handles chemical and liquid waste

reports and records OHS issues

cleans work area

maintain supply of materials

Identifies hazards while working



Unit and element

covered in task

Task No.


Date assessed

Applies knowledge of:

printing processes

substrates and inks

printing requirements for pre-press and finishing processes

colour theory

ICPPR313A1, 2, 3, 4, 5, 6, 7, 8, 9

ICPR214A1, 2, 3, 4, 5, 6, 7

5A FLEXOGRAPHIC PRINTINGReads and interprets job specifications

Checks proofed job conforms

Reel system or sheet system sets up reel system or sheet system

Selects and prepares inks and additives

Sets up machine for complex flex. printing

Sets press, print impressions and web tensions appropriately for proof run

Checks print, drying and substrate for proof run

Conducts proof run

Inspects and/or tests proof

Readjusts settings to production speeds

Adjusts settings, documents and retains samples

Maintains operation of sheet/reel system

Adds and/or removes substrate as reqd

Monitors and adjusts machine to maintain

Job specifications


Safe work practices



Job specifications

Approved proofs


Good housekeeping



Unit and element

covered in task

Task No.


Date assessed

basic printing process

Maintains routine production process

Identifies problems and takes appropriate action to eliminate problems

Shuts down production process

Cleans and washes machine at the end of the run

ICPPR331A1, 2, 3, 4, 5, 6

ICPPR232A1, 2, 3, 4, 5, 6, 7

5B LITHOGRAPHIC PRINTINGConfirms and understands job specifications

Sets up reel system or sheet transportation system


Sets up machine for offset lithographic printing

Conducts OK print run

Inspects and/or tests OK/section

Makes necessary adjustments to settings

Maintains operation of sheet system

Maintains operation of reel system

Adds and removes substrate as required

Maintains lithographic printing



Job specifications


Safe work practices



Approved proofs


Good housekeeping



Unit and element

covered in task

Task No.


Date assessed


Cleans and washes up machine at the end of the run

ICPPR351A1, 2, 3, 4, 5, 6

ICPPR252A1, 2, 3, 4, 5, 6

5C RELIEF PRINTINGConfirms and understands job specifications



Sets up machine for relief printing

Conducts proof run and inspects and/or tests proof

Adjusts settings as required

Maintains operation of sheet system


Adds and removes substrate

Makes adjustments as required to maintain relief printing process




Cleans machine and washes up at the end of run

Job specifications


Safe work practices



Approved proofs


Good housekeeping

ICPPR413A1, 2, 3, 4, 5,6,

6 FLEXOGRAPHIC PRINTINGReads and correctly interprets job

Job specifications

Australian standards for



Unit and element

covered in task

Task No.


Date assessed

7, 8

ICPPR314A1, 2, 3, 4, 5, 6, 7

ICPSU261A1, 2, 3

specifications

Checks proofed job for conformance with job specifications

Sets up reel system to suit job specifications

Sets up machine for complex flexographic printing


Sets up in line-units

Sets press, print impressions and web tensions for proof run

Checks print, drying and substrate for proof run

Conducts proof run

Inspects and/or tests proof

Readjusts settings to production speeds

Makes adjustments to settings, documents and retains samples

storage of hazardous liquids

Safe work practices



Good housekeeping

ICPPR431A1, 2, 3, 4, 5, 6

ICPPR332A1, 2, 3, 4, 5, 6, 7, 8, 9

6 LITHOGRAPHIC PRINTINGConfirms and understands job specifications



Sets up machine for offset lithographic printing

Job specifications


Safe work practices





Unit and element

covered in task

Task No.


Date assessed

Conducts OK print run

Inspects and/or tests OK/section

Makes necessary adjustments to settings


Adds and/or removes substrate from the process

Makes adjustments & monitors machine to maintain basic printing process





Approved proofs


Good housekeeping

ICPPR352A1, 2, 3, 4, 5, 6, 7

6 RELIEF PRINTINGMaintains operation of sheet system


Adds and removes substrate as required

Maintains relief printing






Job specifications

Approved proofs



Safe work practices

Good housekeeping



Unit and element

covered in task

Task No.


Date assessed

ICPSU261A1, 2, 3

7a Offers initial assistance

Reports to appropriate personnel

Obtains first aid/medical assistance

Identifies containment method for spill

Complies with waste procedures and environmental regulations

Uses safety clothing and equipment to clean up area

Reports and records the incident

Removes hazards i.e. Boxes

Uses equipment to carry heavy materials/boxes

Provides instruction to other staff on OHS issue

Safe work practices

Codes of practice


Workplace emergency procedures


Good housekeeping

ICPKN312A2

7b Displays knowledge of principles of OHS

Displays knowledge of environmental protection

Display knowledge of relevant Acts and Regulations



Industry practices

ICPSU203A1, 2, 3, 4

7c Cleans work area regularly

Removes potential hazards

Uses equipment to transfer or carry materials

Stores materials in appropriate location/s

Retrieves information as required

Handles liquid waste appropriately

Safe work practices


MSDS

Manufacturer’s recommendations

Waste management



Unit and element

covered in task

Task No.


Date assessed

ICPSU357A1, 2, 3

7d Completes changeover after clean up

Improves planning and preparation for quick changeover procedures

Improves OHS standards

Trains staff in improved quick changeover procedures

Revises and documents existing procedures

Job instructions

Production schedule


Machine manuals



SECTION EResources for Practical

Tasks

You use this section to access any resources required by the candidate to undertake the practical task/s or scenario/s. They are suggested resources only. You may wish to modify or use other resources for the assessment tasks.



Nil supplied



SECTION FThird Party Verification

The preferred approach in gaining third party validation is to take the forms in this section to the candidate’s previous employers or referees to gain confirmation of the candidate’s skills against the required competencies. This would be done during a conversation or interview with these people.

It may be beneficial to make contact with the employers/referees early in the recognition process to make appointments, particularly if you have to travel some distance to visit them. This may be done on the same day as a practical assessment in the workplace if appropriate.

It is recommended that verification be obtained from one or two referees who can confirm the candidate’s industry skills in context over time.



REFEREE TESTIMONIAL

(Date)

To whom it may concern,

RE: skills in/as (insert candidate name) (insert industry/job title)

I certify that the above named person has:

worked at for a period of years

regularly undertaken the following activities within the workplace since commencing employment with this organisation:

Initial those skills/ competencies (below) that the candidate has or can successfully perform in the workplace

follow OHS requirements

identify workplace hazards and take appropriate actions

set up and operate a lithographic press

set up and operate a flexographic press

set up and operate a press for relief printing

make relief plates

make photopolymer (flexographic) plates

produce offset lithographic plates

carried out quality inspections

perform basic machine maintenance

perform basic industry calculations

use computer systems

carry out quick changeover procedures

communicate effectively in the workplace

prepare and maintain work areas

sound knowledge of printing machine

prepare ink and additives

If you would like any further information or would like to discuss any of the above, I can be contacted on

Yours sincerely

SignaturePrint Name and Position



SECTION GAssessment Tables

You use these tables as a reference tool to see at a glance which units/elements of competency are within the qualification.

Question numbers refer to those found in SECTION C of this kit.

Practical assessment/scenarios numbers refer to those found in SECTION D of this kit.

It is important to note that this section is used for validation purposes only. Any mapping should be done after questions and tasks have been selected.



Elements Performance Criteria Questions Practical Tasks

ICPSU216A Inspect quality against required standards1. Carry out inspection of

quality during job1.1 Job is collected / received and inspected against job specifications according to enterprise standards and procedures

1.2 Quality specifications and tolerances are understood

1.3 Variation to standards is monitored and corrective action taken to rectify the problem according to enterprise procedures

1.4 Inspection and testing procedures are applied at regular intervals to determine conformity with specifications and to minimise waste

1.5 Unsatisfactory work is identified according to predetermined standards and enterprise procedures

C, 1, 2, 3

C, 1, 3

C, 1, 3

C, 1, 3

C, E, 1, 3, 4

2, 3, 4, 5

2, 3, 4, 5

2, 3, 4, 5

2, 3, 4, 5

2, 3, 4, 5

2. Complete documentation

2.1 Documentation is accurately completed to meet required enterprise procedures

2.2 Problems and suggestions for improvement are documented and passed on to appropriate personnel

F, 1, 4

H, 1, 3, 4

2, 3, 4, 5

2, 3, 4, 5

ICPSU261A Follow OHS practices and identify environmental hazards1. Follow enterprise

procedures for hazard identification and risk control

1.1 Hazards in the work area are recognised and reported to designated personnel according to enterprise procedures

1.2 Enterprise procedures and work instructions for controlling risks are followed accurately

1.3 Enterprise procedures for dealing with accidents, fire and emergencies are followed whenever necessary within scope of responsibilities and competencies

5

5

5

2-7

2-7

2-7

2. Follow enterprise procedures for the control of environmental discharges / emissions

2.1 Abnormal or unacceptable emission levels are recognised and reported according to enterprise procedures

2.2 Waste removal from work area complies with enterprise procedures and environmental regulations

2.3 Containment procedures are applied according to standard operating procedures where required

2.4 Correct safety procedures are followed and personal protective equipment used correctly

5

M, 5

M, 5

M, 5

2-7

2-7

2-7

2-7

3. Contribute to participative arrangements for the management of OHS

3.1 OHS issues are raised with designated personnel according to enterprise procedures and relevant OHS legislation

3.2 Contributions to OHS management in the workplace are made within organisational procedures and scope of responsibilities and competencies

6

6

2-7

2-7

ICPSU262A Communicate in the workplace1. Convey and handle

information1.1 Gather, record and convey simple and routine information in a workplace related context

1.2 Personal interaction is courteous in a workplace related context

1.3 Queries are made clearly and concisely in a workplace related context

1.4 Correct procedures for location and storage of information are employed and the particular workplace practices are adhered to

1.5 Information is organised clearly, concisely and logically and complies with workplace practices

1.6 Workplace documents are completed clearly and accurately within a specified time

1.7 Time is used efficiently in a workplace related context

7, 9, 10

7, 9, 10

7, 9, 10

A, 7, 9, 10

7, 9, 10

7, 9, 10

7, 9, 10

1A

1A

1A

1A

1A

1A

1A




2. Give and follow simple routine instructions

2.1 Safe work practices are incorporated in the instructions

2.2 Instructions are accurate, clear, concise, comprehensive and are consistent with the skills of the receiver

2.3 Appropriate methods of instruction are selected

2.4 Interaction with others is efficient, effective, responsive, courteous and supportive

2.5 Prescribed sequences are adhered to in a workplace related context

2.6 Routine checking of own and others’ performance is exercised

2.7 Task is carried out in a workplace related context

8, 9, 10

8, 9, 10

8, 9, 10

8, 9, 10

8, 9, 10

8, 9, 10

8, 9, 10

1A

1A

1A

1A

1A

1A

1A

3. Participate in small informal work groups

3.1 Interaction is supportive, efficient, effective and courteous

3.2 Participation in discussions takes place in a workplace related context

3.3 Contributions are constructive in terms of the goal

3.4 Group decisions are understood and confirmed

8, 9, 10

8, 9, 10

8, 9, 10

8, 9, 10

1A

1A

1A

1A

4. Interact with clients 4.1 Interact with clients within, and external to, an organisation about simple routine matters

4.2 Interaction is consistent with the needs of the organisation and the organisation is presented in a positive and client-centred way

4.3 Correct forms of greeting, identification and address are used according to enterprise practices

4.4 The needs of the client are clarified and noted where appropriate

4.5 Referral processes are followed to establish contact between client and appropriate personnel

4.6 Discretion and confidentiality are exercised where appropriate

4.7 Appropriate follow-up steps are taken according to enterprise customer service practices

7

7

7

7

7

7

7, 10

1A

1A

1A

1A

1A

1A

1A

ICPKN312A Apply knowledge of printing machining1. Apply knowledge of

printing industry1.1 Printing industry terminology and vocabulary are used correctly and accurately

1.2 New technology and new work processes are monitored and implemented when required

1.3 Trends within the printing industry are monitored on an ongoing basis to inform personal work practices

11, 12

11, 13

11, 13

1A

1A

1A

2. Apply knowledge of government acts and regulations

2.1 Basic principles and obligations involved in copyright, OHS, environmental protection, access and equity and industrial awards are understood in relation to the workplace

2.2 The basic principles and obligations involved in copyright, OHS, environmental protection, access and equity and industrial awards are followed in personal work practices

11

11

7

7

3. Apply knowledge of pre-press processes

3.1 The basic principles behind the following pre-press functions: image production (typesetting, scanning, graphic arts camera), image combining (manual and electronic), image output (film, plates, direct to press) and digital workflow are understood and applied as required in the workplace

11 1A, 2, 3, 4




3.2 Different types of images (line, half-tone), digital and their use are understood and general strategies developed for printing

3.3 Different output settings eg screen rulings and angles, shapes, and how they affect final product are understood and general strategies developed for printing

3.4 The different types of output required for different printing processes are understood and general processes developed for printing

3.5 Different output devices eg film setters, plate setters, analogue proofs, digital proofs, are understood and general processes developed for printing

11, 12

11, 12

11, 12

11, 12

1A, 2, 3, 4

1A, 2, 3, 4

1A, 2, 3, 4

1A, 2, 3, 4

4. Apply detailed knowledge of printing processes

4.1 Principles of the following printing processes: lithography, relief, flexography, gravure, pad printing, screen printing, digital / electronic printing are applied when using a selected printing process

4.2 The types of jobs and products for each process are considered to ensure appropriate choices are made to meet client needs

4.3 The capabilities and limitations of each process are considered when using a selected printing process

11, 12

11, 12

11, 12

1A, 5

1A, 5

1A, 5

5. Apply knowledge of converting and finishing processes

5.1 Basic characteristics of the following converting and finishing processes: guillotining, flat-bed and rotary cutting, collating, folding, adhesive, mechanical and thermal fastening are taken into consideration when making print process decisions

5.2 The types of jobs and products for each process are considered to ensure appropriate choices are made to meet client needs

11, 12

11, 12

1A

1A

6. Apply detailed knowledge of substrates and inks

6.1 The range of substrates used for each printing process are taken into consideration when making print set-up decisions knowledge of substrates and inks

6.2 The relationship of different paper sizes is taken into consideration when making print set-up decisions

6.3 Different weights and callipers of substrates and how they affect printing operations are taken into consideration when making print set-up decisions

6.4 Paper grain and how it affects pre-press, printing and finishing operations are taken into consideration when making print set-up decisions

6.5 Different properties of ink such as drying properties, fastness, gloss, and how they affect printing and finishing operations are taken into consideration when making print set-up decisions

6.6 Inks and coatings that are appropriate and those that are not appropriate for particular finishing processes are taken into consideration when making print set-up decisions

11

11

11

11

11

11

5

5

5

5

5

5

7. Apply detailed knowledge of printing requirements for pre-press and finishing processes

7.1 Designs that are appropriate for different printing processes are understood and general strategies developed for printing

7.2 Criteria for evaluating suitability of pre-press outputs for printing processes are understood and general strategies developed for printing

7.3 Mechanisms and techniques for adjusting image registration and position are understood and general strategies developed for printing

7.4 Procedures for determining colour sequence are understood and general strategies developed for printing

7.5 Adjustments that can be made so that product matches approved proof are understood and general strategies developed for printing

7.6 Criteria for determining impositions and image placements for converting, binding and finishing operations are understood and general strategies developed for printing

11

11

11

11

11

11

1A

1A

1A

1A

1A

1A

8. Apply basic knowledge 8.1 Colour theory of additive colours (light), RGB, is understood and used to inform printing decisions 11 5




of colour theory

8.2 Colour theory of subtractive colours (pigments), CMYK, is understood and used to inform printing decisions

8.3 Relationship between ranges of visual colour RGB and CMYK is understood and used to inform printing decisions

8.4 Relationship between hue, greyness and substrate for tone and colour correction is understood and used to inform printing decisions

8.5 Colour matching conditions and colour matching systems are understood and used to inform printing decisions

11

11

11

11

5

5

5

5

9. Apply basic knowledge of costs of production

9.1 The main cost elements (fixed, capital and variable) in printing production are understood and used to inform printing decisions

9.2 The information required to accurately cost jobs and the means of collecting it (manual and computerised) are applied to work practices

9.3 Ways of minimising use of materials without affecting the quality of output is understood and used to inform printing processes

9.4 Ways of maximising efficiency of capital and human resources are understood and used to inform printing processes

11, 12

11

11

11

1A

1A

1A

1A

10. Apply basic knowledge of production management requirements and systems

10.1 The types of information that need to be exchanged between different stages of production to facilitate production efficiency are understood and used to inform personal work practices

10.2 Systems (manual and computerised) that can be used to exchange information are understood and used in the workplace

10.3 The basic principles of efficient production management are understood and used to inform personal work practices

12

12

12

5

5

5

ICPSU201A Prepare, load and unload reels and cores on and off machine1. Prepare reels and

cores1.1 Faulty material is visually identified and removed according to enterprise procedures

1.2 Substrate is positioned in correct unwind direction

1.3 Substrate is spliced / joined according to job requirements

1.4 Reel cores are selected or prepared to meet OHS requirements and job specifications

14

14, B

14

14, 15

5

5

5

5

2. Load reels and cores onto machine

2.1 Reels are loaded according to OHS requirements and manufacturer’s and enterprise procedures and specifications

2.2 Reel cores are loaded to meet job specifications

2.3 Area around machine is cleaned during and on completion of loading

14, 15, 16, B

14, 15, B

14

5

5

5

3. Unload reels off machine

3.1 Reels are unloaded according to OHS requirements and manufacturer’s and enterprise procedures and specifications

3.2 Reels are prepared (stripped, stacked, wrapped, labelled) for next process according to manufacturer’s and enterprise procedures and specifications

3.3 Reels are stored according to manufacturer’s and enterprise procedures and specifications

14, 15, 16, B

14, 15, B

14

5

5

5

ICPSU202A Prepare, load and unload product on and off machine1. Prepare product 1.1 Job sheets or equivalent are interpreted correctly A 5




1.2 Product is located and prepared to meet job specifications

1.3 Product is positioned correctly to the machine to meet job specifications

1.4 Faulty product is visually identified and removed according to OHS requirements and enterprise procedures

B

18, B

18

5

5

5

2. Load product onto machine

2.1 Product is loaded according to OHS requirements and manufacturer’s and enterprise procedures and specifications

2.2 Area around machine is cleaned during and on completion of loading

18, 19, 20

18, 20

5

5

3. Unload product off machine

3.1 Product is unloaded according to OHS requirements and manufacturer’s and enterprise procedures and specifications

3.2 Product is prepared (hand-stripped, stacked, wrapped, labelled) for next process according to manufacturer’s and enterprise procedures and specifications

3.3 Product is stored according to manufacturer’s and enterprise procedures and specifications

18

18

18

5

5

5

ICPSU203A Prepare and maintain the work area1. Perform general

cleaning duties1.1 Requirements for cleaning duties are identified

1.2 Personal safety equipment, where needed, is selected and used according to OHS and enterprise procedures

1.3 Appropriate cleaning equipment and chemicals / detergents for specific tasks are determined, prepared and mixed to manufacturer’s specifications and OHS procedures

1.4 Procedures for handling, storage and correct disposal of cleaning liquids are carried out according to enterprise, OHS and EPA specifications

1.5 Cleaning is carried out to OHS and enterprise requirements

21, K

21, K

21, K

21, K

21, K

2, 4, 7

2, 4, 7

2, 4, 7

2, 4, 7

2, 4, 7

2. Maintain supplies of materials

2.1 Requests are received, where relevant, and tasks are confirmed and organised according to specific procedures materials

2.2 Tools and equipment are identified, stored and maintained according to manufacturer’s recommendations to ensure ease of access and operator safety

2.3 Appropriate equipment for transferring material or equipment is identified and organised, where relevant

2.4 Material or equipment is loaded and unloaded using suitable equipment (other than forklift) according to materials handling requirements, safe work practices and correct manual handling techniques

2.5 Material is transferred to correct destination in a safe manner

22

22

22

22

22

2, 4, 7

2, 4, 7

2, 4, 7

2, 4, 7

2, 4, 7

3. Store and retrieve artwork, information, used plates and film

3.1 Inventory control procedures are followed to ensure correct filing and retrieval of artwork, information, used plates and film artwork, information, used plates and film

3.2 Artwork and other materials are stored and retrieved according to enterprise procedures to ensure preservation

23

23

2, 3, 4, 7

2, 3, 4, 7

4. Handle chemicals and liquid waste

4.1 Material safety data sheets are used to identify safe chemical handling procedures

4.2 Chemicals and liquid waste are handled according to manufacturer’s specifications and enterprise OHS requirements

5, 6, 21, K, M

5, 6, 21, K, M

2, 4, 7

2, 4, 7




4.3 The correct procedure for dealing with spilt chemicals is demonstrated according to OHS requirements 5, 6, 21, K, M 2, 4, 7

ICPSU207A Prepare machine for operations (basic)1. Prepare or set up

substrates (or loads)1.1 Job sheets or equivalent instructions are interpreted correctly

1.2 Product is located, checked and prepared to meet job specifications according to established enterprise procedures and OHS procedures

1.3 Faulty material is visually identified and removed according to established enterprise procedures and OHS procedures

A

B

3, 4, B

5

5

5

2. Set up reel systems (OR Element 3)

2.1 Unwind reel is set up and adjusted to suit job requirements

2.2 Webbing procedures are carried out according to enterprise procedures

2.3 Web-control system is set up and adjusted to suit job requirements

2.4 Reels are spliced / joined to suit job requirements

2.5 Rewind reel is set up and adjusted to suit job requirements

2.6 Folder is set up and adjusted to suit job requirements

2.7 Sheeter is set up and adjusted to suit job requirements

2.8 Readiness of transport and delivery systems is reported according to enterprise procedures for final adjustments by designated person

24, 26

24, 26

24, 26

24, 26

24, 26

24, 26

24, 26

F, 24, 26

5

5

5

5

5

5

5

5

2. Set up sheet or product systems (OR Element 2)

3.1 Feeder is set up and adjusted to suit job requirements

3.2 Sheet / product pick-up and transportation system is set up and adjusted to suit job requirements

3.3 Transfer systems are set up and adjusted to suit job requirements

3.4 Delivery is set up and adjusted to suit job requirements

3.5 Product is removed from process according to job instructions

3.6 Sheet / product transfer and control system is set up and adjusted to suit job requirements

3.7 Readiness of transport and delivery systems is reported according to enterprise procedures for final adjustments by designated person, if required

24, 26

24, 26

24, 26

24, 26

24, 26

24, 26

F, 24, 26

5

5

5

5

5

5

5

4. Prepare machine 4.1 Machine is set up according to job instructions

4.2 Inks, glues, liquid and or other materials are loaded as required according to manufacturer’s instructions and enterprise procedures

4.3 Plates, cutting or other devices are installed as required according to manufacturer’s instructions and enterprise procedures

4.4 Registration, alignment or centering is confirmed according to machine manufacturer’s / supplier’s instructions and enterprise procedures

4.5 Machine is run through cycle at the same time ensuring that the substrate / product is positioned properly and that the process is being performed according to established workplace and OHS procedures

24, 26

24, 26

24, 26

24, 26

24, 26

5

5

5

5

5




4.6 Readiness of machine is reported according to enterprise procedures for final adjustments & proofing by designated person, if required 24, 26 5

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, if required, and in compliance with OHS requirements

5.3 Unused materials are stored according to manufacturer’s / supplier’s specifications and enterprise procedures

5.4 Used plates, cutting and other devices are removed and stored according to manufacturer’s / supplier’s specifications and enterprise procedures

5.5 All product is removed from operating area according to enterprise procedures and OHS standards

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

5.7 Repair / adjustment is verified prior to resumption of operations

I, J

9, I, J

I, J

I, J

25, I, J

F, I, J

I, J

5

5

5

5

5

5

5

6. Clean and wash up machine at end of run

6.1 Machine sections, as relevant to process, are cleaned ready for next run

6.2 Inking / gluing / coating system, if used in process, is washed up ready for next run, and waste is disposed of according to enterprise and regulatory requirements

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

6.4 Feed, transportation and delivery systems are disengaged and cleaned ready for next run

K

K

K

K

5

5

5

5

ICPSU208A Operate and monitor machines (basic)1. Operate and monitor

reel systems or (element 2)

1.1 Job sheets or equivalent instructions are interpreted correctly

1.2 Reel stand is monitored and adjusted to ensure efficient continuous operation according to job instructions

1.3 Web control system is monitored and minor adjustments made to ensure correct tension and accurate continuous positioning of the web for efficient

1.4 Substrate is added to process according to job instructions

1.5 Reel rewind section is monitored and minor adjustments made to maintain correct tension and to ensure no marks, blemishes or damage to finished product

1.6 Substrate is removed from process according to job instructions

1.7 Sheeting section is monitored and minor adjustments made to ensure quality and efficient product delivery

1.8 Need for major adjustments to process are identified and reported according to company operating procedure to designated person

27, 28, A

27, 28, 29

27, 28, 29

27, 28

27, 28

27, 28

27, 28

27, 28, 29

5

5

5

5

5

5

5

5

2. Operate and monitor sheet or product systems (OR Element 1)

2.1 Job sheets or equivalent instructions are interpreted correctly

2.2 Feeder is monitored and minor adjustments made to ensure continuous and efficient feeding to machine

2.3 Sheet or product pick-up and transport system is monitored and minor adjustments made to ensure accurate and continuous sheet or product handling and efficient operation

2.4 Transfer systems are monitored and minor adjustments made to ensure correct and continuous sheet or product handling and efficient

A, 27, 28

27, 28

27, 28

5

5

5




operation

2.5 Product is added to process according to job instructions

2.6 Delivery is monitored and minor adjustments made to ensure quality and efficient product delivery

2.7 Need for major adjustments to process are identified and reported according to company operating procedures to designated person

27, 28

27, 28

27, 28, 29

F, 27, 28, 29

5

5

5

5

3. Maintain and monitor production process

3.1 Production process is operated and monitored in association with fellow workers and according to company specifications and planned daily schedule

3.2 Product is monitored and minor adjustments are made to ensure quality of output is maintained

3.3 Need for major adjustments to process are identified and reported according to operating procedure to other appropriate worker

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

3.5 Waste is sorted according to enterprise procedures

9, 27, 29

27, 29

27, 29

27, 29

L, M

5

5

5

5

5



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

4.3 Unused materials are stored according to manufacturer / supplier specifications and company operating procedures

4.4 Used plates, cutting and other devices are removed and stored according to manufacturer / supplier specifications and company operating procedures

4.5 All product is removed from operating area according to enterprise procedures and OHS standards

4.6 Machine faults requiring repair are identified and reported, according to enterprise procedures to designated person


I, J

9, I, J

I, J

I, J

I, J

F, I, J

I, J

5

5

5

5

5

5

5

5. Clean and wash up machine at end of run

5.1 Machine units, as relevant to process, are cleaned ready for next run

5.2 Inking / gluing / coating system, if used in process, is washed up ready for next run, and waste is disposed of according to company and regulatory requirements

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

5.4 Feed, transportation and delivery systems are disengaged and cleaned ready for next run

K

K

K

K

5

5

5

5

ICPSU211A Prepare ink and additives1. Select ink 1.1 Inks, dyes and additives are selected according to job specifications

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

1.3 Inks and dyes are selected according to suitability of substrate, adhesion, physical and chemical resistance, and light fastness, drying method and print process

30, 31, 32, 34, A

2, 31, 32, 34

31, 32, 34

5

5

5




2. Prepare ink 2.1 Inks, dyes and additives are prepared according to OHS requirements, and manufacturer’s / supplier’s instructions with suitable precautions to minimise waste

2.2 Correct colour and weight / volume of ink are mixed and prepared to match the requirements of the job specifications and the printing press to be used

2.3 Formulation of the ink and the approved colour is appropriately recorded

30, 33, 34, L M

30, 33, 34

30, 33, 34, F

5

5

5

3. Store and handle ink 3.1 Inks, dyes and additives are appropriately stored, handled and labelled according to manufacturer’s / supplier’s instructions to prevent damage and hazards to personnel

34 5

ICPSU224A Perform basic machine maintenance1. Carry out minor routine

maintenance and programmed cleaning of reel handling system

1.1 Unwind unit is cleaned, checked and lubricated according to manufacturer’s recommendations and enterprise standard operating procedures

1.2 Web control devices are cleaned, checked and lubricated according to manufacturer’s recommendations and enterprise standard operating procedures

1.3 Rewind unit is cleaned, checked and lubricated according to manufacturer’s recommendations and enterprise standard operating procedures

1.4 Folding unit is cleaned, checked and lubricated according to manufacturer’s recommendations and enterprise standard operating procedures

1.5 Sheeting unit is cleaned, checked and lubricated according to manufacturer’s recommendations and enterprise standard operating procedures

1.6 Basic maintenance is carried out according to OHS requirements

35, 36, 37, K

35, 36, 37, K

35, 36, 37, K

35, 36, 37, K

35, 36, 37, K

35, 36, 37

5

5

5

5

5

5

2. Carry out minor routine maintenance and programmed cleaning of sheet or object handling systems

2.1 Feeder is cleaned, checked and lubricated according to manufacturer’s recommendations and enterprise standard operating procedures

2.2 Lays and transfer gripper system are cleaned, checked and lubricated according to manufacturer’s recommendations and enterprise standard operating procedures

2.3 Delivery is cleaned, checked and lubricated according to manufacturer’s recommendations and enterprise standard operating procedures


35, 36, K

35, 36, K

35, 36, K

35, 36

5

5

5

5

3. Carry out minor routine maintenance and programmed cleaning of printing units

3.1 Cylinder / screen / plate and roller surfaces, safety devices, gears and bearings are checked, lubricated and maintained according to manufacturer’s recommendations and enterprise standard operating procedures

3.2 Ink distribution system components are checked, lubricated, maintained and replaced according to manufacturer’s recommendations and enterprise standard operating procedures

3.3 Various print control devices are checked, lubricated and maintained according to manufacturer’s recommendations and enterprise standard operating procedures

35, 36, 38, K

35, 36, 38, K

35, 36, 38, K

5

5

5




3.4 Basic maintenance is carried out according to OHS requirements 35, 36, 38 5

4. Carry out minor routine maintenance and programmed cleaning of cutting units

4.1 Cutting devices and knives are checked, lubricated, maintained and replaced according to manufacturer’s recommendations and enterprise standard operating procedures

4.2 Machine bed is checked and maintained according to manufacturer’s recommendations and enterprise standard operating procedures


35, 36, K

35, 36, K

35, 36

5

5

5

5. Carry out minor routine maintenance and programmed cleaning of folding/collating units

5.1 Folding / collating system components are checked, lubricated and maintained according to manufacturer’s recommendations and enterprise standard operating procedures



35, 36, K

35, 36, K

35, 36

5

5

5

6. Carry out minor routine maintenance and programmed cleaning of fastening units

6.1 Adhesive and mechanical fastening components are checked, lubricated and maintained according to manufacturer’s recommendations and enterprise standard



35, 36, K

35, 36, K

35, 36

5

5

5

ICPSU263A Perform basic industry calculations1. Calculate costs and

dimensions1.1 Additions, subtractions, multiplications and divisions of costs and dimensions are correctly calculated

1.2 Material and time costs are correctly calculated for the elements of a brief

1.3 Percentages of cost and time are correctly calculated to fulfil the requirements of a brief

1.4 Results of calculations are correctly recorded

39

39

39

39

1A

1A

1A

1A

2. Calculate area, density and volume

2.1 The density and / or volume of fluids and colours are correctly calculated and applied

2.2 Percentages of densities and volumes are correctly calculated to fulfil the requirements of a brief

39

39

1A

1A

3. Use basic measuring tools and apply results of measurement

3.1 Appropriate measuring tools are selected and used correctly and accurately

3.2 Measurements are correctly interpreted and used in appropriate calculations

39, 40

39, 40

1A

1A

ICPSU281A Use computer systems1. Use a stand alone

computer/terminal correctly

1.1 Correct posture at the keyboard is adopted according to OHS

1.2 Data is correctly accessed to ensure no loss of data

1.3 Data is manipulated correctly to ensure access, retrieval and storage of data

1.4 Keyboarding technique is safe and meets the speed requirements of the job, if necessary

41

42

42

42

1B

1B

1B

1B




2. Perform computer / terminal functions

2.1 Data is accessed, saved and retrieved for reference and for amendment

2.2 The appropriate program is selected for the job to be undertaken

2.3 Mouse and / or keyboard functions are used correctly to operate the computer system

2.4 Features of applications are used correctly to deliver a specified output

2.5 Data is saved in correct format and file location

2.6 Master pages, templates and style sheets, as appropriate, are used consistently to ensure data is the same after exchange or transfer

42

42

42

42

42

42

1B

1B

1B

1B

1B

1B

ICPSU357A Apply quick changeover procedures1. Prepare for changeover 1.1 Timing of changeover is determined according to production schedule

1.2 All required tools / parts / materials are obtained for changeover

1.3 Process and tools / parts / materials are organised ready for changeover

1.4 Liaison with relevant people is conducted for quick changeover

B, 43, 44, 45, N

B, 43, 44, 45

B, 43, 44, 45

8, 9, 43, 44, 45

7

7

7

7

2. Make quick changeover 2.1 Quick changeover is planned according to quick changeover principles

2.2 Changeover is completed according to enterprise procedures

2.3 Output is checked to meet specifications

2.4 Any steps which cause a problem are noted and changes recommended to problematic steps

B, 43, 44, 45

43, 44, 45

2, 3, 43, 44, 45

43, 44, 45, F

7

7

7

7

3. Improve OHS 3.1 Hazards in all steps/actions are identified

3.2 Risks from each hazard are determined

3.3 Actions which may be performed in a more ergonomic manner are identified

3.4 Changes are recommended to improve OHS

5, 43

5, 6, 43

5, 6, 43

5, 6, 43

7

7

7

7

ICPPP267A Produce offset lithographic plates1. Select and prepare

plate1.1 The job specifications are interpreted to determine the appropriate type and size of plate for the job

1.2 The plate is selected to deliver the quality of output required by the job brief

1.3 Plate is prepared to accommodate printing machine plate positioning requirements

A

A

A

4

4

4

2. Expose the plate 2.1 The work area is tidied and cleaned to ensure quality of output

2.2 Film is correctly positioned on the plate according to job specification

2.3 The correct exposure unit is selected to deliver the required output

2.4 Exposure control is correctly established utilising a quality control step wedge

80, 82

80, 82

80, 82

80, 82

4

4

4

4




2.5 Exposure and vacuum frame are maintained according to manufacturer’s specifications 80, 82 4

3. Process the plate 3.1 The plate processing unit is maintained according to manufacturer’s specifications

3.2 The plate is processed according to plate manufacturer’s specifications

80

80

4

4

4. Post-treat the plate 4.1 The plate is checked for quality of outcome and analysed for conformance to job specifications

4.2 Changes to the plate image are carried out correctly to ensure the standard of output required by the job brief

4.3 The plate is chemically treated and / or baked according to job specifications

4.4 The plate is prepared for storage prior to printing according to manufacturer’s specifications

80, 81

80, 81

80, 81

80, 81

4

4

4

4

ICPPP268A Make photopolymer plates (flexographic)1. Select the plate 1.1 Job specifications are interpreted to ensure appropriate plate selection

1.2 The correct plate is selected according to the printing requirements and job specifications

49, A

49, B

2

2

2. Pre-plan the process 2.1 Film negatives are checked for conformance with job specifications

2.2 Any extra exposure masking is planned by examining the film

2.3 Appropriate exposure masks are cut

2.4 The appropriate amount of plate material is calculated to ensure economical use

49, B

49, B

49, B

49, B

2

2

2

2

3. Expose the plate 3.1 Exposure is determined by using step wedges and depth gauge to establish the correct front and back exposure time

3.2 The plate is exposed according to job specification

3.3 The exposure unit and vacuum frame are maintained according to manufacturer’s specifications

49, 50, 52, 53

49, 50, 52, 53

49, 50, 52, 53

2

2

2

4. Develop the plate 4.1 The chemistry balance is maintained according to manufacturer’s specifications

4.2 The washout unit is maintained according to manufacturer’s specifications

4.3 The plate is washed out to pre-determined depth that has been pre-set by front and back exposures

49, 50, 52, 53

49, 50, 52, 53

49, 50, 52, 53

2

2

2

5. Finish the plate 5.1 The plate is dried in a drying oven at a temperature and time according to manufacturer’s specifications

5.2 The back of the plate is cleaned

5.3 The plate is post-exposed according to manufacturer’s specifications

5.4 The plate is light finished according to manufacturer’s specifications

5.5 OHS procedures are observed to ensure a safe working environment when making plates

49, 50, 52, 53

49, 50, 52, 53

49, 50, 52, 53

49, 50, 52, 53

49, 50, 52, 53

2

2

2

2

2

6. Establish and maintain a chemical register

6.1 A chemical register is established to identify and describe the purpose of each chemical and to ensure finished plates meet set specifications

49, F 2




6.2 All chemicals used in the workplace are identified and registered correctly according to safe working practices 49, F 2

ICPPR214A Produce basic flexographic printed product1. Maintain routine

operation of reel system (OR Element 2)

1.1 Reel stand and rewind sections are monitored and adjusted to ensure efficient continuous operation and maintain correct tension and to ensure no marks, blemishes or damage to finished product

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 and removed to process according to job instructions

1.4 Sheeting action is monitored and adjusted to ensure quality and efficient product delivery

1.5 Set-off / marking prevention system is monitored and adjusted to ensure quality of printed product without set-off or marking meets the standard of approved proof

55

55

55

1, 2, 3, 4, 55

1, 2, 3, 4, 55

5

5

5

5

5

2. Maintain routine operation of sheet system (OR Element 1)

2.1 Feeder and delivery are monitored and adjusted to ensure continuous and efficient feeding and delivery to and from machine

2.2 Sheet pick-up and transport system is monitored and adjusted to ensure accurate and continuous sheet handling and efficient operation

2.3 Transfer systems are monitored and adjusted to ensure correct and continuous sheet handling and efficient operation

2.4 Set-off / marking prevention system is monitored and adjusted to ensure quality of printed product meets the standard of approved proof

2.5 Substrate is added to process according to job instructions

55

55

55

55

55

5

5

5

5

5

3. Maintain basic flexographic printing process

3.1 Flexographic plate and plate cylinder or sleeve condition is monitored and adjusted to ensure the quality of printed product meets the standard of the approved proof

3.2 Flexographic impression roller condition is monitored to ensure the quality of printed product meets the standard of approved proof

3.3 Flexographic inking system and doctor blade are monitored and adjusted to ensure quality of printed product meets the standard of approved proof

3.4 Drying systems are monitored and adjusted to ensure quality of printed product meets the standard of approved proof

3.5 Basic in-line printing / converting / binding / finishing process(es) are monitored and adjusted to ensure quality of printed product meets the standard of approved proof

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

5

5

5

5

5

4. Maintain basic flexographic printing process

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

4.2 Production is maintained according to OHS requirements, manufacturer’s specifications and enterprise procedures

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

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

4.5 Ink performance, colour, register and position of print are monitored and adjusted throughout production run

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

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

5

5

5

5

5

5




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



56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

5

5

5

5. Identify and rectify faults

5.1 Problem in flexographic machine operation is identified and reported according to enterprise procedures

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

5.3 Flexographic machine operation is checked to ensure correct operation


4, F

4

3, 4

4, F

5

5

5

5




6.3 Reels and cores are removed from press if web-fed

6.4 Unused ink is drained back to containers and correctly labelled and stored according to manufacturer’s / suppliers specifications and enterprise procedures

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

6.6 All product is removed from operating area

I, J

9, I, J

I, J

34, I, J

L

I, J

5

5

5

5

5

5

7. Clean and wash up printing machine at end of print run

7.1 Cylinders or sleeves, plate and roller surfaces are cleaned ready for next run

7.2 Inking rollers and doctor blades or chamber blade systems are cleaned with correct solvents according to OHS guidelines

7.3 Ink pumps, tanks and hoses are cleaned correctly

7.4 Impression rollers / central impression and press rollers are cleaned

7.5 In-line printing / converting / binding / finishing units are cleaned ready for next run

7.6 Reel of sheet-feed transportation and delivery systems are disengaged and cleaned ready for next run

7.7 Press is lubricated and protected according to duration of shutdown

7.8 Production records or other documentation are accurately completed where required by enterprise procedures

K

K

K

K

K

K

K

F, K

5

5

5

5

5

5

5

5

ICPPR313A Set up for basic flexographic printing1. Confirm routine job

specifications1.1 Job requirements are read and interpreted from job documentation or production control system

1.2 Set-up is carried out correctly in minimum time with minimum wastage

1.3 Availability of all job related components is checked

1.4 Proofed job is checked for conformance with job specifications

A

A, L

A

A

5

5

5

5




2. Set up routine reel system (OR Element 3)

2.1 Reels are checked for treatment levels, coatings, printing side and age of product system

2.2 Unwind reels are secured on reel shaft according to job specifications

2.3 Reels are correctly positioned on unwind stand according to job specifications

2.4 Correctly cut cores are positioned and mounted securely on rewind shafts

2.5 Press is webbed for single-sided surface print according to job specifications

2.6 Edge guide is centred and set according to job specifications

2.7 Unwind tension is set to suit substrate according to job specifications

2.8 Rewind tension is set to suit substrate according to job specifications

2.9 Nip rollers are set according to job specifications

2.10 PIV (Positively Infinitely Variable) drive is set for appropriate tensioning of substrate

61, 66

61, 66

61, 66

61, 66

61, 66

61, 66

61, 66

61, 66

61, 66

61, 66

5

5

5

5

5

5

5

5

5

5

3. Set up routine reel system (OR Element 2)

3.1 Feeder is set up and adjusted according to job specifications system

3.2 Sheet pick-up and transportation system is set up and adjusted according to job specifications

3.3 Transfer systems are set up and adjusted according to job specifications

3.4 Delivery is set up and adjusted according to job specifications

3.5 Substrate is removed from stacker according to job specifications

3.6 Sheet transfer and control system is set up and adjusted according to job specifications

3.7 Set off / marking prevention devices are set up and adjusted according to job specifications

61, 66

61, 66

61, 66

61, 66

61, 66

61, 66

61, 66

5

5

5

5

5

5

5

4. Select and prepare inks and solvents

4.1 Inks and solvents are selected according to routine job specifications and end-user requirements

4.2 Quality and suitability of inks and solvents are checked and appropriate action is taken

4.3 Inks and solvents are prepared according to OHS requirements, and manufacturer’s / supplier’s instructions with suitable precautions to minimise waste

4.4 Correct colour and weight / volume of ink are mixed and viscosities checked and modified according to press requirements and routine job specifications

4.5 Ink formula and approved colour draw downs appropriately recorded

4.6 Inks and solvents are appropriately labelled, handled and stored according to manufacturer’s / supplier’s instructions and the relevant hazardous liquids storage regulations

30-34, 61

2, 30-34, 61

30-34, L, M, 61

30-34, 61

30-34, 61, F

34, 61

5

5

5

5

5

5

5. Set up machine for basic fleoxgraphic printing

5.1 Flexographic plate cylinders are installed and register adjustments centred OR

5.2 Sleeves are installed in press and register adjustments made OR

5.3 Plate mounting sheets are mounted on cylinders in press and register adjustments made

62

62

62

5

5

5




5.4 Plate cylinders are gauged up or pre-set to impression

5.5 Inking system is set up and roller nips / blades are set correctly

5.6 Ink circulation is maintained at correct level and flow for machine requirements

5.7 Viscosities are adjusted according to job specifications

5.8 Air volume and drier temperatures or curing systems are selected to suit inks, substrate, solvents and according to job specifications

5.9 Air volume is adjusted between colours to maximise drying and minimise air overspill

62

62, 63

62, 63

62, 63

62, 63

62, 63

5

5

5

5

5

5

6. Set up in-line units for basic process(es)

6.1 Minor in-line printing / converting / binding units are set up for basic process(es) and adjusted to suit machine requirements and job specifications

6.2 Assistance is given in the set-up of major in-line printing / converting / binding units. (Note: if entire set-up is done refer to appropriate Set up competency standards.)

62, 63

62, 63

5

5

7. Conduct proof run 7.1 Material to be used for proof is organised correctly

7.2 Press is set up and operated according to OHS guidelines

7.3 Print impressions are set to minimum kiss impression

7.4 Web tensions are correctly set at unwind, between stations and rewind

7.5 The print is checked for register

7.6 Drying is checked as sufficient to key ink to the substrate

7.7 The viscosities are adjusted to obtain the correct colour at proof speed and checked against colour matching system

7.8 The substrate is checked against job specifications

64, 65, C, D, E

64, 65, C, D, E

64, 65, C, D, E

64, 65, C, D, E

64, 65, C, D, E

64, 65, C, D, E

64, 65, C, D, E

64, 65, C, D, E

5

5

5

5

5

5

5

5

8. Organise proof inspection and / or testing

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

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

64, 65, C, D, E

64, 65, C, D, E

5

5

9. Readjust settings to production speed

9.1 Production speed print results are interpreted and appropriate adjustments are made to press, ink and substrate settings

9.2 Adjustments are made according to product specifications and press performance

9.3 Web is spliced at production speed and further samples are obtained for quality inspections at appropriate intervals

9.4 Press setting is documented and samples are retained

E

E

E

F

5

5

5

5

ICPPR314A Produce complex flexographic printed product1. Maintain non-routine

operation of reel transportation system

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


55

55

6

6




1.3 Substrate is added to process according to job instructions 55, A 6

2. Maintain non-routine operation of reel delivery system

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

2.2 Substrate is removed from process according to non-routine job instructions

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


55

55, A

1, 2, 3, 4, 55

1, 2, 3, 4, 55

6

6

6

6

3. Maintain complex flexographic printing process

3.1 Flexographic plate and plate cylinder or sleeve condition is monitored and adjusted to ensure the quality of printed product meets the standard of the approved proof

3.2 Flexographic impression roller condition is monitored to ensure the quality of printed product meets the standard of approved proof

3.3 Flexographic inking system and doctor blade condition are monitored and adjusted to ensure quality of printed product meets the standard of approved proof


3.5 In-line printing / converting / binding / finishing processes are monitored and adjusted to ensure quality of product meets the standard of the approved proof

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

6

6

6

6

6

4. Maintain non-routine production process

4.1 Production process is operated in association with fellow workers and according to company specifications and planned daily schedule

4.2 Production is maintained within OHS requirements and company and manufacturer’s specifications

4.3 Manual and / or automatic control is used as per specification







56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

56, 58, 59, 60

F, 56, 58, 59, 60

4, F, 56, 58, 59, 60

56, 58, 59, 60, L

6

6

6

6

6

6

6

6

6

5. Identify and rectify faults

5.1 Problem in flexographic machine is identified and reported according to enterprise procedures


5.3 Flexographic machine operation is checked to ensure correct operation


F, 4, 57

4, 57

57

4, F, 57

6

6

6

6







6.3 Reels and cores are removed from press

6.4 Unused ink is drained back to containers and correctly labelled and stored according to manufacturer / supplier specifications and enterprise procedures



I, J

9, I, J

I, J

34, I, J

I, J

I, J

6

6

6

6

6

6


7.1 Cylinders or sleeves, plate and roller surfaces are cleaned ready for next run

7.2 Inking rollers and doctor blades or chamber blade systems are cleaned with correct solvents according to OHS guidelines

7.3 Ink pumps, tanks and hoses are cleaned correctly

7.4 Impression rollers / central impression and press rollers are cleaned


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

7.7 Press is lubricated and protected according to duration of shutdown


K

K

K

K

K

K

K

F

6

6

6

6

6

6

6

6

ICPPR232A Produce basic lithographic printed product1. Maintain routine

operation of reel system (OR Element2)

1.1 Reel stand and rewind section are is monitored and adjusted to maintain correct tension and to ensure no marks or blemishes to finished product and to ensure efficient continuous operation


1.3 Substrate is added to and removed from process according to job instructions


67

67

67

67

5

5

5

5

2. Maintain routine operation of sheet system (OR Element 1)

2.1 Feeder and delivery sections are is monitored and adjusted to ensure continuous and efficient feeding to machine operation of sheet




67

67

67

67

5

5

5

5

3. Maintain basic routine lithographic printing process

3.1 Lithographic plate and plate cylinder condition is monitored and adjusted to ensure the quality of printed product meets the standard of the approved proof

3.2 Lithographic blanket and blanket cylinder condition is monitored and adjusted to ensure the quality of printed product meets the

67

67

5

5




standard of approved proof

3.3 Lithographic impression cylinder condition is monitored and adjusted to ensure quality of printed product meets the standard of approved proof

3.4 Lithographic inking condition is checked and maintained to ensure quality of printed product meets the standard of approved proof

3.5 Lithographic dampening system condition is monitored and adjusted maintained to ensure quality of printed product meets the standard of approved proof

67

67

67

5

5

5

4. Maintain routine production process




4.4 Performance is monitored and verified according to enterprise procedures

4.5 In performance, colour, register and position of print are monitored and adjusted maintained throughout production run



B, 9, 69

69

69

69

69

F, 4, 69

69

5

5

5

5

5

5

5

5. Rectify minor lithographic machine faults


5.2 Problems with lithographic machine operation is identified and reported according to enterprise procedures

5.3 Lithographic machine operation is checked to ensure correct operation

4, 68

F, 4, 68

4, 68

5

5

5




6.3 Unused ink is correctly labelled and stored according to manufacturer / supplier specifications and enterprise procedures





I, J

9, I, J

I, J

I, J

I, J

F, I, J

I, J

5

5

5

5

5

5

5


7.1 Cylinders, plate and roller surfaces are cleaned ready for next run

7.2 Inking system and dampening system are washed up ready for next run, and liquid waste is disposed of according to company and regulatory requirements


7.4 Reef Reel-fed, transportation and delivery systems are disengaged and cleaned ready for next run

7.5 Sheet feed, transport and delivery system are disengaged and cleaned ready for next run

K

K

K

K

K

5

5

5

5

5




7.6 Production records or other documentation are accurately completed where required by enterprise procedures F, K 5

ICPPR331A Set up for basic lithographic printing1. Confirm job


1.2 Standard set up is planned for carried out correctly in minimum time with minimum wastage


A

A, L

A

5

5

5

2. Set up reel system (OR Element 3)

2.1 Unwind and rewind reels is are set up and standard settings adjusted according to job specifications

2.2 Webbing procedures are carried out according to standard operating procedures and OHS

2.3 Web-control system is set up and standard settings adjusted according to job specifications

2.4 Reels are spliced / joined according to job specifications

2.5 Printed web viewing devices are set up and standard settings adjusted according to job specifications

2.6 The folder and sheeter are is set up and standard settings adjusted according to job specifications

73

73

73

73

73

73

5

5

5

5

5

5

3. Set up sheet system (OR Element 2)

3.1 Feeder and delivery sections are is set up and standard settings adjusted according to job specifications

3.2 Registration system is identified and adjusted according to job specifications

3.3 Sheet pick-up, and transportation, control and transfer systems is are set up and standard settings adjusted according to job specifications


73

73

73

73

5

5

5

5

4. Select and prepare inks and additives (basic)

4.1 Inks, dyes or additives are checked and appropriate action is taken and end-user requirements

4.2 Quality and suitability of inks, dyes or additives are selected according to job specifications and end-user requirements

4.3 Inks, dyes and additives are prepared according to OHS requirements, and manufacturer’s / supplier’s instructions with suitable precautions to minimise waste

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

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

4.6 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

30-34, 74

2, 30-34, 74

M, 30-34, 74

30-34, 74

F, 30-34, 74

34, 74

5

5

5

5

5

5

5. Set up machine for basic offset lithographic printing

5.1 Plate cylinder are set up and adjusted and lithographic plates are selected and installed according to job specifications

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

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

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

75, 77

75, 77

75, 77

75, 77

5

5

5

5




5.5 Dampening system is set up and adjusted according to job specifications 75, 77 5

6. Conduct OK print run 6.1 Material to be used for proof OK sheet / section is organised correctly

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

6.3 OK / section is visually inspected and / or tested or laboratory testing organised according to enterprise procedures

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

6.5 If necessary, results are interpreted and adjustment are carried out according to product and machine specifications

C, D, E

C, D, E

C, D, E

C, D, E

C, D, E

5

5

5

5

5

ICPPR332A Produce complex lithographic printed product1. Maintain non-routine

operation of reel system (OR Element 2)

1.1 Reel stand and rewind sections are monitored and adjusted to maintain correct tension and to ensure no marks, blemished or damage to finished product and to ensure efficient continuous operation


1.3 Substrate is added to and removed from the process according to job instructions



67

67

67

67

67

6

6

6

6

6

2. Maintain non-routine operation of sheet system (OR Element 1)

2.1 Feeder and delivery sections are monitored and adjusted to ensure continuous and efficient feeding to machine





67

67

67

67

67

6

6

6

6

6

3. Maintain complex lithographic printing process

3.1 Non-routine lithographic plate and plate cylinder condition are monitored and adjusted to ensure the quality of printed product meets the standard of the sample sheet

3.2 Non-routine lithographic blanket and blanket cylinder condition are monitored and adjusted to ensure the quality of printed product meets the standard of sample sheet

3.3 Non-routine lithographic impression cylinder condition is monitored and adjusted to ensure quality of printed product meets the standard of sample sheet

3.4 Non-routine lithographic inking system is checked and maintained to ensure quality of printed product meets the standard of sample sheet

3.5 Non-routine lithographic dampening system condition is monitored and adjusted to ensure quality of printed product meets the standard of sample sheet

67

67

67

67

67

6

6

6

6

6




3.6 Set off / marking prevention and drying system is monitored and adjusted to ensure quality of printed product meets the standard of sample sheet


67

67

6

6

4. Maintain production process










B, 9, 69

69

69

69

69

69

F, 69

4, F, 69

69

6

6

6

6

6

6

6

6

6

5. Identify and investigate lithographic machine operating problem

5.1 Problem in lithographic machine operation is investigated

5.2 Problem in lithographic machine is identified and reported according to enterprise procedures

4, 68

F, 4, 68

6

6

6. Rectify minor lithographic machine faults


6.2 Lithographic machine operation is checked to ensure correct operation

4, 68

68

6

6


7.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures production process







I, J

9, I, J

I, J

I, J

I, J

F, I, J

I, J

6

6

6

6

6

6

6


8.1 Cylinders, plate and roller surfaces are cleaned ready for next run printing machine at end of print run

8.2 Inking system and dampening system are washed up ready for next run, and liquid waste is disposed of according to company and regulatory requirements


K

K

K

6

6

6





8.5 Sheet feed, transport and delivery systems are disengaged and cleaned ready for next run

K

K

6

6

9. Complete records 9.1 Production records or other documentation are accurately completed where required by enterprise procedures F, G, H 6

ICPPR252A Produce basic relief printed product1. Maintain operation of

reel system (OR Element 2)

1.1 Reel stand and rewind section is monitored and adjusted to maintain correct tension and to ensure no marks or blemishes to finished product and to ensure efficient continuous operation




1.5 Set off / marking prevention system is monitored and adjusted to ensure quality of printed product meets the standard of the approved proof

73

73

73, A

73

73

5

5

5

5

5

2. Maintain operation of sheet system (OR Element 1)

2.1 Feeder and delivery sections are is monitored and adjusted to ensure continuous and efficient feeding to machine




2.5 Set off / marking prevention system is monitored and adjusted to ensure quality of printed product meets the standard of the approved proof

73

73

73

A, 73

73

5

5

5

5

5

3. Maintain basic routine relief printing process

3.1 Relief forme or plate cylinder condition is monitored and adjusted to ensure the quality of printed product meets the standard of the approved proof

3.2 Relief impression surface condition is monitored and adjusted to ensure the quality of printed product meets the standard of approved proof

3.3 Relief inking system is monitored and adjusted to ensure quality of printed product meets the standard of approved proof

75

75

74, 75

5

5

5

4. Maintain routine production process








B, 9, 73

73

73

73

73, 74

73

73

5

5

5

5

5

5

5




4.8 Waste is sorted according to enterprise procedures 73, L 5

5. Identify and rectify problems


5.2 Problem in relief machine operation is identified and reported according to enterprise procedures


5.4 Relief machine operation is checked to ensure correct operation

F, 4, 75, 76

F, 4, 75, 76

4, 75, 76

75, 76

5

5

5

5









I, J

9, I, J

I, J

I, J

I, J

F, I, J

I, J

5

5

5

5

5

5

5



7.2 Inking system is washed up ready for next run, and liquid waste is disposed of according to company and regulatory requirements





K

K

K

K

K

K

5

5

5

5

5

5

ICPPR351A Set up for basic relief printing1. Confirm job


1.2 Set up is carried out correctly in minimum time with minimum wastage


A

A, L

A, B

5

5

5


2.1 Unwind and rewind reels is are set up and adjusted according to job specifications

2.2 Webbing procedures are carried out and web-control system is set up and adjusted according to job specifications


2.4 Printed Web viewing devices are set up and adjusted according to job specifications

77

77

77

77

5

5

5

5




2.5 Folder and sheeters are set up and adjusted according to job specifications


77

77

5

5

3. Set up sheet transportation system on sheet-fed machine (OR Element 2)

3.1 Feeder and delivery sections are is set up and adjusted according to job specifications transportation system on sheet-fed machine

3.2 Sheet pick-up and transportation system is set up and adjusted according to job specifications

3.3 Transfer and control system systems are set up and adjusted according to job specifications



77, 79

77, 79

77, 79

77, 79

77, 79

5

5

5

5

5

4. Select and prepare inks and additives (basic)

4.1 Quality and suitability of inks, dyes or additives are selected according to job specifications and end-user requirements



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



2, 30-34, 77

2, 30-34, 77

L, M, 30-34, 77

30-34, 77

30-34, 77

34, 77

5

5

5

5

5

5

5. Set up machine for basic relief printing

5.1 Appropriate relief plates are selected and secured to the machine

5.2 Relief plates or formes or cylinders are positioned and set up and adjusted according to job specifications (platen and rotary)

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

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

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

77, 78

77, 78

77, 78

77, 78

77, 78

5

5

5

5

5


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

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


6.5 Results are interpreted and adjustment changes are carried out according to product and machine specifications to determine adjustment requirements

C, D, E

C, D, E

C, D, E

C, D, E

C, D, E

5

5

5

5

5

ICPPR352A Produce complex relief printed product1. Maintain non-routine

operation of reel 1.1 Reel stand and rewind section are is monitored and adjusted to maintain correct tension and to ensure no marks, blemishes or damage 73 6




system (Or Element 2) to finished product and to ensure efficient continuous operation





73

73, A

73

73

6

6

6

6

2. Maintain operation of sheet system (Or Element 1)

2.1 Feeder and delivery is monitored and adjusted to ensure continuous and efficient feeding to machine sheet system





73

73

73

73

73

6

6

6

6

6

3. Maintain complex relief printing process

3.1 Relief polymer forme or plate cylinder condition is monitored and adjusted to ensure the quality of printed product meets the standard of the sample sheet

3.2 Relief polymer impression surface condition is monitored and adjusted to ensure the quality of printed product meets the standard of sample sheet

3.3 Relief polymer inking system is monitored and adjusted to ensure quality of printed product meets the standard of sample sheet


75

75

75

75

6

6

6

6

4. Maintain production process


4.2 If required, in-line printing / converting / binding / finishing processes are monitored and adjusted to ensure quality of product meets the standard of the approved proof









B, 9, 73

73

73

73

73

73, 74

73

73

73

L, 73

6

6

6

6

6

6

6

6

6

6




5. Identify and rectify problems

5.1 Problem in relief machine operation is identified and reported according to enterprise procedures



5.4 Relief machine operation is checked to ensure correct operation

F, 4, 75, 76

F, 4, 75, 76

4, 75, 76

75, 76

6

6

6

6


6.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures production process







C, D, E

C, D, E

C, D, E

C, D, E, K

C, D, E

C, D, E, f

C, D, E

6

6

6

6

6

6

6



7.2 Inking system is washed up ready for next run, and liquid waste is disposed of according to company and regulatory requirements





K

K

K

K

K

K

6

6

6

6

6

6

ICPPR413A Set up for complex flexographic printing1. Confirm non-routine job


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


1.4 Proofed job is checked for conformance with job specifications

A

A, B, L

A, B

A

6

6

6

6

2. Set up reel transportation and delivery system on web-fed machine

2.1 Reels are checked for treatment levels, coatings and printing side and age of product

2.2 Unwind reels are secured on reel shaft transportation and delivery system on web-fed machine

2.3 Reels are correctly positioned on unwind stand

2.4 Press is webbed for surface or reverse or perfecting printing according to non-routine job specifications

2.5 Edge guide is centred and set to non-routine job specifications

61, 66

61, 66

61, 66

61, 66

61, 66

6

6

6

6

6




2.6 Unwind tension is set to suit substrate

2.7 Rewind tension is set to suit substrate

2.8 Nip rollers are set according to non-routine job specifications

2.9 PIV (Positively Infinitely Variable) drive is set for appropriate tensioning of substrate

61, 66

61, 66

61, 66

61, 66

6

6

6

6

3. Select and prepare inks and solvents

3.1 Inks and solvents are selected according to job specifications and end-user requirements

3.2 Quality and suitability of inks and solvents are checked and appropriate action is taken

3.3 Inks and solvents are prepared according to OHS 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 viscosities checked and modified according to the press requirements and non-routine job specifications

3.5 Ink formula and approved colour draw downs are appropriately recorded

3.6 Inks and solvents are appropriately labelled, handled and stored according to manufacturer’s / supplier’s instructions and the relevant hazardous liquids storage regulations

2, 30-34, 61, 66

2, 30-34, 61, 66

L, M, 30-34, 61, 66

30-34, 61, 66

F, 30-34, 61, 66

34, 61, 66

6

6

6

6

6

6

4. Set up machine for complex flexographic printing

4.1 Flexographic plate cylinders are installed and register adjustments centred OR

4.2 Sleeves are installed in press and register adjustments made OR

4.3 Plate mounting sheets are mounted on cylinders in press and register adjustments made

4.4 Plate cylinders are gauged up or pre-set to impression

4.5 Anilox rollers are selected to suit individual colour and plate reproduction requirements for each unit

4.6 Appropriate ink metering system is selected for each unit

4.7 Inking system is set up and roller nips / blades are set correctly

4.8 Ink circulation is maintained at correct level and flow for machine

4.9 Viscosities are adjusted according to job specifications

4.10 Air volume and drier temperatures curing units are selected to suit inks, substrate, solvents and according to job specifications

4.11 Air volume is adjusted between colours to maximise drying and minimise air overspill

62, 63

62, 63

62, 63

62, 63

62, 63

62, 63

62, 63

62, 63

62, 63

62, 63

62, 63

6

6

6

6

6

6

6

6

6

6

6

5. Set up in-line units for basic process(es)

5.1 Minor in-line printing / converting / binding units are set up for basic process(es) and adjusted according to machine requirements and job specifications

5.2 Assistance is given in set-up of major in-line printing / converting / binding units

62, 63

62, 63

6

6


6.2 Press is set up and operated according to OHS guidelines

C, D, E

C, D, E

6

6




6.3 Print impressions are set to minimum kiss impression

6.4 Web tensions are correctly set at unwind, between stations and rewind

6.5 The print is checked for register

6.6 Drying is checked as sufficient to key ink to the substrate

6.7 The viscosities are adjusted to obtain the correct colour at proof speed and checked against colour matching system

6.8 The substrate is checked against job specifications

C, D, E

C, D, E

C, D, E

C, D, E

C, D, E

C, D, E

6

6

6

6

6

6

7. Organise proof inspection and / or testing

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

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

C, D, E

C, D, E

6

6

8. Readjust settings to production speed

8.1 Production speed print results are interpreted and appropriate adjustments are made to press, ink and substrate settings

8.2 Adjustments are made according to product specifications and press performance

8.3 Web is spliced at production speed and further samples are obtained for quality inspections at appropriate intervals

8.4 Press settings are documented and samples are retained

E

E

E

F

6

6

6

6

ICPPR431A Set up for complex lithographic printing1. Confirm complex job


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


A

A, L

A

6

6

6


2.1 Unwind and rewind reels set up options are analysed and set up is completed and adjusted according to job specifications

2.2 Webbing procedures are carried out to meet non-routine job specifications

2.3 Web-control system is set up options are analysed and set up is completed and adjusted according to job specifications


2.5 Printed web viewing devices are set up and adjusted according to job specifications

2.6 The folder and sheeter are set up and adjusted according to job specifications


70, 71

70, 71

70, 71

70, 71

70, 71

70, 71

70, 71

6

6

6

6

6

6

6

3. Set up sheet system (OR Element 2)

3.1 Feeder and delivery sections are set up options are analysed and set up is completed and adjusted to non-routine suit job specifications

3.2 Sheet pick-up, transportation, control and transfer systems are set up and adjusted according to job specifications



70, 71

70, 71

70, 71

70, 71

6

6

6

6




4. Select and prepare inks and additives

4.1 Colour sequence for the job is considered and confirmed inks and additives

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



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



B, 74

2, 30-34, 74

2, 30-34, 74

L, M, 30-34, 74

30-34, 74

30-34, 74

30-34, 74

6

6

6

6

6

6

6

5. Set up machine for complex lithographic printing

5.1 Plate cylinder is set up and adjusted according to job specifications complex lithographic printing

5.2 Lithographic plate is selected and prepared for installation

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

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

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

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

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

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

72

72

72

72

72

72

72

72

6

6

6

6

6

6

6

6


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


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

76, C, D, E

76, C, D, E

76, C, D, E

76, C, D, E

6

6

6

6

ICPPP266A Produce relief plates1. Produce plates 1.1 The plate processor is prepared and maintained according to manufacturer’s specifications and enterprise standards

1.2 Exposure control is established and maintained utilising vacuum frames and plate processors according to job specifications

1.3 Plates are produced that conform to job specifications

46, 47, 48, B

46, 47, 48

46, 47, 48

3

3

3

2. Proof relief plates 2.1 Relief plates are proofed according to job specifications

2.2 Relief plates are proofed according to manufacturer’s specifications and enterprise standards

1, 46

1, 46

3

3
