NZQA Expiring unit standard
10147 version 6
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Title
Operate a flexo folder gluer die cutter for complex new work in the
corrugated packaging industry
Level
4
Credits
8
Purpose
People credited with this unit standard are able to: plan ahead,
to avoid delays during make ready and during production
running; communicate to ensure that job requirements are met;
make ready the machine to make printed, die cut, folded, and
glued product without avoidable delays; run the machine, in
accordance with workplace practices, to make printed, die cut,
folded, and glued product 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 10146, Operate a flexo folder gluer for new work 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
Complex jobs are those that meet the requirements of explanatory notes 7 and 8.
4
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
Competenz
SSB Code 101571
 New Zealand Qualifications Authority 2016
NZQA Expiring unit standard
10147 version 6
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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.
5
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.
6
Competence in this unit standard must be assessed for a new production task at any
flexo folder gluer with two or more print stations, and configured for rotary die cutting
or for making simple cut outs e.g., by use of Sauer gear.
7
Competence must be demonstrated in printing three colours in not more than two
printing passes with requirements for registration and trapping and alignment. Where
production involves two printing passes to obtain three colours, the candidate must
demonstrate competence in meeting the printing requirements for all three colours
whether directly or by being in control throughout the printing process.
8
Competence in die cutting must be demonstrated by making die cut features.
Range simple die cut outs may include – hand holes, staple holes, vent holes,
perforations.
Outcomes and evidence requirements
Outcome 1
Plan ahead, to avoid delays during make ready and during production running.
Evidence requirements
1.1
Procedures for the handling of priority orders where special job prioritisation is
scheduled are described and followed in accordance with workplace practices.
1.2
Before make ready work begins, production order documentation is confirmed
as the documentation required for the next job scheduled.
1.3
Identification for the initial pallet load or slip sheet load is prepared in advance
of production running in accordance with workplace practices.
1.4
All required materials and documentation are confirmed as available prior to
make ready.
Competenz
SSB Code 101571
 New Zealand Qualifications Authority 2016
NZQA Expiring unit standard
Range
10147 version 6
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materials may include, but are not limited to – glue, glue heads,
stereos, samples, inks, colour swatches, lay cards, overlays, slip
sheets, pallets, tools, board to be run, documentation, load
identification.
Outcome 2
Communicate to ensure that job requirements are met.
Evidence requirements
2.1
Any forward rescheduling to match up similar jobs is agreed with other staff in
accordance with workplace practices.
Range
2.2
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.
Range
2.3
forkhoist operators, pre-press, own machine crew.
Machine crew confirm that they understand the specific make ready and
production tasks they are responsible for.
Range
2.4
supervisor, manager, planning department.
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 3
Make ready the machine to make printed, die cut, folded, and glued product without
avoidable delays.
Evidence requirements
3.1
Make ready is completed in accordance with workplace practices and to meet
job requirements.
Range
Competenz
SSB Code 101571
time allowed, board condition;
job requirements which may include – run length, printing
requirements, take off requirements, gluing requirements.
 New Zealand Qualifications Authority 2016
NZQA Expiring unit standard
10147 version 6
Page 4 of 6
Outcome 4
Run the machine, in accordance with workplace practices, to make printed, die cut, folded,
and glued product to meet job requirements.
Evidence requirements
4.1
Production running speed is maintained ensuring that the required quality and
production standards are met.
4.2
Checks for faults are carried out during production running.
4.3
Action is immediately taken to identify and rectify any faults, and fault-free
production running is successfully resumed.
4.4
Proactive measures to reduce the likelihood of faults occurring during
production are followed.
Range
proactive measures may include but are not limited to checks on –
machine settings and machine running, condition of board being
input, condition of finished product at take off, ink viscosity levels,
ink levels, ink shades, glue levels.
4.5
Actions available to counter the effect of board warp exceeding 2% are
explained in terms of workplace practices.
4.6
Print position and registration of all print meets workplace practices within the
first five sheets.
4.7
Colour shades are confirmed as meeting the job requirements.
4.8
Viscosity adjustments are made to rectify any incorrect colour shade caused by
viscosity outside specifications.
4.9
All impression faults are recognised and rectified.
Range
impression faults may include – light and/or missing print, distorted
print, board crush, halo, print fill in.
4.10
Die to sheet registration is achieved and maintained.
4.11
Slotting, creasing, folding, gluing, and squaring are achieved to meet the job
requirements.
Range
Competenz
SSB Code 101571
faults may include – skewing, fishtailing, failure of board to fold at
crease lines, failure to achieve continuous and unbroken glue
application, excessive glue squeezed out, glue applied out of
position, ragged slots, liner slit at creases, slots and creases more
than 1mm from specified position, alignment of creases to slots
exceeding 1.0mm.
 New Zealand Qualifications Authority 2016
NZQA Expiring unit standard
4.12
Bonding of product is achieved to meet the job requirements.
Range
4.13
10147 version 6
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bonding problems may include – failure to bond from inadequate
compression, or the occurrence of flat crush from excessive
compression.
Load format and load identification are carried out.
Range
load format may include – specific requirements for counts,
bundling, strapping, unitising, palletising.
4.14
Internal and external scrap is removed.
4.15
Documentation is completed.
Range
may include but is not limited to – internal fault error sheets, time
sheets, record of waste, production order data, quality control
data, machine fault reports, feed stock sheets, maintenance
sheets, load identification, provision of product sample(s), final
count confirmation, information required for the next time the job is
run.
Outcome 5
Follow safety requirements for the machine being used.
Range
operating manual, workplace practices.
Evidence requirements
5.1
Machine start up, shutdown and emergency procedures in the workplace are
explained.
5.2
Hazard control measures, as circulated by the company, are described and
followed.
5.3
Hazards or potential hazards in the workplace are identified and reported in
accordance with workplace practices.
Replacement information
This unit standard, unit standard 3682, unit standard
10145, unit standard 10146, unit standard 10157, unit
standard 10158, unit standard 10159, and unit standard
18245 have been replaced by unit standard 27799.
This unit standard is expiring. Assessment against the standard must take place by
the last date for assessment set out below.
Competenz
SSB Code 101571
 New Zealand Qualifications Authority 2016
NZQA Expiring unit standard
10147 version 6
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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
Revision
4
12 December 2008
Review
5
20 September 2012
31 December 2019
Rollover
6
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