Page 1 of 7 Title Make ready a flat bed die cutter in the corrugated packaging industry Level 3 Credits 25 Purpose People credited with this unit standard are able to: set up a hopper for a flat bed die cutter; operate a hopper feeder for a flat bed die cutter; take proactive measures at the times of board changes to minimise the occurrence of delays and misfeeds; set up for accumulation at a flat bed die cutter; change dies and carry out all checks in accordance with workplace practices; establish cutting, creasing, and die to print registration meet production order requirements prior to production running; follow safety requirements for the machine being used. Classification Fibreboard Packaging > Corrugated Case Converting Available grade Achieved Entry information Critical health and safety prerequisites Recommended skills and knowledge Unit 340, Demonstrate knowledge of safe working practices in the printing and graphic pre-press industries, or demonstrate equivalent knowledge and skills. Unit 10112, Demonstrate knowledge of a hopper feeder in the corrugated packaging industry; Unit 10132, Demonstrate knowledge of flat bed die cutting faults in the corrugated packaging industry; Unit 10160, Identify common faults in corrugated board in the corrugated packaging industry; Unit 10116, Demonstrate knowledge of stacking machinery for a die cutter in the corrugated packaging industry; Unit 10117, Stack converted product on a pallet or slip sheet in the corrugated packaging industry; Unit 10129, Demonstrate knowledge of a clamshell die cutter in the corrugated packaging industry; and Unit 10130, Demonstrate knowledge of a platen flat bed die cutter 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
Page 2 of 7 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 the unit standard may be demonstrated at any manually loaded hopper feeder, or hopper feeder with pre-feeder, used at a flat bed die cutter or cylinder die cutter, for a repeat production task. 4 This unit standard is not to be used to assess competence regarding hopper feeder set up and operation at a flexo folder gluer, a rotary die cutter, or a specialty gluer. 5 Competence in this unit standard is to be demonstrated on repeat jobs only, at any clamshell, cylinder, or flat bed (platen) die cutter. 6 Where competence in this unit standard is demonstrated at a clamshell or cylinder die cutter, the prerequisite entry is unit standard 10129. Where competence in this unit standard is demonstrated at a hopper fed flat bed platen die cutter, the prerequisite entry is unit standard 10130. 7 Make ready for stripping is not included within this unit standard. 8 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. 9 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. 10 Assessments must be for a repeat production task only. Outcomes and evidence requirements Outcome 1 Set up a hopper feeder for a flat bed die cutter. 1.1 The board for the job is confirmed against production order documentation in grammage, calliper, dimensions. 1.2 Side lays are set in accordance with machine configuration and specifications and to meet job requirements.
Page 3 of 7 1.3 Callipers are set to feed single sheets only. 1.4 Backstops are set square, and accommodate board dimensions. 1.5 All feed mechanisms are set in 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 in accordance with workplace practices ensuring that the upper surface and flute direction meet production order instructions. 1.7 Board edges are parallel to the callipers. 1.8 Pre-printed board is loaded ensuring its orientation meets workplace practices. Outcome 2 Operate a hopper feeder for a flat bed die cutter. 2.1 Production is maintained in accordance with workplace practices, 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 form 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. applies only to machine directional faces of the column. 2.4 Faulty and substandard board is identified, and rejected as unsuitable for feeding, in faults are warped board, incorrect board specification, delamination (extensive or localised), visible damage and/or deformation of corrugations. 2.5 Requirements for identifying and using or rejecting faulty and substandard board is explained in terms of workplace practices. 2.6 Board is continuously loaded ensuring that production is not delayed through inadequate supply, misfeeding, or board damage. production delays may include those resulting from board damage in loading, misfeeds, board upper faces and/or crease orientation and/or flute direction not in accordance with production order requirements and workplace practices, board damage during production.
Page 4 of 7 2.7 Machine and board checks are undertaken in accordance with workplace practices. Outcome 3 Take proactive measures at the times of board changes to minimise the occurrence of delays and misfeeds. 3.1 Awareness of forthcoming board changes is demonstrated. checking production documentation, communication with other crew members, visually assessing warp conditions. 3.2 Problems that might occur as board warp changes, and the proactive measures available in the workplace to overcome them are explained. Outcome 4 Set up for accumulation at a flat bed die cutter. 4.1 All checks on production order documentation are carried out in accordance with workplace practices. 4.2 Initial machine settings are made in accordance with workplace practices to meet production order requirements. accumulator backstops, side guides, shutters; counter ejector set to specified number. 4.3 Where grip edge stripping fingers are configured, the number and positioning of the fingers are in 4.4 Where a grip edge stripping forme is configured, the forme is mounted in accordance with workplace practices, and securely locked in position. 4.5 Stacking to required production order specifications is achieved within the first three sheets run through the machine, prior to the production running.
Page 5 of 7 Outcome 5 Change dies, and carry out all checks in 5.1 All required checks are undertaken. checks may include but are not limited to production order, print position being within machine adjustment ranges, board size and grade, condition of die being removed, condition of die to be used in production, absence of foreign matter on the reverse side of the die and on the chase or plate on which the die is to be mounted. 5.2 Die and (where required) a make ready sheet, are removed and disposed of. 5.3 Die and (where specified) a make ready sheet, are selected to meet the job requirements. 5.4 Checks required by workplace practices for determining the condition of dies being removed or selected are explained in terms of the faults that may be present. rubber missing elements, partially detached elements, placement, type; wood freedom from cracks, splits, splintering, warp likely to cause cutting problems; cutting and creasing knives and rules freedom from visible damage, missing elements. 5.5 Areas of waste from the die are identified. 5.6 Die and (where required) the make ready sheet are mounted in accordance with machine configuration and specifications. 5.7 The mounted die is secured, and is flush with the chase or plate. 5.8 Actions to be taken in the event that checks indicate potential for production faults are followed.
Page 6 of 7 Outcome 6 Establish cutting, creasing, and die to print registration meet production order requirements prior to production running. 6.1 Clean cutting is obtained within the first three sheets run. 6.2 Creasing meets production order specifications within the first three sheets run. board bends at crease lines, no splitting at crease lines. 6.3 Die to print registration on printed board meets production order specifications within the first three sheets run. 6.4 Corrective measures required, where the first sheet run fails to display clean cuts and/or creasing to production order specifications, are undertaken in corrective measures may include taping, pressure adjustments, using additional rubber, using channel matrix, using less rubber. 6.5 Corrective measures required, where the first sheet run fails to achieve die to print registration to meet production order specifications, are undertaken in Outcome 7 Follow safety requirements for the machine being used. operating manual, workplace practices. 7.1 Machine start up, shutdown and emergency procedures in the workplace are explained. 7.2 Hazard control measures, as circulated by the company, are described and followed. 7.3 Hazards or potential hazards in the workplace are identified and reported in
Page 7 of 7 Replacement information This unit standard, unit standard 10134, and unit standard 10135 have been replaced by unit standard 27793. This unit standard replaced unit standard 10114, unit standard 10120, and unit standard 10131. 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 27 April 2005 31 December 2015 Rollover and Revision 2 12 December 2008 31 December 2015 Review 3 20 September 2012 31 December 2019 Rollover 4 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.