10136 Operate a Printer Flat Bed Die Cutter for Repeat Work in the Corrugated Packaging Industry

NZQA Expiring unit standard 10136 version 6 Page 1 of 6

Title Operate a printer flat bed die cutter for repeat work in the corrugated packaging industry

Level 4 Credits 25

Purpose People credited with this unit standard are able to: plan ahead, to avoid delays during make ready and during production running; communicate to ensure job requirements are met; make ready the machine to make printed and die cut product without avoidable delays; run the machine, in accordance with workplace practices, to make product to meet job requirements; and follow safety requirements for the machine being used.

Classification Fibreboard Packaging > Corrugated Case Converting

Available grade Achieved

Entry information

Critical health and Unit 340, Demonstrate knowledge of safe working practices in safety prerequisites the printing and graphic pre-press industries, or demonstrate equivalent knowledge and skills.

Recommended skills Unit 10135, Operate a flat bed die cutter for complex new work and knowledge in the corrugated packaging industry; and Unit 10108, Produce two colour printed board in the corrugated packaging industry; or demonstrate equivalent knowledge and skills.

Explanatory notes

1 All workplace practices must meet any applicable and recognised codes of practice, and documented workplace health, safety, and environmental procedures for personal, product, workplace health, safety, and environmental matters, and the obligations required under current law including the Health and Safety in Employment Act 1992, Hazardous Substances and New Organisms Act 1996, Resource Management Act 1991, Privacy Act 1993 and their subsequent amendments.

2 Workplace practices refer to the documented procedures for the machine and/or workplace.

Competenz Ó New Zealand Qualifications Authority 2018 SSB Code 101571 NZQA Expiring unit standard 10136 version 6 Page 2 of 6

3 Board warped in excess of 2% is not to be used during assessment. The process for defining and calculating warp percentage is as follows: when a warped board is laid on a level surface so as to form a shallow arch, the maximum vertical deviation from the horizontal is expressed as a percentage of the board dimension that forms the arch.

4 Assessments must be conducted where board sheet size is 20% above the machine’s specified minimum limit and 20% below the machine’s specified maximum limit.

5 Competence in this unit standard must be demonstrated by the candidate assuming responsibility as sole operator in charge of a flat bed die cutter and linked printing machine. The machine must also be configured with at least a hopper feeder and accumulator section.

6 Competence in this unit standard is to be demonstrated in the production of a single pass repeat job only, requiring die cutting and creasing and perforating, as well as printing two colours.

7 Competence in printing is to be demonstrated by printing two colours with a registration requirement, and a requirement for either trapping or alignment.

8 Competence in stripping is not to be assessed in this unit standard.

Outcomes and evidence requirements

Outcome 1

Plan ahead, to avoid delays during make ready and during production running.

Evidence requirements

1.1 Procedures for the handling of priority orders where special job prioritisation is scheduled are described and followed in accordance with workplace practices.

1.2 Before make ready work begins, production order documentation is confirmed as the documentation required for the next job scheduled.

1.3 Identification for the initial pallet load or slip sheet load is prepared in advance of production running in accordance with workplace practices.

1.4 All required materials and documentation are confirmed as available prior to make ready.

Range may include but is not limited to – make ready sheets, dies, stereos, samples, inks, colour swatches, lay cards, overlays, slip sheets, pallets, tools, board to be run, load identification, production order, matrix.

Outcome 2

Communicate to ensure that job requirements are met.

2.1 Any forward rescheduling to match up similar jobs is agreed with other staff in accordance with workplace practices.

Range supervisor, manager, planning department.

2.2 Staff responsible for delivering materials for the next job are clearly advised of the requirements in accordance with workplace practices ensuring that no avoidable delays occur.

Range forkhoist operators, pre-press, own machine crew.

2.3 Machine crew confirm that they understand the specific make ready and production tasks they are responsible for.

Range task responsibilities – stripping down machine from the previous job, setting up for the next job, checks at feed end, checks to be made at take off.

2.4 Potential problems during make ready and production, and any special production needs are identified, and their requirements are met through clear communication with crew members.

Outcome 3

Make ready the machine to make printed and die cut product without avoidable delays.

3.1 Make ready is completed in accordance with workplace practices and to meet job requirements.

Range time allowed, board condition; job requirements may include – run length, printing requirements, take off requirements, number of ups in die cutting.

Outcome 4

Run the machine, in accordance with workplace practices, to make printed and die cut product to meet job requirements.

4.1 Production running speed is maintained ensuring that required quality and production standards are met.

4.2 Checks for faults are carried out during production.

4.3 Action is immediately taken to identify and rectify any faults, and fault free production running is successfully resumed.

4.4 Proactive measures to reduce the likelihood of faults occurring during production are followed.

Range proactive measures may include but are not limited to checks on – machine settings and machine running, condition of board being input, condition of finished product at take off, ink viscosity levels, ink levels, ink shades.

4.5 Actions available to counter the effect of board warp exceeding 2% are explained in terms of workplace practices.

4.6 Load identification requirements are carried out.

4.7 Print position and registration of all print meets workplace practices within the first three sheets.

4.8 Colour shades are confirmed as meeting the requirements of the job.

4.9 Viscosity adjustments are made to rectify any incorrect colour shade caused by viscosity.

4.10 All impression faults are recognised and rectified.

Range impression faults may include – light and/or missing print, distorted print, board crush, halo, print fill in.

4.11 Cutting, creasing and die cutting to print are all achieved.

4.12 Job is stacked.

4.13 Documentation is completed.

Range may include but is not limited to – internal fault error sheets, time sheets, record of waste, production order data, quality control data, machine fault reports, feed stock sheets, maintenance sheets, load identification, provision of product sample(s), final count confirmation, information required for the next time the job is run.

Outcome 5

Follow safety requirements for the machine being used.

Range operating manual, workplace practices.

5.1 Machine start up, shutdown and emergency procedures in the workplace are explained.

5.2 Hazard control measures, as circulated by the company, are described and followed.

5.3 Hazards or potential hazards in the workplace are identified and reported in accordance with workplace practices.

Replacement information This unit standard and unit standard 10137 have been replaced by unit standard 27794.

This unit standard is expiring. Assessment against the standard must take place by the last date for assessment set out below.

Status information and last date for assessment for superseded versions Process Version Date Last Date for Assessment Registration 1 18 February 1998 31 December 2015 Revision 2 27 March 2001 31 December 2015 Review 3 27 April 2005 31 December 2015 Rollover and 31 December 2015 4 12 December 2008 Revision Review 5 20 September 2012 31 December 2019 Rollover 6 10 December 2015 31 December 2019

Consent and Moderation Requirements (CMR) reference 0005 This CMR can be accessed at http://www.nzqa.govt.nz/framework/search/index.do.

Please note Providers must be granted consent to assess against standards (accredited) by NZQA, before they can report credits from assessment against unit standards or deliver courses of study leading to that assessment.

Industry Training Organisations must be granted consent to assess against standards by NZQA before they can register credits from assessment against unit standards.

Providers and Industry Training Organisations, which have been granted consent and which are assessing against unit standards must engage with the moderation system that applies to those standards.

Requirements for consent to assess and an outline of the moderation system that applies to this standard are outlined in the Consent and Moderation Requirements (CMR). The CMR also includes useful information about special requirements for organisations wishing

Competenz Ó New Zealand Qualifications Authority 2018 SSB Code 101571 NZQA Expiring unit standard 10136 version 6 Page 6 of 6 to develop education and training programmes, such as minimum qualifications for tutors and assessors, and special resource requirements.

Competenz Ó New Zealand Qualifications Authority 2018 SSB Code 101571