Application
This unit describes the skills and knowledge required to produce complex rotary die cut or embossed product, maintain operation of machinery and the production process, rectify problems and shut down the equipment.
No licensing, legislative or certification requirements apply to this unit at the time of publication.
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
Elements describe the essential outcomes. | Performance criteria describe the performance needed to demonstrate achievement of the element. |
1. Maintain operation of delivery systems | 1.1 Delivery systems are monitored and adjusted to ensure efficient and continuous operation and ensure no damage to finished product 1.2 Substrate is added to and removed from the process according to job specifications |
2. Maintain operation of complex rotary die cutting or embossing process | 2.1 Knife condition is monitored and adjusted to ensure product quality meets the approved sample standard 2.2 Cutting pressures are monitored and adjusted to ensure product quality meets the approved sample standard 2.3 Registration of knife(s) is monitored and adjusted to ensure quality 2.4 Packing of cutting devices is monitored and adjusted to ensure product quality meets the approved sample standard |
3. Maintain production process | 3.1 In-line printing/converting/binding/finishing processes are monitored and adjusted to ensure product quality meets the approved sample standard 3.2 Production process is operated in association with fellow workers and according to enterprise procedures and planned daily schedule 3.3 Production is maintained according to Work Health and Safety (WHS) requirements, manufacturer’s specifications and enterprise procedures 3.4 Manual and/or automatic control is used according to job specifications 3.5.Performance is monitored and verified using the process control system according to enterprise procedures 3.6 Production difficulties are anticipated and preventive action is taken to prevent occurrence by timely intervention 3.7 Process adjustments to eliminate problems are reported according to enterprise procedures 3.8 Faulty performance of equipment is identified and reported according to enterprise procedures 3.9 Waste is sorted according to enterprise procedures |
4. Identify and rectify rotary cutting machine problems and faults | 4.1 Problems in rotary cutting machine are identified and reported according to enterprise procedures 4.2 Adjustments or corrections are carried out according to specified procedures and are consistent with operator’s skill level 4.3 Cutting rotary machine operation is checked to ensure correct operation |
5. Conduct shutdown of production process | 5.1 Correct shutdown sequence is followed according to manufacturer’s specifications and enterprise procedures 5.2 Shutdown is conducted in association with fellow workers and in compliance with WHS requirements 5.3 Substrate waste is removed from operating area and recycled or disposed of, where required, according to regulatory requirements and enterprise procedures 5.4 Machine faults requiring repair are identified and reported to designated person according to enterprise procedures 5.5 Repair/adjustment is verified prior to resumption of operations |
6. Clean rotary cutting units at end of run | 6.1 Knife and machine bed are cleaned ready for next run 6.2 Cutting devices are sharpened correctly according to WHS requirements and enterprise procedures 6.3 Cutting machine is disengaged and cleaned ready for next run 6.4 In-line printing/converting/binding/finishing units are cleaned ready for next run 6.5 Transportation and delivery systems are disengaged and cleaned ready for next run 6.6 Production records or other documentation are accurately completed, where required by enterprise procedures |
Evidence of Performance
Evidence of the ability to:
produce complex products on EITHER rotary die cutting OR embossing. For either process produce TWO complex jobs (including in-line processes) with different substrates, sizes and patterns according to manufacturer’s and job specifications, enterprise procedures and listed performance criteria.
Note: If a specific volume or frequency is not stated, then evidence must be provided at least once.
Evidence of Knowledge
To complete the unit requirements safely and effectively, the individual must:
All Systems
identify work health and safety (WHS) factors for:
setting up and/or operating machine transport systems
setting up and/or operating machine delivery systems
maintaining the cutting process
problem-solving on the rotary machine cutting process
conducting machine shutdown procedures
identify areas of the machinery that require cleaning at the end of the run
identify items of importance to consider when maintaining rotary cutting operations
lists checks to be made:
on cutting pressures, cutting registration, packing of cutting area, condition of cutting edges, and the smooth running of the operation
cutting accuracy once it has been adjusted
when removing substrate from the machine
when packing cutting devices
when waste is removed from the machine and surrounding area for disposal or recycling
when cutting devices or knives are cleaned, stored or replaced ready for the next run
when shutting down the machine
determine indicators that demand replacement of cutting edges
identify ways to guarantee a clean and precise result
explain production difficulties expected during production runs and procedure for correcting any machine faults
identify cleaning agents used to clean the machine
identify production records to be kept or written up and the information that should be included
determine quality aspects to consider in a completed rotary cutting job
list steps to ensure important features of the production control system are followed
identify production areas that may have to be adjusted to meet client requirements
identify items to check against the client sample
identify machine manuals, safety and other documentation relevant to this task, where they are kept, and the information included in them
For Reel Systems Only
identify areas of the:
reel stand to monitor to ensure trouble-free operation
web control system to adjust to maintain correct web tension and the correct positioning of the web
delivery system to observe to maintain tension and prevent damage to the finished product
For Sheet Systems Only
identify areas of the sheet-fed feeder to monitor to ensure trouble-free operation
list parts of the sheet pick-up system to adjust to ensure accurate and continuous sheet handling.
Assessment Conditions
Gather evidence to demonstrate consistent performance in conditions that are safe and replicate the workplace. Noise levels, production flow, interruptions and time variances must be typical of those experienced in the converting, binding and finishing field of work and include access to relevant facilities, equipment and materials.
Assessors must satisfy NVR/AQTF assessor requirements.
Foundation Skills
This section describes language, literacy, numeracy and employment skills incorporated in the performance criteria that are required for competent performance.
Skill | Performance Criteria | Description |
Reading | 5.1 | Recognises and interprets text to establish job requirements from information in procedures and specifications |
Writing | 3.7, 3.8, 4.1, 5.4, 6.6 | Enters routine data associated with production processes and enterprise procedures |
Oral Communication | 3.2, 3.7, 3.8, 4.1, 5.2, 5.4 | Speaks clearly using appropriate vocabulary, tone and pace to report faults and discrepancies Participates effectively in spoken interactions to confirm or clarify requirements |
Navigate the world of work | 2.1-2.4, 3.1-3.3, 3.5, 3.7-3.9, 4.1, 4.2, 5.1-5.4, 6.1-6.6 | Recognises and follows all procedures for operation and maintenance of equipment, incorporating regulatory and enterprise requirements |
Interact with others | 3.2, 3.7, 4.8, 4.1, 5.2, 5.4 | Cooperates with others as part of familiar routine activities, and contributes to specific activities requiring joint responsibility and accountability Understands what to communicate, with whom and how, in routine work situations |
Get the work done | 1.1, 1.2, 2.1-2.4, 3.1-3.9, 4.1-4.3, 5.1-5.5, 6.1-6.6 | Determines priorities and sequences steps involved in clearly defined, familiar tasks Recognises and anticipates an increasing range of familiar problems, their symptoms and causes, actively looking for early warning signs and implementing contingency plans Follows routine procedures for using digital technology by reading data from electronic monitoring and control systems |
Range Statement
This section specifies different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Delivery systems MUST include EITHER: | reel OR sheet. |
Monitoring and adjusting MUST include: | reel stand and rewind stand web control system sheeting section OR feeder and delivery systems sheet pick-up and transportation systems transfer systems. |
Sectors
Converting, Binding and Finishing