PROPF401 – Set up and control cutting and creasing machinery

Overview

This standard is for print finishers using automated cutting and creasing machinery. They will be expected to set up the equipment and control it whilst running production jobs.

This standard consists of two elements:

• Set cutting and creasing machinery
• Run cutting and creasing machinery and monitor quality

This is what the standard covers:

1. identifying the job requirements
2. checking that the automated cutting and creasing machinery is working properly
3. checking that safety devices are working properly
4. running the automated cutting and creasing machinery safely
5. adjusting settings, where necessary to maintain the required standard
6. checking that work meets the required standard
7. identifying faults and taking action to deal with them
8. unloading and stacking the finished product

Performance criteria

You must be able to:

Set cutting and creasing machinery

1. check that you have all the details required for the job
2. check that you have enough materials of the right type to meet job requirements
3. report when the material provided is not correct or sufficient in accordance with organisational procedures
4. check that your work area is safe and ready for production
5. load materials in the appropriate way for effective production
6. check that the cutting forme matches the job
7. make the cutting and creasing machinery ready to run at the intended speed and so that material is fed squarely into the machine
8. set up the cutting and creasing machinery in accordance with organisational requirements, so that:
   1. the position of cuts and creases is correct
   2. material is cut and creased squarely and delivered without damage
   3. the cut size is within variations allowed by your company
9. check that samples produced by the machine match the required standard
10. make any necessary adjustments to enable standards to be met
11. report when standards cannot be met in accordance with organisational procedures
12. prepare your work area so that it is safe and ready for production

Run cutting and creasing machinery and monitor quality

13. run cutting and creasing machinery so that it is safe and efficient and at the required speed in accordance with organisational procedures
14. keep up sufficient supplies of materials so that runs continue as long as necessary to meet job requirements
15. check at regular intervals that quality standards are met
16. identify production faults which result in:
    1. unacceptable variation in cut size or position
    2. ragged cuts
    3. uneven or misaligned creases or marking
    4. damage or distortion to the product
17. make running repairs to formes and replace materials as necessary
18. adjust machines, using approved methods and equipment, to correct faults which it is your job to remedy
19. use agreed procedures to report any faults which it is not your job to correct
20. check that the machinery is safe to operate, once faults have been corrected, in accordance with organisational procedures
21. record production and quality assurance details, checking information meets organisational procedures
22. follow the organisational procedures for the removal of waste
23. stack work using the approved method

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 purpose of cutting and creasing
12. the information and materials required to meet job specification
13. safety devices found on cutting and creasing machinery, their purpose and how to check they are functional
14. how to set up and adjust cutting and creasing machinery to meet job requirements
15. the causes of common faults and how to rectify them including unacceptable variation in cut size or position, ragged cuts, uneven or misaligned creases or marking, damage or distortion to the product
16. the causes of faults with raw materials, processes and machinery used in your business and how to identify and treat them
17. techniques for controlling quality including inspection, testing, sampling and use of input and output controls
18. the impact that faults, in the process you are involved with, have on later processes and the quality of the end product
19. 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
20. 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
21. 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
22. 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
23. the types of paper, board and other commonly used substrates including commonly used uncoated, coated, embossed papers and boards
24. the grammage, thickness, opacity, brightness/whiteness, strength, dimensional stability, gloss of paper, board and other commonly used substrates
25. how to maintain the quality of materials and protect them from damage, humidity and temperature during storage and handling
26. how to label and identify materials

Scope/range

In addition to being able to produce commercially acceptable work, operators should be competent to operate the equipment to produce a variety of products cut and creased to various shapes as one-up or multiple copies.

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, post-press, print finishing, machinery, cutting, creasing