To complete the unit requirements safely and effectively, the individual must:
Reel transportation and web control
identify what can cause the reel to wander
describe what can cause the web to break at the unwind unit
outline the difference between a "flying paster" and "zero speed" type reel-stand
discuss what print fault results from the reel being run out of centre
describe types of faults in the unwind section which can cause a web break
Reel delivery for rewinding and sheeting
discuss WHS risks associated with rewinding and sheeting
describe the safety feature in the delivery system for when the web jams
discuss the cause of sheet cut-off wander
outline effects of poorly adjusted nip rollers when rewinding and sheeting
Printing and drying unit
discuss how a build-up of ink on the impression cylinder can affect printed product
outline the cause of ink foaming in the ink tray
describe the effect of too much reducer in the ink
identify how to reduce doctor blade wear
describe why it is necessary to remove all solvents from the final ink film
discuss the link between driers and set-off and marking
identify what causes the substrate to distort
discuss what happens in the chillers if the drying temperature is too low
outline the effect of incorrect drying temperature on finished product
In-line processes
discuss why it is necessary to frequently examine in-line components of the job
outline how consistency of the punching unit is checked
describe the impact of excessive pressure on the slitters
discuss the benefit of identification numbers on jobs with multiple similar images
describe how the ratio of print to in-line speed is controlled
Maintaining production process
discuss possible effects of inadequate communication within the work team on a gravure printing machine
describe safety features within the organisation which aid in maintaining effective production
identify ramifications if machine guards are removed and/or micro switches are disconnected on a machine
name the person held legally responsible for the removal of machine guards and/or disconnection of micro switches
discuss the most accurate method of checking register during a production run
outline why it is necessary to take immediate action when production problems are anticipated
describe what to do to eliminate further processing of unacceptable printed product
discuss what happens to the substrate if the relative humidity increases in the press room
outline the correct procedure to care for a newly delivered substrate to the press room
discuss why waste should be sorted
describe advantages of keeping reusable waste
outline industry standards to enhance effective communication with clients
discuss procedures a client should follow to OK a printed product
Gravure machine operating problems
describe when it is necessary to call service personnel to correct a machine problem
identify enterprise procedures to report machine operating problems
Shutdown procedures
discuss what happens if correct shutdown procedures are not followed
describe why it is necessary that correct shutdown procedures are conducted with fellow workers
outline advantages of proper labelling and storage of excess inks and materials
discuss why printed product should be clearly labelled prior to removal from the press room
outline further operations required for printed reels after removal from the printing machine
describe how printed jobs should be stored after removal from the printing machine
Cleaning and washing the printing unit
list WHS concerns of handling ink
outline safety precautions for cleaning the printing cylinders
discuss why it is necessary to thoroughly clean and wash the printing unit prior to the next print run
describe why the doctor blades should be thoroughly cleaned
explain why doctor blades should be handled with extreme care
describe how to store printing cylinders to minimise damage
Cleaning feed, transportation, delivery and in-line sections
list WHS precautions for cleaning these sections of the machine
discuss why it is necessary to maintain a clean substrate handling section of the machine
Completing production records
outline how completed records are used in the final analysis of the job
describe benefits of comprehensive records when considering production of future jobs
identify what machine manuals, safety and other documentation are relevant to this task, where they are they kept and describe the information contained.