PROPF313 – Repair and maintain feeder machinery

Overview

This standard is for print finishers working with feeder machinery. It is likely to be most useful to those working on newspapers and periodicals.

They will be expected to repair and maintain feeder machinery.

This standard consists of two elements:

• Repair feeder machinery
• Maintain feeder machinery in working order

This is what the standard covers:

1. finding out what repairs are needed
2. getting the materials, tools and equipment you need to make the repair
3. making repairs which it is your job to do
4. checking that machines are safe to operate, after repair
5. monitoring feeder machinery during production
6. identifying faults which you can deal with
7. reporting faults which it is not your responsibility to deal with
8. keeping records of repairs.

Performance criteria

You must be able to:

Repair feeder machinery

1. switch off machinery following the correct shut down procedure before examining it
2. identify faults requiring repair and use repair methods which are appropriate for those faults in accordance with organisational procedures
3. report the need for repairs which are outside your responsibilities using agreed reporting methods
4. assemble materials, tools and equipment which are appropriate to make repairs
5. make repairs following approved procedures
6. use approved checks to verify machinery is safe to operate once repairs are completed
7. keep accurate records of repairs you have made in accordance with organisational procedures

Maintain feeder machinery in working order

8. monitor the operation of feeders at regular intervals, to check that materials are fed square and at the rate required for production
9. identify faults which produce a shortfall in output, cause damage to the end product, affect the efficient operation of equipment or create risks to health and safety
10. adjust the machine to correct faults which it is your job to deal with, using approved methods and equipment
11. follow organisation procedures to report faults which it is not your job to deal with
12. give sufficient information about faults to colleagues who are responsible for correcting them
13. use approved checks to verify the machinery is safe to operate, once faults are corrected
14. record production details in line with company requirements

Knowledge and understanding

You need to know and understand

1. your duties and responsibilities for health and safety as defined by any specific legislation covering your job role
2. regulations such as those covering manual handling, noise at work, personal protective equipment, safe handling of equipment and materials, and the safe use of computer equipment
3. workplace policies and written operating procedures relating to written health and safety policy statement, provision, use and processes of workplace equipment, training, prohibited equipment, young persons, safe systems of work
4. the way you actually do your job, more particularly the activities and techniques and the way that materials and equipment are used
5. typical hazards and risks in the printing industry and those that relate to your own job
6. risk assessment techniques and the action to take to deal with them
7. codes of practice relevant to your role and where to obtain information on them
8. manufacturers' and suppliers' health and safety instructions and advice for operating machinery, guarding machinery and data sheets for substances harmful to health
9. the requirements for personal presentation including personal hygiene, suitable clothing and accessories, fitness for work, such as not under the influence of drugs, alcohol or medication, smoking policies in the workplace
10. how to stop a machine in the event of an emergency
11. the causes of faults with raw materials, processes and machinery used in your business and how to identify and treat them
12. techniques for controlling quality including inspection, testing, sampling and use of input and output controls
13. the impact that faults, in the process you are involved with, have on later processes and the quality of the end product
14. types of problems that may need to be solved including machinery - electrical, mechanical, electronic, settings, component wear and tear, consumables needing replacement, materials - defects, shortages, incompatibility, systems, organisation and lack of skills or knowledge
15. sources of information for solving problems including manufacturer’s documentation / troubleshooting guides, colleagues, tutors / trainers / mentors and reference material – in house or external, such as the internet
16. techniques for solving complex problems including changing one thing only at a time and assessing effect of the change, using the problem solving cycle, root cause analysis, brainstorming and visual representations, such as fishbone / mindmap diagrams
17. techniques for assessing machine faults including observation, listening, inspection of product, reports from colleagues / log reports, touch or smell (if safe to do so) and testing - such as electrical, mechanical, electronic
18. the types of paper, board and other commonly used substrates including commonly used uncoated, coated, embossed papers and boards
19. the grammage, thickness, opacity, brightness/whiteness, strength, dimensional stability, gloss of paper, board and other commonly used substrates
20. how to maintain the quality of materials and protect them from damage, humidity and temperature during storage and handling
21. how to label and identify materials
22. the principal activities involved with machine cleaning, lubrication and maintenance
23. roles and responsibilities for cleaning, lubrication and maintenance for engineers, manufacturer’s agents, machine operators and machine assistants
24. types of machine faults such as electrical, mechanical, electronic and how they can be rectified
25. skills needed to repair particular types of faults
26. the maintenance plans for machines which you operate including manufacturer’s specifications and recommended maintenance plans
27. company plans and arrangements for maintenance which components wear or become degraded over time including filters, bearings, belts and chains, machine or process-specific components
28. what is meant by the phrase 'safe system of work' and how it applies to cleaning, lubrication and maintenance activities
29. what parts of the machine you are allowed to clean, lubricate and maintain
30. preventive versus predictive maintenance
31. documented procedures to be followed
32. isolating equipment before commencing cleaning and maintenance
33. replacement of all guards after cleaning and maintenance
34. the choice and use of suitable cleaning agents and lubricants
35. manufacturer’s specification/recommendations
36. environmental considerations
37. toxicity/health issues
38. disposal of contaminated cleaning materials

Scope/range

Operators should be able to deal with all running problems within his/her responsibility. Operators are also responsible for ensuring that the machine is in a safe and clean condition for normal production operations.

Keywords: post-press, print finishing, machinery, maintain, feeder