NZQA Expiring unit standard
21725 version 4
Page 1 of 6
Title
Operate a semi-automatic stitcher in the corrugated packaging
industry
Level
3
Credits
15
Purpose
People credited with this unit standard are able to: identify the
components of a semi-automatic stitcher used in the
workplace, and demonstrate knowledge of their functions and
adjustments; demonstrate knowledge of stitching faults and the
corrective actions to rectify them; plan ahead, to avoid delays
during make ready and production running; undertake checks
and set up the machine in accordance with workplace
practices; run machine, in accordance with workplace
practices, 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
safety prerequisites
Unit 340, Demonstrate knowledge of safe working practices in
the printing and graphic pre-press industries, or demonstrate
equivalent knowledge and skills.
Recommended skills
and knowledge
Unit 10117, Stack converted product on a pallet or slip sheet 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
The stitching faults included in this unit standard are dealt with in the publication
Corrugating Defect/Remedy Manual, editor James T. Carbone, TAPPI Press, Atlanta
Competenz
SSB Code 101571
 New Zealand Qualifications Authority 2016
NZQA Expiring unit standard
21725 version 4
Page 2 of 6
USA, Sixth Edition 1999. This publication, together with any required revisions or
updates issued by the PrintNZ Training g, must be used to determine the evidence
requirements in this unit standard.
4
Competence in this unit standard may be demonstrated at any type of stitching or
stapling machinery used in corrugated or solid board converting.
5
A semi-automatic stitcher is here defined as a stitcher requiring manual folding and
feeding prior to the subsequent automatic stitching process.
6
No assessment of outcome 4 is possible should final checks at outcome 3 indicate
that squareness is not achievable in the board to be used in production running.
7
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.
8
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.
9
Competence in this unit standard must be demonstrated by the production running of
a task new to the candidate, as well as a repeat production task.
Outcomes and evidence requirements
Outcome 1
Identify the components of a semi-automatic stitcher used in the workplace, and
demonstrate knowledge of their functions and adjustments.
Evidence requirements
1.1
The stitching machine components are identified, and their functions described.
Range
components may include but are not limited to – stitching head,
stitching shoe, timing controls, pressure controls, wire spool, wire
cutters, clincher, stitching anvil.
1.2
All adjustments requiring to be made to the components identified at 1.1 are
explained in terms of workplace practices.
1.3
A wire spool is changed and replaced in accordance with workplace practices.
Competenz
SSB Code 101571
 New Zealand Qualifications Authority 2016
NZQA Expiring unit standard
21725 version 4
Page 3 of 6
Outcome 2
Demonstrate knowledge of stitching faults and the corrective actions to rectify them.
Evidence requirements
2.1
Faults are identified from photographs or diagrams or physical samples.
Range
2.2
A minimum of one cause is described for each stitching fault identified at 2.1.
Range
2.3
broken stitches, malformed stitches, improperly placed stitches,
incorrect number of stitches, poor clinching, poor lateral
placement, poor vertical placement, stitch lap breaking at stitches.
the causes described are those most often experienced in the
workplace.
A minimum of one corrective action is described for each stitching fault cause
described at 2.1.
Range
the corrective actions described are those most often taken in the
workplace.
Outcome 3
Plan ahead, to avoid delays during make ready and production running.
Evidence requirements
3.1
Requirements for the handling of priority orders are described and followed
where special job prioritisation is scheduled.
3.2
Forward production schedules are checked to identify and match up similar jobs
ensuring that make ready times are kept to a minimum.
3.3
Before make ready work begins, production order documentation is confirmed
as the documentation required for the next job scheduled.
3.4
Identification for the initial pallet load or slip sheet load is prepared in advance
of production running.
3.5
All required materials and documentation are confirmed as available prior to
make ready.
Range
3.6
may include but is not limited to – stitching machine, samples, slip
sheets, pallets, tools, board to be run, load identification,
production order.
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.
Competenz
SSB Code 101571
 New Zealand Qualifications Authority 2016
NZQA Expiring unit standard
Range
3.7
forkhoist operators, own machine crew.
Machine crew confirm that they understand the specific make ready and
production tasks they are responsible for.
Range
3.8
21725 version 4
Page 4 of 6
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.
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 4
Undertake checks and set up the machine in accordance with workplace practices.
Evidence requirements
4.1
Production order documentation is checked and the requirements for the job are
confirmed.
4.2
Production order documentation requirements are followed.
Range
4.3
Checks are carried out on the board to be folded and stitched.
Range
4.4
checks must include but are not limited to checking to ensure
board – has clean cuts and slots and edges, folds squarely and at
crease lines, is free from visible crush and damage and printing
defects.
Machine settings are made ensuring that a secure closure is achieved, and that
stitch position, number and formation meet production order specifications
within the first two sheets of board fed.
Range
4.5
includes but is not limited to – agreeing palletisation and/or
bundling requirements with take off crew, agreeing ongoing quality
checks with take off crew.
sidelay, roller pressures, stitch timing and delivery, stitch spacing,
number of stitches.
All final checks to be undertaken prior to production running are carried out.
Range
squareness, make-up of box, glue stitch position, stitch number,
stitch formation.
4.6
Action is immediately taken to rectify any faults ranged at evidence requirement
4.5.
4.7
The requirements for running board warped in excess of 2% are described in
terms of workplace practices.
Competenz
SSB Code 101571
 New Zealand Qualifications Authority 2016
NZQA Expiring unit standard
21725 version 4
Page 5 of 6
Outcome 5
Run machine, in accordance with workplace practices, to meet job requirements.
Evidence requirements
5.1
Production running is maintained ensuring that the required quality and
production standards are maintained.
5.2
At least one sheet in every 300 or one sheet per pallet load (whichever is the
more frequent) is physically checked to establish production specifications are
met.
Range
5.3
checks must include but are not limited to, those for – squareness,
make-up of box, stitch position, stitch number, stitch formation.
Communications are maintained with the take off crew during production
running ensuring that all required ongoing visual checks are made.
Range
checks must include at least those to establish – no missing
stitches, stitch position to specification.
5.4
Actions to be taken, if any faults ranged at 2.1 occur, are followed.
5.5
Load format and load identification are carried out to meet job requirements.
Range
load format may include – specific requirements for counts,
bundling, strapping, unitising, palletising.
Outcome 6
Follow safety requirements for the machine being used.
Range
operating manual, workplace practices.
Evidence requirements
6.1
Machine start up, shutdown and emergency procedures in the workplace are
explained.
6.2
Hazard control measures, as circulated by the company, are described and
followed.
6.3
Hazards or potential hazards in the workplace are identified and reported in
accordance with workplace practices.
Competenz
SSB Code 101571
 New Zealand Qualifications Authority 2016
NZQA Expiring unit standard
Replacement information
21725 version 4
Page 6 of 6
This unit standard has been replaced by unit standard
27805.
This unit standard replaced unit standard 10151, unit
standard 10152, and unit standard 10456.
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
Review
3
20 September 2012
31 December 2019
Rollover
4
10 December 2015
31 December 2019
31 December 2015
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
SSB Code 101571
 New Zealand Qualifications Authority 2016