10113 Set up and Run a Hopper Feeder for High Speed Machinery in the Corrugated Packaging

NZQA Expiring unit standard 10113 version 6 Page 1 of 5

Title Set up and run a hopper feeder for high speed machinery in the corrugated packaging industry

Level 3 Credits 15

Purpose People credited with this unit standard are able to: set up machine prior to production; operate the machine during production; take proactive measures at board changes to minimise delays and misfeeds; 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 10112, Demonstrate knowledge of a hopper feeder in the and knowledge corrugated packaging industry; and Unit 10160, Identify common faults in corrugated 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.

3 Competence in this unit standard may be demonstrated at any manually loaded hopper feeder, or hopper feeder with prefeeder, used at a flexo folder gluer or a rotary die cut printer or an automatic straight line gluer, for a repeat production task.

Competenz Ó New Zealand Qualifications Authority 2018 SSB Code 101571 NZQA Expiring unit standard 10113 version 6 Page 2 of 5

4 This unit standard is not to be used to assess competence regarding hopper feeder set up and operation at a flat bed die cutter or a specialty gluer.

5 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.

6 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.

Outcomes and evidence requirements

Outcome 1

Set up machine prior to production.

Evidence requirements

1.1 Board to be used is confirmed as that specified on the production order documentation for the job.

Range grammage, calliper, dimensions.

1.2 Side lays are set in accordance with workplace practices to meet the requirements of the production order specifications.

1.3 Callipers are set to feed single sheets only.

1.4 Backstops are set square, and to accommodate board dimensions specified for the job.

1.5 All feed mechanisms are set in accordance with workplace practices.

Range mechanisms may include but are not limited to – feed roll, kicker bar, lead edge feeder, side and back spankers, shingle section feed gate.

1.6 Board is loaded so that upper surface and flute direction are in accordance with production order instructions and workplace practices.

1.7 Board edges are confirmed as being parallel to the callipers.

1.8 Where pre-printed board is being fed, its orientation at loading is in accordance with workplace practices.

Outcome 2

Operate the machine during production.

2.1 Production is maintained ensuring that the gap between the edge of board and side lay does not exceed 2mm.

2.2 Reasons why the gap should not exceed 2mm are explained in terms of the faults that may result from exceeding this amount.

2.3 The edges of individual boards in the board column do not deviate by more than 2mm from the flush vertical faces of the column.

Range applies only to machine directional faces of the column.

2.4 Requirements for identifying and using or rejecting faulty and substandard board are explained in terms of workplace practices.

Range faults are – warped board, incorrect board specification, delamination (extensive or localised), visible damage and/or deformation of corrugations.

2.5 Faulty and substandard board is identified, and rejected as unsuitable for feeding in accordance with workplace practices.

2.6 Board is continuously loaded ensuring that no production delays are experienced through inadequate supply, misfeeding, or board damage.

Range production delays may include those resulting from – board damage in loading, misfeeds, board upper faces and/or crease orientation and/or flute direction, board damage during production.

2.7 Machine and board checks are made during production running in accordance with workplace practices.

Outcome 3

Take proactive measures at board changes to minimise delays and misfeeds.

3.1 Awareness of forthcoming board changes is demonstrated.

Range checking production documentation, communication with other crew members, visually assessing warp conditions.

3.2 Problems that might occur as board warp changes are explained in terms of the proactive measures available to overcome them.

Outcome 4

Follow safety requirements for the machine being used.

Range operating manual, workplace practices.

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

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

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

Replacement information This unit standard and unit standard 10112 have been replaced by unit standard 27785.

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 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