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

ELEMENT

PERFORMANCE CRITERIA

1. Maintain operation of reel transportation system on web-fed machine

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

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

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

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

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

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

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

3. Maintain complex laminating process

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

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

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

4. Maintain production processes

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

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

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

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

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

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

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

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

4.9. Waste is sorted according to enterprise procedures

5. Identify and rectify machine operating problem

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

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

5.3. Laminating machine operation is checked to ensure correct operation

6. Conduct shutdown of production process

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

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

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

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

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

7. Clean laminating machine at end of run

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

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

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

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

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

Required skills

OHS in relation to operating machinery such as safely switching off machinery before cleaning is started

communication skills when monitoring and verifying performance using process control systems

planning and organising when following the correct shutdown sequence

teamwork when conducting the shutdown with fellow workers

using technology when adjusting machinery to improve performance and ensuring correct and continuous feeding and delivery of substrate

problem solving when identifying problems and faults and developing solutions

Required knowledge

OHS factors that must be considered when operating web machine transport and delivery systems

areas of the reel stand that should be monitored to ensure trouble-free operation

area of the web control system that should be adjusted to maintain correct web tension

area of the web control system that should be adjusted to maintain correct positioning of the web

areas of the delivery system that should be observed to maintain tension

areas of the delivery system that should be observed to prevent damage to the finished product

checks to be made when substrate is removed from the machine

OHS factors that must be considered when maintaining the laminating process

ways in which registration of laminating s assured

ways in which adjustment achieved

ways in which the pressure can be adjusted during production

areas of production that must be monitored to ensure trouble-free operations

OHS factors that must be considered when maintaining the complex in-line processes

areas of the in-line processes that should be monitored to ensure a quality product

laminating problems that may occur during the operation of the machine

adjustments or correction procedures that may need to be made to ensure accurate operation of the process

OHS factors that must be considered when shutting down and cleaning the machine

checks to be made when correctly shutting down the machine

areas of the machine that need regular cleaning

materials that need to be cleaned from the machine

keeping the machine clear of surface rust (condensation)

recommended cleaning agents

production records that need to be kept or written up

information that should be included in this reporting procedure

quality aspects that should be considered in a completed laminated job

steps that should be taken to ensure that important features of the production control system are followed

alterations to production to meet client requirements

items that must be checked against the client's sample

machine manuals, safety and other documentation that are relevant to this task and where they are kept and information that is included in these documents

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

Overview of assessment

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

Evidence of the following is essential:

produce complex laminated product that meets job specifications, production timeframes and quality standards. At least one machine used must be fully automated

demonstrate an ability to find and use information relevant to the task from a variety of information sources

competency must be demonstrated on any TWO of moisture, chemical and extrusion laminating. For each process operate a laminating machine (2 or more ply) to complete TWO jobs on different substrates and of different sizes (large/small formats including one in-line process) while demonstrating splicing techniques in minimum time according to manufacturer's and job specifications, enterprise procedures and the listed Performance Criteria

demonstrate use of computerised control, monitoring and data entry systems if available and appropriate.

Context of and specific resources for assessment

Assessment must ensure:

assessment may take place on the job, off the job or a combination of these

off the job assessment must be undertaken in a closely simulated workplace environment.

Method of assessment

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

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

Guidance information for assessment

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

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

Substrate delivery may include:

wide and narrow reel handling systems.

Laminatingprocess may include:

moisture, chemical and thermal cured, and extrusion process

thermal fastening such as high frequency and head welding.

In-line process may include:

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

Adhesives may include:

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

Laminating units may include:

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

Substrate types may include:

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

Unit sector

Converting, Binding and Finishing

This unit contains employability skills.