null  null
Level 3 NVQ in Mechanised Print
Finishing and Binding - General
Print (5158-32)
Standards and assessment requirements
500/1475/4
www.cityandguilds.com
April 2007
Version 1.0
About City & Guilds
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across a wide range of industries, and progressing from entry level to the highest levels of
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Level 3 NVQ in Mechanised Print
Finishing and Binding - General
Print (5158-32)
Standards and assessment requirements
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
www.cityandguilds.com
April 2007
Version 1.0
3
This page is intentionally blank
4
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Contents
1
Introduction
7
2
About the qualification
8
2.1
Proskills UK and the National Occupational Standards
8
2.2
Publications and sources of information
10
3
Candidate entry requirements and progression
11
4
Centre resource requirements
13
4.1
Centre, qualification and fast track approval
13
4.2
Registration and certification
14
5
Assessment method requirements
15
6
Roles and occupational expertise requirements
17
7
Recording assessment and evidence
19
7.1
Data protection and confidentiality
19
7.2
Recording forms to use
20
8
The qualification structure
21
9
Relationships to other qualifications
22
9.1
Relationship to previous versions of the qualifications
22
9.2
Key skills
24
10
About the National Occupational Standards (NOS)
26
11
The units
27
Unit 246
Control foil blocking machinery
28
Unit 301
Ensure your own actions reduce risks to health and safety in the workplace
38
Unit 302
Improve individual and organisational performance
42
Unit 328
Control adhesive binding machinery
49
Unit 329
Control case making machinery
62
Unit 330
Control casing-in machinery
75
Unit 331
Control programmatic guillotines
88
Unit 332
Control folding machinery
101
Unit 333
Control in-line booklet-making machinery
114
Unit 334
Control non-automatic finishing machines
127
Unit 335
Control multiple hopper feeders
137
Unit 336
Control auto-fed sewing machinery
147
Unit 337
Control multi-knife trimming machinery
157
Unit 338
Set and operate booklet-making machinery
167
Unit 339
Control parallel folding
174
Unit 340
Run and monitor adhesive binding machinery
184
Unit 341
Control in-line insetting-stitching-trimming machinery
191
Unit 342
Control in-line gathering-adhesive binding-trimming machinery
204
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
5
6
Unit 343
Control in-line block feeding-forwarding- case binding machinery
217
Appendix 1
Accreditation, national frameworks and qualification level descriptors
230
Appendix 2
The qualification structure
231
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
1
Introduction
About this document
This document contains the information that centres need to offer the following National Vocational
Qualification (NVQ):
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
QCA accreditation number:
500/1475/4
This document contains details and guidance on:
• centre resource requirements
• candidate entry requirements
• information about links with other qualifications
• qualification standards and specifications
• assessment requirements.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
7
2
About the qualification
2.1 Proskills UK and the National Occupational Standards
Background to the National Occupational Standards (NOS) development
The NVQs in Printing (5158) at Levels 2 and 3 are work-based qualifications, designed for those who
work in the printing industry.
For workers in the print industry, job descriptions and task lists will indicate which NVQ and which
optional units within the NVQ are most suitable.
Every centre (training providers, training centres, colleges, etc) must ensure that each candidate,
trainee and student is enrolled for qualifications and programmes in which they stand every
reasonable chance of succeeding.
Contacting the Standards Setting Bodies
This qualification is based on the National Occupational Standards (NOS) developed by:
Sector Skills Council Proskills UK
Address
Centurion Court
85b Milton Park
Abingdon
Oxfordshire
OX14 4RY
Telephone
01235 833844
URL
www.proskills.co.uk
8
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Imported units
The majority of units have been developed by the Print and Graphic Communication National
Training Organisation (PGCNTO). However, some units have been imported from the other NTOs,
for example: Information Technology NTO (ITNTO); National Forum for Management, Education and
Development (formerly MCI); Employment NTO (ENTO); Small Firms Enterprise Development
Initiative (SFEDI) and; Institute for Customer Service (CSI).
The printing industry established that these units were directly relevant to individuals who would be
expected to achieve the NVQs in Printing at Levels 2 or 3 and consequently decided to adopt them
into the Printing qualifications
Apprenticeship frameworks
The NVQs in Printing have been approved by the SSC Proskills UK as part of the Apprenticeship
Framework in England.
Full details of the requirements of the apprenticeship frameworks for the sector are available from:
Sector Skills Council Proskills UK
Address
Centurion Court
85b Milton Park
Abingdon
Oxfordshire
OX14 4RY
Telephone
01235 833844
URL
www.proskills.co.uk
City & Guilds also offers the following qualifications which are also part of the Apprenticeship
framework:
• City & Guilds Level 2 Certificate in Printing and Graphic Communications 5261-02
• City & Guilds Level 3 Certificate in Printing and Graphic Communications 5261-03
Accreditation details
This qualification is accredited by the Qualifications and Curriculum Authority as part of the National
Qualifications Framework.
For further details about accreditation, national qualification frameworks and level descriptors
please refer to Appendix 1.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
9
2
About the qualification
2.2 Publications and sources of information
This document has been designed to be used with the City & Guilds N/SVQ Guides:
Publication
Content
Available
from
Centre guide
An overview of N/SVQ assessment, delivery and quality
assurance issues.
EN-12-001
Candidate guide
An introduction to N/SVQs, candidate responsibilities
and an overview of the assessment process.
TS-12-001
Recording forms
Forms both centres and candidates may use to record
evidence.
TS-33-0001
Visit the City & Guilds website (www.cityandguilds.com) for the latest versions of these
documents.
Other essential City & Guilds documents
There are other City & Guilds documents which contain general information on City & Guilds
qualifications:
•
Providing City & Guilds qualifications – a guide to centre and qualification approval
contains detailed information about the processes which must be followed and requirements
which must be met for a centre to achieve ‘approved centre’ status, or to offer a particular
qualification.
•
Ensuring quality
contains updates on City & Guilds assessment and policy issues.
•
Centre toolkit
contains additional information on Providing City & Guilds qualifications, in a CD-ROM, which
links to the internet for access to the latest documents, reference materials and templates.
•
Directory of qualifications
contains details of general regulations, registration and certification procedures and fees. This
information is also available online.
For the latest updates on our publications and details of how to obtain them and other City & Guilds
resources, please refer to the City & Guilds website.
10
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
3
Candidate entry requirements and progression
Candidate work role requirements
The NVQs in Printing are for those working in the printing industry in the following roles:
Pathway
Job Roles
Carton Manufacture
Carton Maker
Printed carton operative
Carton die maker
Digital Print Production – Digital Artwork
for Print
Desk Top Publisher
Graphic designer
Print Designer
Pre-press manager
Digital Print Production – Digital Printing
Printer
Digital Printer
Digital Print Production – Pre-Press
Desk Top Publisher
Graphic designer
Print Designer
Pre-press manager
Envelope Manufacture
Envelope printer
Machine Printing – Die stamping
Printer
Die stamping printer
Machine Printing – Flexography
Printer
Flexographic Printer
Machine Printing – Gravure
Printer
Gravure Printer
Machine Printing – Lithography
Printer
Lithographic printer
Machine Printing – Pad Printing
Printer
Pad printer
Machine Printing – Screen
Printer
Screen printer
Machine Printing – Web offset
Printer
Web offset printer
Mechanised Print – Finishing and Binding
Print finisher
Print Administration
Print Production manager
Print production scheduler
Print administrator
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
11
Candidate entry requirements
Candidates should not be entered for a qualification of the same type, content and level as that of a
qualification they already hold.
Age restrictions
The NVQs in Printing are not approved for use by candidates under the age of 16.
For candidates above this age, there are no age limits unless this is a legal requirement of the
process or the environment.
Otherwise, there are no formal entry requirements for candidates undertaking these qualifications,
however centres must ensure that candidates have the potential and opportunity to gain evidence
for the qualification in the work place.
For funding purposes, centres are reminded that candidates should not be entered for a
qualification of the same type, level and content as that of a qualification they already hold.
12
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
4
Centre resource requirements
4.1 Centre, qualification and fast track approval
Centres not yet approved by City & Guilds
To offer this qualification, new centres will need to gain both centre and qualification approval.
Please refer to the Centre guide and Providing City & Guilds Qualifications for further information.
Existing City & Guilds centres
To offer this qualification, centres already approved to deliver City & Guilds qualifications will need
to gain qualification approval. Please refer to the Centre guide and Providing City & Guilds
Qualifications for further information.
Centres already offering City & Guilds qualifications in this subject area
Centres approved to offer the 5157 NVQs in Printing may apply for approval for the new 5158 NVQs
in Printing using the fast track form, available from the regional/national office or City & Guilds
website.
Centres may apply to offer the new qualifications using the fast track form:
• providing there have been no changes to the way the qualifications are delivered, and
• if they meet all of the approval criteria specified in the fast track form guidance notes.
Fast track approval is available for 12 months from the launch of the qualification. After this time,
the qualification is subject to the standard Qualification Approval Process. It is the centre’s
responsibility to check that fast track approval is still current at the time of application.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
13
4
Centre resource requirements
4.2 Registration and certification
Registration and certification period
Centres should be aware of time constraints regarding the registration and certification periods for
the NVQs in Printing, as specified in the City & Guilds Directory of qualifications.
Please check the Directory of qualifications for the latest information on length of registration and
the last registration and certification dates.
Where the period of access to assessment offered by a centre is less than the period covered by the
candidates’ registration with City & Guilds, centres must ensure that this is understood by the
candidates.
14
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
5
Assessment method requirements
This guidance is based on and amplifies the assessment strategy developed for the NVQs in
Printing, by the Sector Skills Council for Printing Proskills UK.
External quality control
External quality control is provided by the usual City & Guilds external verification process which
includes the use of the electronically scannable report form which is designed to provide an
objective risk analysis of individual centre assessment and verification practice.
Accreditation of Prior Experience and Learning (APEL)
Please refer to the City & Guilds N/SVQ Guides documents which can be found on our website,
www.cityandguilds.com
Evidence and location of assessment
The majority of the candidate’s evidence should come from direct observations of competence in
the real workplace, unless specified in the unit content. Other types of acceptable evidence include,
but are not limited to:
• Witness Testimony (details of acceptable witnesses are found in section 6 of this document
‘Expertise of Assessors, Internal Verifiers and Witnesses’)
• logs/diaries kept by the candidate
• recorded answers to questions posed by the Assessor
• recorded/transcribed interviews with the candidate
• recorded use of up-to-date commercial/industrial equipment
• e-portfolios and other forms of digital media
• works documentation attributable to the candidate
• both interim and final internal verification.
Although the majority of the candidate’s evidence should come from direct observations of
competence in the real work place, in exceptional circumstances simulation of the real workplace
may be allowed. Occasions in which this may be approved are provided below.
Simulation
Where simulated activities are not stated within the unit, a centre must discuss and agree their use
in advance with the external verifier. Consideration for simulation should be given to those units
which have real health, safety and environment implications.
All evidence from simulated activities must result from activities that have taken place in a realistic
working environment, which replicates the conditions and circumstances in which the candidate
usually works and meets the following conditions:
• Working conditions should reflect those found in the workplace and include facilities, equipment
and materials used in the workplace for the activities being assessed. It should also include
relationships, constraints and pressures met in the workplace.
• The activity to which the candidate is required to demonstrate competence must be realistic
and reasonable in terms of its scale.
• Any assessment conducted under simulated conditions must require the candidates to take into
consideration what would be typical ambient conditions encountered in the normal workplace
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
15
•
Information available to the candidate on the nature of the activity must be consistent with the
policies and practices of typical recycling operations.
The overarching principle to be applied to units identified as suitable for simulation is that it should
only be undertaken in a minority of cases where:
• there is a high risk to the security or safety of the candidate, individuals, key people in their lives
and others
• the opportunity to present evidence from work-based practice happens infrequently and
therefore insisting that candidates wait for such an occurrence would be unreasonable or
create blockages in the assessment system and might carry the risk of de-motivating candidates
• there would otherwise be a breach of confidentiality or privacy.
To reiterate, any simulation must be approved in advance by the External Verifier, and clear
reasons must be given for its intended use. If approval is given, all Awarding Body guidance and
requirements must be observed. Simulation should not be the primary source of a candidate’s
claim to competence
16
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
6
Roles and occupational expertise requirements
Expertise of Assessors, Internal Verifiers and Witnesses
Assessors
Assessors must:
• be registered and recognised by an approved centre
• be competent to make qualitative judgements about the units they are assessing. Illustrations of
competence include, but are not limited to, the assessor:
o having achieved the award themselves
o having substantial demonstrable experience in the job roles they are assessing
o being in a day-to-day line management or quality assurance role with responsibility
for the job roles they are assessing
• be in possession of or working towards the A1/A2 award or the D32/33 award, or (in Scotland
only) has gained an exemption in TQFE/TQSE, as recommended by SQA/QCA and supported by
an appropriate Continuing Professional Development (CPD) record
• carry out their duties in accordance with the current NOS for Assessment, and in line with
current guidance on assessment practice issued by the regulatory authorities and the
appropriate Awarding Body
• maintain appropriate evidence of development activities to ensure their assessment skills and
occupational understanding are current (CPD)
• have a working knowledge of awards and a full understanding of that part of the award for
which they have responsibility. The Awarding Body will confirm this through examination of
relevant CVs supported by relevant references.
• be approved by the Awarding Body who must maintain records demonstrating how they meet
the assessment strategy. The appointment of Assessors may require the prior approval of the
Awarding Body
• meet any additional requirements as specified in the unit specific content.
Internal Verifiers
Internal verifiers must:
• be registered and recognised by an approved centre
• be in possession of or working towards the V1 award or the D34 award, as recommended by
SQA/QCA and supported by an appropriate CPD record
• carry out their duties in accordance with the current NOS for Verification, and in line with
current guidance on verification practice issued by the regulatory authorities and the
appropriate Awarding Body
• maintain appropriate evidence of development activities to ensure their verification skills and
occupational understanding are current (CPD)
• have expertise and knowledge of awards and a full understanding of that part of the award for
which they have responsibility. The Awarding Body will confirm this through examination of
relevant CVs supported by relevant references
• be approved by the Awarding Body who must maintain records demonstrating how they meet
the assessment strategy. The appointment of Internal Verifiers may require the prior approval of
the Awarding Body
• meet any additional requirements as specified in the award specific annex.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
17
Enhanced Quality Control
All Internal Verifiers must provide evidence of having verified:
• evidence supporting any key units (where specified in the award specific guidance) and
evidence supporting at least one other unit from the award
or
• the evidence supporting at least two distinct units (or as documented in the Award Specific
Guidance) for each award per annum.
As well as:
• all evidence from all simulations/simulators
• over time, an example of each unit the Assessor is qualified to assess
• over time, an example of each assessment method used in the centre
• evidence of internal verification.
Witnesses
There are no specific occupational expertise requirements for witnesses. Witness testimony can
provide evidence to establish consistency in a candidate’s practice and/or to evidence events which
are difficult to plan to observe.
As the assessment decision lies with the Assessor, it is their responsibility to verify this and, where
challenged, to justify their acceptance of third party 'witness testimony' to the Internal Verifier.
In order that the assessor may make an informed judgement about the contribution of the witness’
testimony to the overall evidence presented for a unit or qualification, a statement of the witness’
status should be included in the candidate’s portfolio of evidence. This can be done by using the
Witness Status list (form N/SVQ5) or including it as part of the witness testimony itself.
The statement should indicate the relationship between the candidate and the witness and should
enable the assessor, by defining the role that the witness has played in the gathering of evidence (ie
as colleague, worker from another organisation) to judge the extent of the witness’ knowledge of
the National Occupational Standards and understanding of the work roles involved.
Please note: The use of witness testimony from relatives or those with whom the candidate has a
significant personal relationship is not acceptable.
Continuous Professional Development requirements
City & Guilds expects all those with formal roles in the assessment or verification process to
participate in a minimum of two CPD activities per annum. This can be to update either vocational
skills/knowledge or assessment/verification skills/knowledge.
18
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
7
Recording assessment and evidence
7.1 Data protection and confidentiality
Data protection and confidentiality
Data protection and confidentiality must not be overlooked when assessing candidates.
Centres offering the NVQs in Printing may need to provide City & Guilds with personal data for staff
and candidates. Guidance on data protection and the obligations of City & Guilds and centres are
explained in Providing City & Guilds qualifications.
Protecting identity
It is extremely important to protect the identity of the service users encountered by candidates in
the work setting, eg customers, clients and patients.
Confidential information must not be included in candidate portfolios or assessment records.
Confidential information should remain in its usual location, and a reference should be made to it in
the portfolio or assessment records.
When recording evidence towards these qualifications, candidates are expected in particular to
protect the identity of children in their care by disguising their names and that of the placement
nursery.
Images of minors being used as evidence
If videos or photographs of minors (those under 18) are used as the medium to present evidence as
part of the qualification, both centre and candidate have responsibilities for meeting child
protection legislation.
It is the responsibility of the centre to inform the candidate of the:
• need to obtain permission from the minor’s parent/guardian prior to collecting the evidence
• reasons and restrictions for using photographs or video recordings as evidence
• period of time for which the photographs or video recordings may be kept
• obligation to keep photographs or video recordings secure from unauthorised access
• secure electronic storage requirements of photographs or video recordings
• associated child protection legislation.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
19
7
Recording assessment and evidence
7.2 Recording forms to use
City & Guilds has developed a set of Recording forms including examples of completed forms, for
new and existing centres to use as appropriate (see NVQ Guide for centres and candidates Recording forms, available on the City & Guilds website.
Although it is expected that new centres will use these forms, centres may devise or customise
alternative forms, which must be approved for use by the external verifier, before they are used by
NVQ candidates and assessors at the centre. City & Guilds also endorses the electronic recording
systems Quick Step and Paper Free.
Amendable (MS Word) versions of the forms are available on the City & Guilds website.
20
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
8
The qualification structure
Level 3 NVQ in Mechanised Print Finishing and Binding - General
Print (5158-32)
To achieve the Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
candidates must complete two mandatory common units, plus two Group A optional technical
units and one Group B optional technical unit.
Mandatory common units
301
Ensure your own actions reduce risks to health and safety in the workplace
302
Improve Individual and Organisational Performance
Optional technical units – Group A
328 3 Control adhesive binding machinery
329
Control case making machinery
330
Control casing-in machinery
331
332
Control programmatic guillotines
2
Control folding machinery
333 1 Control in-line booklet making machinery
Optional technical units – Group B
246
Control foil blocking machinery
334
Control non-automatic finishing machines
335
Control multiple hopper feeders
336
Control auto-fed sewing machinery
337
Control multi-knife trimming machinery
338 1 Set and operate booklet-making machinery
339 2 Control parallel folding
340 3 Run and monitor adhesive binding machinery
341
Control inline insetting-stitching-trimming machines
342
Control inline gathering-adhesive-binding-trimming machinery
343
Control inline block-feeding-forwarding-case binding machinery
Notes
1
Unit 338 may not be used in conjunction with Unit 333
2
Unit 339 may not be used in conjunction with Unit 332
3
Unit 340 may not be used in conjunction with Unit 328
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
21
9
Relationships to other qualifications
9.1 Relationship to previous versions of the qualifications
City & Guilds has identified the connections to the NVQ previously offered by City & Guilds in this
subject area.
This mapping is provided as guidance and suggests areas of overlap and commonality between the
qualifications. It does not imply that candidates completing units in the forerunner qualification are
automatically covering all of the content of the new NVQs listed in the mapping.
Relationship between this Level 3 NVQ in Mechanised Print Finishing and Binding General Print (5158-32) and the forerunner Level 3 NVQ in Mechanised Print Finishing and
Binding - General Print (5157-18)
22
Level 3 NVQ in Mechanised Print Finishing and
Binding - General Print (5158-32)
Level 3 NVQ in Mechanised Print Finishing
and Binding - General Print (5157-18)
Unit Number/Title
Related units
246 Control foil blocking machinery
323 Control foil blocking machinery
301 Ensure your own actions reduce risks to health
and safety in the workplace
001 Reduce risks to health and safety in your
workplace
302 Improve Individual and Organisational
Performance
002 Develop yourself in your job
328 Control adhesive binding machinery
316 Control adhesive binding machinery
329 Control case making machinery
317 Control case making machinery
330 Control casing-in machinery
318 Control casing-in machinery
331 Control programmatic guillotines
347 Control programmatic guillotines
332 Control folding machinery
348 Control folding machinery
333 Control in-line booklet making machinery
351 Control in-line booklet-making machinery
334 Control non-automatic finishing machines
340 Control non-automatic finishing machines
335 Control multiple hopper feeders
341 Control multiple hopper feeders
336 Control auto-fed sewing machinery
342 Control auto-fed sewing machinery
337 Control multi-knife trimming machinery
346 Control multi-knife trimming machinery
338 Set and operate booklet-making machinery
356 Set and operate booklet-making machinery
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
339 Control parallel folding
358 Control parallel folding
340 Run and monitor adhesive binding machinery
360 Run and monitor adhesive binding
machinery
341 Control inline insetting-stitching trimming
machines
352 Control in-line insetting-stitching-trimming
machinery
342 Control inline gathering-adhesive bindingtrimming machinery
353 Control in-line gathering-adhesive bindingtrimming machinery
343 Control inline block-feeding forwarding-case
binding machinery
354 Control in-line block-feeding-forwardingcase binding machinery
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
23
9
Relationships to other qualifications
9.2 Key skills
This qualification includes opportunities to develop and practise many of the underlying skills and
techniques described in Part A of the standard for each key skills qualification in England, Northern
Ireland and Wales.
Where candidates are working towards any key skills alongside this qualification they will need to be
registered with City & Guilds for the key skills qualifications.
The ‘signposts’ below identify the potential for key skills portfolio evidence gathering that can be
naturally incorporated into the completion of each unit. Any key skills evidence needs to be
separately assessed and must meet the relevant standard defined in the QCA document ‘Key skills
qualifications standards and guidance’.
Please note:
Unit
number
24
Key Skills Level 2 is illustrated as 2
Key Skills Level 3 is illustrated as 3
Communication
Application of Number
246
2
301
3
2
302
3
2
328
2
329
2
330
2
331
2
332
2
333
2
334
2
335
2
336
2
337
2
338
2
2
339
2
2
340
2
2
341
2
2
342
2
2
343
2
2
Information Technology
2
2
2
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
2
Unit
number
Problem Solving
Improving own learning
and performance
Working With Others
246
2
2
2
301
3
3
2
302
3
3
3
328
2
2
2
329
2
2
330
2
2
331
3
2
332
2
2
333
2
2
334
2
2
335
3
3
2
336
2
2
2
337
2
2
338
2
2
339
2
2
340
2
2
2
341
2
2
2
342
2
2
2
343
2
2
2
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
25
10
About the National Occupational Standards (NOS)
Availability of standards
The units for the qualification follow.
They may also be obtained from the Printing and Graphic Communications industry section of the
City & Guilds website.
26
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
11
The units
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
27
Unit 246
Introduction
Control foil blocking machinery
To obtain your unit certificate, you must show that you can:
1
Element 246.1 Set up foil blocking machinery
2
Element 246.2 Run foil blocking machinery
3
Element 246.3 Maintain foil blocking machinery in clean, safe and useable condition
This involves:
• identifying and understanding the job requirements
• checking that the foil blocking machine is working properly
• checking that safety devices are working properly
• setting up the foil blocking unit
• running foil blocking machinery safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Note: this unit is for use on equipment that is either semi-automatic or fully automatic.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in the You must
show that section in each element, and must be the result of real work activities in actual
production situations. Simulation is not acceptable for this unit.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence. Here are some
examples:
• a photocopy of the job instructions
• a photocopy of the documentation confirming all the material requirements for the production
of the job
• samples of the job including a signed pass copy
• samples of running faults as they arise
• a written or spoken report describing faults, their causes and how you corrected them
• production records showing the time taken to produce the job and/or the quantity produced.
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Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 246.1 Set up foil blocking machinery
Performance criteria
You must show that you:
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up foil blocking machinery correctly, so that:
a
the temperature is correct for the material to be blocked
b
material to be blocked is fed squarely, coming to the register against stops
c
the foil is fed evenly, to give minimum gap between impressions
d
images are clean, sharp and have overall solid colour density
e
images are correctly positioned on the material
f
subsequent colours are in register and fit with other colours
5
produce a sample from the machine and check that it matches the required standard
6
make adjustments when the standards cannot be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
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Element 246.1 Set up foil blocking machinery
Knowledge and understanding
You must understand:
30
K1
what details should be in a job specification
K2
the principles of foil blocking
K3
the sequence of set up tasks for foil blocking machinery
K4
why temperature, pressure and dwell settings will vary for:
a
paper
b
coated fabrics
c
PVC material
d
leather
K5
the range of foils available, and their different uses
K6
how to achieve register in multi-colour workings
K7
the risks associated with setting up foil blocking machinery, and how to avoid them
K8
what the common foil blocking machine faults are, what causes them and how to prevent
them
K9
the emergency shut down procedures.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 246.1 Set up foil blocking machinery
Performance evidence
You must show that you can set blocking machinery consistently over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
R2
R3
you can set up for at least two of the following:
a
fine line patterns
b
fine line type
c
coarse line type or solid
for case, cover, card stock which is of at least two of the following kinds:
a
plastic
b
cloth
c
paper
d
leather
... using at least two of the following blocking methods:
a
single roll foil
b
multi foil roll
c
blind blocking
d
blocking two-up.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
31
Element 246.2 Run foil blocking machinery
Performance criteria
You must show that you:
1
32
run foil blocking machinery:
a
at the required speed to produce the output
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that quality standards are met
4
accurately identify the cause of production faults, which result in:
a
image out of square
b
foil not sticking to material surface
c
image not having solid appearance
d
image blurred
e
marking of material outside image area
f
loss of fine detail
5
correct mechanical faults which it is your job to remedy
6
promptly report mechanical faults which it is not your job to correct
7
check that the machine is safe to operate, once faults are corrected
8
accurately record production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 246.2 Run foil blocking machinery
Knowledge and understanding
You must understand:
K1
your company’s quality standards
K2
the principles of foil blocking
K3
the merits of different materials used for block making
K4
the risks associated with running foil blocking machinery and how to avoid them
K5
the emergency shut down procedures
K6
the common foil blocking machine faults, what causes them and how to correct them
K7
what other faults can occur during foil blocking
K8
how to recognise when you should correct faults yourself and when you should ask for help
K9
to whom you must report:
a
defects in the materials
b
defects in the products (produced in previous processes)
c
mechanical problems
K10
where to find documents giving help in identifying the causes of faults
K11
the procedures for the removal of waste from your machine
K12
what production and quality assurance details you are required.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
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Element 246.2 Run foil blocking machinery
Performance evidence
You must show that you can run blocking machinery consistently, over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
34
you can maintain the supply of:
a
cases, covers, cards
b
foils
R2
you maintain the quality of the product and avoid waste by promptly identifying any defects
in the product and taking appropriate action
R3
you determine action to remedy faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 246.3 Maintain foil blocking machinery in clean, safe
and useable condition
Performance evidence
You must show that you:
1
have a 'safe system of work' before commencing any cleaning
2
obtain or prepare a schedule of cleaning, lubrication and maintenance for the machine
3
identify the recommended intervals for maintenance and lubrication
4
ensure that the schedule is implemented and kept up to date, within the time allowed by
your company for cleaning, lubrication and maintenance.
5
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
6
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
7
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
8
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
9
after cleaning, check that the machine is safe to operate
10
examine machinery for defective components or excessive wear at intervals required by
your company
11
are able to remove and replace faulty or worn components that are your responsibility
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
35
Element 246.3 Maintain foil blocking machinery in clean, safe
and useable condition
Performance evidence
You must understand:
36
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept
K10
what kinds of components wear or become degraded over time on a foil blocking machine
K11
what kinds of lubricants to use on a foil blocking machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 246.3 Maintain foil blocking machinery in clean, safe
and useable condition
Performance evidence
Your evidence must show that you:
R1
R2
R3
R4
R5
you keep appropriate documents to enable you to ensure that cleaning, lubrication and
maintenance:
a
is kept up to date as far as is permitted within your company’s production schedule
and policy
b
takes account of the machine manufacturer's recommended cleaning, lubrication
and maintenance schedule (if available)
c
complies with any HSE/PIAC code of practice for foil blocking machines
d
is undertaken at times required by your company
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
check that after cleaning the machine is safe to operate and that:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
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Unit 301
Ensure your own actions reduce risks to
health and safety in the workplace
Introduction
Workplaces and work activities contain hazards that may create risks to the health and safety of
workers and visitors. One of the key ways of minimising risk is to identify hazards, evaluate the risks
from them, and implement a programme of action to reduce any risks to an acceptable level. This
process is known as risk assessment.
This unit requires the candidate to identify the hazards in the workplace and reduce risks from those
hazards by ensuring that actual working practice follows the advice and guidance contained in
written documents such as the employer’s workplace policies and procedures, the industry’s codes
of practice, suppliers’ data sheets on use of substances harmful to health, etc.
Users of this unit must refer to the Knowledge and Understanding Glossary for the Printing suite of
NOS for important definitions of terms used in this unit. Text in bold in this unit is defined more fully
in the glossary.
There are two elements in this unit:
1
Element 301.1 Identify hazards and evaluate risks
2
Element 301.2 Reduce risks to health and safety in the workplace
This is what the unit covers
Fundamental to this unit is an understanding of the terms hazard and risk. This unit does not require
the candidate to undertake a full risk assessment; it is about having an appreciation of significant
risks in the workplace and knowing how to identify them and deal with them.
The Health and Safety Executive define a hazard as ‘something with the potential to cause harm’
and a risk is ‘the likelihood of a hazard’s potential being realised’. Each organisation should have its
own risk control strategy and the candidate is required to work within this.
Almost anything may be a hazard, but it may or may not become a risk. For example: a trailing
electrical cable from a piece of equipment is a hazard. If it is trailing across a passageway there is a
high risk of someone tripping over it, but if it lies along a wall out of the way, the risk is much less.
Toxic or flammable chemicals stored in a building are a hazard, and by their nature may present a
high risk. However, if they are kept in a properly designed secure store, and handled by properly
trained and equipped people, the risk is much less than if they are left about in a busy workshop for
anyone to use -or misuse.
The risks covered by this unit are those which could result from:
• the use or maintenance of machinery or equipment
• the use of materials or substances
• working practices which do not conform to laid down policies or codes of practice
• unsafe behaviour
• accidental breakages and spillages
• environmental factors.
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Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 301.1 Identify hazards and evaluate risks in your
workplace
Performance criteria
This is what you need to do:
1
correctly name and locate the person(s) responsible for health and safety in your workplace
2
identify which workplace policies and procedures are relevant to your working practices
3
identify those working practices in any part of your job role which could harm yourself or
other persons
4
identify those aspects of the workplace which could harm yourself or other persons
5
evaluate which of the potentially harmful working practices and the potentially harmful
aspects of the workplace are those with the highest risk to you or to others
6
report any hazards which present a high risk to the persons responsible for health and safety
in the workplace
7
deal with hazards with a low risk in accordance with workplace policies and legal
requirements.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
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Element 301.2 Reduce risks to health and safety in the
workplace
Performance criteria
This is what you need to do:
40
1
carry out your working practices in accordance with legal requirements
2
follow the most recent workplace policies and procedures for your job role
3
rectify those health and safety risks within your capability and the scope of your job
responsibilities
4
pass on any suggestions for reducing risks to health and safety within your job role to the
responsible persons
5
make sure your personal conduct in the workplace does not endanger the health and safety
of yourself or other persons
6
follow suppliers’ or manufacturers’ instructions for the safe use of equipment, materials or
products
7
report any differences between workplace policies and procedures and suppliers /
manufacturers instructions
8
make sure your personal presentation at work:
a
meets any legal duties
b
ensures the health and safety of yourself and others
c
is in accordance with workplace policies and procedures.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 301
Ensure your own actions reduce risks to
health and safety in the workplace
Knowledge and understanding
This is the knowledge and understanding you need to complete this unit successfully. For further
detail you must refer to the Knowledge and Understanding Glossary for the Printing suite of National
Occupational Standards.
K3
Health and Safety
1
Legal duties for health and safety in the workplace as defined by the relevant health and
safety legislation
2
Your duties and responsibilities for health and safety as defined by any specific legislation
covering your job role
3
Workplace policies and procedures
4
Working Practices
5
Hazards and risks in the workplace, their assessment and the action to take to deal with
them
6
Hazards and risks in your own job, their assessment and the action to take to deal with them
7
Manufacturers' and suppliers' health and safety instructions / advice
8
Personal Presentation
9
How to stop a machine in the event of an emergency
K6
Communication
1
With colleagues
2
With visitors
K7
Workplace policy and practice
1
The working practices existing in the workplace
K21
Environmental
1
The legal requirements for the classification, storage, carriage and disposal of waste
2
Any specific environmental legislation that covers processes in your company
3
Control of pollution
K25
Cleaning, Lubrication and Maintenance
1
What is meant by the phrase ‘safe system of work’ and how it applies to cleaning, lubrication
and maintenance activities
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
41
Unit 302
Improve individual and organisational
performance
Introduction
In order to compete successfully, commercial businesses have to continuously improve their
products and services; other kinds of organisations need to keep up to date with technology and
best practice.
One of the ways in which organisations improve is by adopting a culture that encourages their
people to take responsibility for improving their own and their organisation’s performance. This
often involves individuals acquiring new skills or expertise, taking on additional responsibilities and
making improvements to working practices.
This unit is about regularly reviewing, planning, implementing and evaluating the success of
objectives designed to improve your own performance as well as the performance of your
organisation or team.
This unit consists of three elements:
1
Element 302.1 Evaluate and develop your own skills and expertise
2
Element 302.2 Improve customer service delivery
3
Element 302.3 Improve quality, productivity and team working within your organisation
This is what the unit covers
The first stage of the planning cycle involves review. You will need to involve colleagues at work and
ideally customers. You should discuss which kinds of performance improvements are likely to
benefit you and your organisation. Detailed notes should be kept to help in the preparation of an
action plan.
Once you have collected sufficient constructive advice and ideas, you will need to discuss them with
your manager and agree on the priorities. It is important to ensure that the objectives agreed are
achievable.
The objectives that you agree with your manager should enable specific targets to be identified that
can be written into an action plan. There must be a way of measuring any targets that you set and
you should agree how they will be measured. It is also important to set out realistic timescale.
For the purpose of this unit, the action plan should include, as a minimum, proposals for:
• improvement to your own skills and knowledge
• improvement to customer service delivery
• improvements to quality, productivity and team working within your organisation.
Once agreed, the action plan should become a ‘working’ document – not one which is put away and
forgotten about. You should frequently check progress towards achievement of the objectives, and
make a note of any changes to the timescales that were previously agreed.
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Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
If the plan soon becomes out of date because, for example,
• all the targets or objectives are achieved very quickly
• it proves impossible to make progress towards any of the targets
• there is a change of strategy within your organisation
• operational changes affect your or your team’s plans
you must go back to your manager and revise the plan as soon as it becomes apparent that major
changes are necessary
It is perfectly normal to achieve some things in an action plan and not others. What is important is to
honestly evaluate the progress made towards the entire plan at reasonable intervals – at least every
three months, but more often if you wish -and then create a revised or a new plan for the next
period.
Scope
To achieve this unit, it is not necessary to show that all objectives or targets in action plans have
been met.
However, the evidence must show that action planning and review covering all the areas specified
in this standard is a continuing activity over a reasonable timescale. It is unlikely that such evidence
could be produced in less than six months.
The evidence must show that action plans have been used as working documents and updated
regularly. A single action plan with little evidence of the cycle of review through to evaluation is also
insufficient.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
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Element 302.1 Evaluate and develop your own skills and
expertise
Performance criteria
This is what you need to do:
44
1
objectively assess your existing skills and expertise against current industry standards
2
identify ways in which you can improve your performance at work by improving your skills
and expertise
3
seek constructive feedback from others on how your performance at work could be
improved
4
identify with your manager areas for development to maintain and improve your own skills
and expertise
5
set yourself improvement objectives which are specific and achievable
6
agree an action plan with your manager that includes realistic timescales and measurable
targets
7
evaluate your progress and update your action plan regularly with your manager.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 302.2 Improve customer service delivery
Performance criteria
This is what you need to do:
1
check that the service you and your team give meets your customers’ needs and
expectations
2
where you or your team could have given better service to your customers identify how the
service could have been improved
3
include in your personal action plan at least one target that should result in an improvement
to the service you or your team give to customers
4
share relevant information with others in your team to improve your organisation’s
customer service delivery
5.
provide evidence that the service you and / or your team give to customers has improved
over time.
*customers in this context may be ‘internal’ or ‘external’ to the workplace
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
45
Element 302.3 Improve quality, productivity and team
working within your organisation
Performance criteria
This is what you need to do:
1
2
46
periodically identify possible improvements to the quality of your organisation’s products or
services by improvements to:
a
your organisation’s systems or procedures
b
your own skills or expertise
c
your organisation’s resources
d
team working within your organisation
periodically identify possible improvements to your organisation’s productivity by
improvements to:
a
your organisation’s systems or procedures
b
your own skills or expertise
c
your organisation’s resources
d
team working within your organisation
3
discuss with your manager the improvements to quality, productivity and team working that
you have identified
4
include in your personal development plan at least one target that might contribute to
improvements in your organisation’s quality of product / service, productivity and team
working
5
provide evidence that the quality of product or service, productivity and team working
within your organisation has been maintained or improved over time.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 302
Improve individual and organisational
performance
Knowledge and understanding
This is the knowledge and understanding you need to complete this unit successfully. For further
detail you must refer to the Knowledge and Understanding Glossary for the Printing suite of National
Occupational Standards.
K6
Communication
1
With colleagues
2
With customers
K7
Workplace policy and practice
1
Workplace objectives, priorities, standards and procedures
2
The range of work carried out in the workplace
3
The working practices existing in the workplace
4
The key job roles within the printing and graphic communications industry and their main
purposes
K8
The identification and assessment of printing options
1
The reasons for selecting one process over another
2
The choice of processes for any particular product
3
The stages in the printing process from pre-press to printed product
K9
Time and Resources
1
The different types of resource, including labour, materials, machinery
2
The relationship between resource usage and profitability
3
How to maximise productivity
4
The relationship between productivity and competitiveness
K20
Management
1
Target-setting
2
Problem solving
3
Ways of presenting and describing workplace activities
4
Business Improvement Techniques
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
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48
K22
Quality Assurance and Control
1
The main features of quality assurance and quality control systems
2
Techniques for controlling quality, including inspection, testing, sampling, use of input and
output controls
3
Equipment for controlling quality in printing
K27
Personal Development
1
The principles of personal development planning and training
2
Developing people at work
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 328
Introduction
Control adhesive binding machinery
To achieve your unit certificate, you must show that you can:
1
Element 328.1 Set up adhesive binding machinery
2
Element 328.2 Run adhesive binding machinery
3
Element 328.3 Plan and implement a programme of maintenance for adhesive binding
machinery
4
Element 328.4 Keep adhesive binding machinery in a clean and safe operating
condition
This involves:
• identifying the job requirements
• checking that adhesive binding machinery is working properly
• checking that safety devices are working properly
• running the adhesive binding machine safely
• adjusting settings, where necessary to maintain the required standard
• checking that the work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
Please note: unit 340 may not be used in conjunction with unit 328.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
49
Element 328.1 Set up adhesive binding machinery
Performance criteria
You must show that you:
50
1
check that you have all the details you need for the job
2
check that you have enough adhesive of the right type for the job
3
promptly report to your manager, if the adhesive provided is not correct or sufficient
4
correctly prepare the book-block spine to receive the adhesive
5
set up the adhesive binding machinery, so that:
a
covers are fed squarely
b
score lines do not break the cover surface
c
book blocks are transferred squarely within clamps
d
spine preparation gives the correct glue penetration of the paper
e
glue is applied evenly at the correct temperature
f
books are delivered from the machine without damage or marking
6
produce a sample from the machine and check that it matches the required standards
7
make adjustments if necessary, to enable the standards to be met
8
report promptly to your manager, if the standards cannot be met
9
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 328.1 Set up adhesive binding machinery
Knowledge and understanding
You must understand:
K1
what details you need for the job
K2
the principles of adhesive binding
K3
the sequence of set up tasks for the adhesive binding machine
K4
the common adhesive binding set-up faults, what causes them and how to prevent them
K5
the risks associated with setting up adhesive binding machinery, and how to avoid them
K6
the emergency shut-down procedures
K7
the binding requirements of:
a
unsewn and sewn sections
b
covers with two and four scores
c
coated and uncoated papers
K8
the purpose of collating marks and signature marks
K9
how grain direction of material affects binding quality
K10
the difference between binding with Hot Melt and Emulsion adhesives.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
51
Element 328.1 Set up adhesive binding machinery
Performance evidence
You must show that you can set up adhesive binding machinery consistently over a period of time.
Your performance will be observed on at least four occasions. Your evidence must show that:
R1
R2
R3
R4
52
you set up for at least one of the following types of section:
a
unsewn sections
b
sewn book blocks
and the following types of cover:
a
two scored
b
four scored (hinge) and side glue
and at least one of the following types of cover stock:
a
paper
b
card
c
laminated/varnished
you test and adjust machinery by:
a
visual inspection
b
checking control settings
c
producing a sample from the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 328.2 Run adhesive binding machinery
Performance criteria
You must show that you:
1
run adhesive binding machinery:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify the causes of faults in production, which result in:
a
cracking of the surface along score lines
b
print being out of square on the front cover and spine
c
rounding of spines
d
too much and too little glue penetration
e
poor page-pull strength
f
covers not registering correctly with book blocks
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
53
Element 328.2 Run adhesive binding machinery
Knowledge and understanding
You must understand:
54
K1
your company’s quality standards
K2
the risks associated with running adhesive binding machines and how to avoid them
K3
the emergency shut-down procedures
K4
the common adhesive binding machine running faults, what causes them and how to correct
them
K5
what other faults can occur during adhesive binding
K6
how to recognise when you should correct faults yourself, and when you should ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedures for the removal of waste from your machine
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance records you are required to keep.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 328.2 Run adhesive binding machinery
Performance evidence
You must show that you can run adhesive binding machinery consistently, over a period of time.
Your performance will be observed on at least four occasions. Your evidence must show that:
R1
you maintain the quality of the product and avoid waste by promptly identifying any defects
in the product and taking appropriate action
R2
you maintain the supply of:
R3
R4
a
book blocks and/or sections
b
end papers (if used)
c
covers
d
adhesive
and maintain the quality of:
a
cover position
b
bond strength
c
spine and side-gluing
you decide on action to correct faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
55
Element 328.3 Plan and implement a programme of
maintenance for adhesive binding machinery
Performance criteria
You must show that you:
56
1
obtain or prepare a schedule of maintenance for the adhesive binding machinery
2
identify the recommended intervals and points for lubrication and cleaning
3
ensure that the maintenance plan for the adhesive binding machine is implemented and kept
up to date
4
keep records of maintenance work undertaken
5
examine machinery for defective components or excessive wear at intervals required by
your company
6
keep records of faults that occur or are developing and that appropriate action is taken to
deal with them either:
a
as part of the maintenance programme
b
as an urgent repair by you (if it is your job to deal with it) or
c
by reporting the problem to the relevant person in your organisation
7
are able to remove and replace faulty or worn components that are your responsibility
8
maintain a list of parts or consumables that are likely to require periodic replacement and
identify those parts that may be required at short notice
9
ensure that any parts or consumables identified as being required to be kept 'in stock' are
available in the required quantities.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 328.3 Plan and implement a programme of
maintenance for adhesive binding machinery
Knowledge and understanding
You must understand:
K1
why manufacturer's of adhesive binding machines specify a schedule of preventative
maintenance
K2
what kinds of components wear or become degraded over time on an adhesive binder
K3
what kinds of lubricants to use on the adhesive binder
K4
the properties of different kinds of lubricants
K5
how to replenish lubricants in dispensers and reservoirs
K6
how to find part reference numbers and order replacement parts
K7
the consequences of failing to maintain or inspect your machine in accordance with the
manufacturer's specification or any relevant code of practice
K8
legal requirements and industry guidelines for the safe handling, use and disposal of
hazardous substances
K9
the risks of handling lubricants
K10
the personal protective equipment which should be worn when handling hazardous
substances and lubricants.
K11
where the principal lubrication points are on your adhesive binder
K12
to whom you should report existing and developing faults
K13
what is meant by the term 'safe system of work' and how it applies to maintenance and
lubrication activities on an adhesive binder.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
57
Element 328.3 Plan and implement a programme of
maintenance for adhesive binding machinery
Performance evidence
You must show that you plan and implement maintenance of the adhesive binder consistently, over
a period of time. Your evidence must show that:
R1
a
the machine manufacturer's recommended maintenance schedules
b
the machine manufacturer's operating manual and any other relevant documents
c
HSE/PIAC code of practice for adhesive binders (if there is one)
d
lists of consumables and parts, including those normally kept 'in stock'
e
maintenance records
f
fault reports
R2
you have a maintenance schedule for the machine, and take part in its implementation as far
as your company’s production schedules and policies allow
R3
you identify defective or deteriorating components during:
R4
58
you keep appropriate documents to enable the planning and implementation of
maintenance, such as:
a
normal machine running
b
planned maintenance work
you are able to diagnose actual or developing machine faults by:
a
examining output from the machine
b
examining the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 328.4 Keep adhesive binding machinery in a clean
and safe operating condition
Performance criteria
You must show that you:
1
have a 'safe system of work' and a risk assessment in place before commencing any
cleaning
2
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
3
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
4
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
5
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
6
after cleaning, check that the machine is safe to operate.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
59
Element 328.4 Keep adhesive binding machinery in a clean
and safe operating condition
Knowledge and understanding
You must understand:
60
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 328.4 Keep adhesive binding machinery in a clean
and safe operating condition
Performance evidence
You must show that you keep the adhesive binding machinery in a clean and safe operating
condition consistently, over a period of time. Your performance will be observed on at least four
occasions. Your evidence must show that you:
R1
R2
R3
R4
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
d
spent adhesive
check that after cleaning the machine is safe to operate:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
c
any guards designed to give protection from the milling station and the glue tank are
fitted and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
61
Unit 329
Introduction
Control case making machinery
To achieve your unit certificate, you must show that you can:
1
Element 329.1 Set up case making machinery
2
Element 329.2 Run case making machinery
3
Element 329.3 Plan and implement a programme of maintenance for case making
machinery
4
Element 329.4 Keep case making machinery in a clean and safe operating condition
This involves:
• identifying the job requirements
• checking that case making machinery is working properly
• checking that safety devices are working properly
• running the case making machine safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
62
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 329.1 Set up case making machinery
Performance criteria
You must show that you:
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up the case making machine correctly, so that:
a
boards and hollows transfer from feeders squarely and evenly
b
cover material transfers from the feeder squarely and evenly
c
glue is applied evenly at the correct temperature
d
cover material is turned in evenly and squarely onto boards
e
cases are delivered from the machine without damage or distortion
5
produce a sample from the machine and check that it matches the required standards
6
make adjustments if necessary to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
63
Element 329.1 Set up case making machinery
Knowledge and understanding
You must understand:
K1
what details you need for the job
K2
the principles of case making
K3
the sequence of set up tasks for the case making machine
K4
the common case making machine set-up faults, what causes them and how to prevent
them
K5
the risks associated with setting up case making machinery, and how to avoid them
K6
the emergency shut-down procedures
K7
which glues are suitable to use with:
K8
64
a
paper and cloth covering materials
b
laminated and coated covering materials
how the grain direction of boards and cover materials can affect binding quality.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 329.1 Set up case making machinery
Performance evidence
You must show that you can set up case making machinery consistently over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
R2
R3
R4
R5
you set up for at least one of the following binding styles:
a
full bound case work
b
quarter bound case work
and at least one of the following types of cover:
a
plastic coated paper
b
cloth
c
paper
d
pre-printed cover case work
and at least one of the following types of hollow lining:
a
paper
b
board
for at least one of the following types of book:
a
rounded and backed
b
square backed
you test and adjust machinery by:
a
visual inspection
b
checking control settings
c
producing a sample from the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
65
Element 329.2 Run case making machinery
Performance criteria
You must show that you:
1
66
run case making machinery:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify the causes of faults in production which result in:
a
blistering of cover material
b
uneven turn-ins
c
turn-ins not tight
d
cover boards not parallel with each other
e
cover material not adhering to boards
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 329.2 Run case making machinery
Knowledge and understanding
You must understand:
K1
your company’s quality standards
K2
the risks associated with running case making machines and how to avoid them
K3
the emergency shut-down procedures
K4
the common case making machine running faults, what causes them and how to correct
them
K5
what other faults can occur during case making
K6
how to recognise when you should correct faults yourself, and when you should ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedures for the removal of waste from your machine
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance records you are required to keep.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
67
Element 329.2 Run case making machinery
Performance evidence
You must show that you can run of case making machinery consistently, over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
you maintain the quality of the product and avoid waste by promptly identifying any defects
in the product and taking appropriate action
R2
you maintain the supply of:
R3
R4
68
a
boards
b
covers
c
linings
d
adhesive
... and maintain the quality of:
a
turn-ins
b
hollow lining
you decide on action to correct faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 329.3 Plan and implement a programme of
maintenance for case making machinery
Performance criteria
You must show that you:
1
obtain or prepare a schedule of maintenance for the case making machinery
2
identify the recommended intervals and points for lubrication and cleaning
3
ensure that the maintenance plan for the case making machine is implemented and kept up
to date
4
keep records of maintenance work undertaken
5
examine machinery for defective components or excessive wear at intervals required by
your company
6
keep records of faults that occur or are developing and that appropriate action is taken to
deal with them either:
a
as part of the maintenance programme
b
as an urgent repair by you (if it is your job to deal with it) or
c
by reporting the problem to the relevant person in your organisation
7
are able to remove and replace faulty or worn components that are your responsibility
8
maintain a list of parts or consumables that are likely to require periodic replacement and
identify those parts that may be required at short notice
9
ensure that any parts or consumables identified as being required to be kept 'in stock' are
available in the required quantities.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
69
Element 329.3 Plan and implement a programme of
maintenance for case making machinery
Knowledge and understanding
You must understand:
70
K1
why manufacturers of case making machines specify a schedule of preventative
maintenance
K2
what kinds of components wear or become degraded over time on a case making machine
K3
what kinds of lubricants to use on the case making machine
K4
the properties of different kinds of lubricants
K5
how to replenish lubricants in dispensers and reservoirs
K6
how to find part reference numbers and order replacement parts
K7
the consequences of failing to maintain or inspect your machine in accordance with the
manufacturer's specification or any relevant code of practice
K8
legal requirements and industry guidelines for the safe handling, use and disposal of
hazardous substances
K9
the risks of handling lubricants
K10
the personal protective equipment that should be worn when handling hazardous
substances and lubricants
K11
where the principal lubrication points are on your case making machine
K12
to whom you should report existing and developing faults
K13
what is meant by the term 'safe system of work' and how it applies to maintenance and
lubrication activities on as case making machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 329.3 Plan and implement a programme of
maintenance for case making machinery
Performance evidence
You must show that you plan and implement maintenance of the case making machine consistently
over a period of time. Your evidence must show that:
R1
you keep appropriate documents to enable the planning and implementation of
maintenance, such as:
a
the machine manufacturer's recommended maintenance schedules
b
the machine manufacturer's operating manual and any other relevant documents
c
HSE/PIAC code of practice for case making machines (if there is one)
d
lists of consumables and parts, including those normally kept 'in stock'
e
maintenance records
f
fault reports
R2
you have a maintenance schedule for the machine, and take part in its implementation as far
as your company’s production schedules and policies allow
R3
you identify defective or deteriorating components during:
R4
a
normal machine running
b
planned maintenance work
you are able to diagnose actual or developing machine faults by:
a
examining output from the machine
b
examining the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
71
Element 329.4 Keep case-making machinery in a clean and
safe operating condition
Performance criteria
You must show that you:
72
1
have a 'safe system of work' and a risk assessment in place before commencing any
cleaning
2
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
3
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
4
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
5
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
6
after cleaning, check that the machine is safe to operate.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 329.4 Keep case-making machinery in a clean and
safe operating condition
Knowledge and understanding
You must understand:
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
73
Element 329.4 Keep case-making machinery in a clean and
safe operating condition
Performance evidence
You must show that you keep the case-making machinery in a clean and safe operating condition
consistently, over a period of time. Your performance will be observed on at least four occasions.
Your evidence must show that you:
R1
R2
R3
R4
74
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap materials
b
dust, including paper dust
c
excessive lubricant
d
adhesive
check that after cleaning the machine is safe to operate:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 330
Introduction
Control casing-in machinery
To achieve your unit certificate, you must show that you can:
1
Element 330.1 Set up casing-in machinery
2
Element 330.2 Run casing-in machinery
3
Element 330.3 Plan and implement a programme of maintenance for casing-in
machinery
4
Element 330.4 Keep casing-in machinery in a clean and safe operating condition
This involves:
• identifying the job requirements
• checking that casing-in machinery is working properly
• checking that safety devices are working properly
• running the casing-in machine safely
• adjusting settings, when necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
75
Element 330.1 Set up casing-in machinery
Performance criteria
You must show that you:
76
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up the casing-in machine correctly, so that:
a
book blocks are transported squarely and evenly
b
cases are transported squarely, evenly and without distortion
c
adhesive is applied evenly to book joints and endpapers
d
book blocks are securely and cleanly attached to cases
e
squares are of equal size all round
f
books are delivered without damage or distortion
5
produce a sample from the machine and check that it matches the required standards
6
make adjustments if necessary to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 330.1 Set up casing-in machinery
Knowledge and understanding
You must understand:
K1
what details you need for the job
K2
the principles of casing-in
K3
the sequence of set up tasks for the casing-in machine
K4
the common casing-in machine set-up faults, what causes them and how to prevent them
K5
the risks associated with making ready casing-in machinery, and how to avoid them
K6
the emergency shut-down procedures
K7
the different binding requirements of:
a
square backed books
b
rounded and backed books
K8
which glues are suitable for the casing-in process
K9
how the grain direction of boards and book blocks can affect binding quality
K10
the degree of warping produced by gluing different types of boards and papers.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
77
Element 330.1 Set up casing-in machinery
Performance evidence
You must show that you can set up casing-in machinery consistently over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
you set up to produce:
a
case bound rounded and backed books
or
b
R2
case bound square backed books
for jobs which include:
a
tape sewn sections
or
b
multi book back linings
or
c
R3
head and tail bands
and the following types of case cover stock:
a
plastic/coated
or
b
cloth
or
c
R4
paper
and the following types of hollow lining
a
paper
or
b
R5
78
board
you test and adjust machinery by:
a
visual inspection
b
checking control settings
c
producing a sample from the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 330.2 Run casing-in machinery
Performance criteria
You must show that you:
1
run casing-in equipment:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify the causes of faults in production, which result in:
a
the book block incorrectly positioned within the case
b
the book block not glued securely into the case
c
glue marking of the case and book block
d
lifting of endpapers from cover turn-in
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
79
Element 330.2 Run casing-in machinery
Knowledge and understanding
You must understand:
80
K1
your company’s quality standards
K2
the risks associated with running casing-in machinery and how to avoid them
K3
the emergency shut-down procedures
K4
the common casing-in machine running faults, what causes them and how to correct them
K5
what other faults can occur when casing-in
K6
how to recognise when you should correct faults yourself and when you should ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedures for the removal of waste from your machine
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance details you are required to keep.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 330.2 Run casing-in machinery
Performance evidence
You must show that you can run casing-in machinery consistently, over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
R2
R3
R4
you produce:
a
case bound rounded and backed books
b
case bound square backed books
you maintain the supply of:
a
cases
b
book blocks
c
adhesive
and maintain the quality of:
a
case position
b
spine shape
c
bond strength
you decide on action to correct faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
81
Element 330.3 Plan and implement a programme of
maintenance for casing-in machinery
Performance criteria
You must show that you:
82
1
obtain or prepare a schedule of maintenance for the casing-in machinery
2
identify the recommended intervals and points for lubrication and cleaning
3
ensure that the maintenance plan for the casing-in machine is implemented and kept up to
date, within the time allowed by your company for lubrication and maintenance
4
keep records of maintenance work undertaken
5
examine machinery for defective components or excessive wear at intervals required by
your company
6
keep records of faults that occur or are developing and that appropriate action is taken to
deal with them either:
a
as part of the maintenance programme
b
as an urgent repair by you (if it is your job to deal with it) or
c
by reporting the problem to the relevant person in your organisation
7
are able to remove and replace faulty or worn components that are your responsibility
8
maintain a list of parts or consumables that are likely to require periodic replacement and
identify those parts that may be required at short notice
9
ensure that any parts or consumables identified as being required to be kept 'in stock' are
available in the required quantities.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 330.3 Plan and implement a programme of
maintenance for casing-in machinery
Knowledge and understanding
You must understand:
K1
why manufacturers of casing-in machines specify a schedule of preventative maintenance
K2
what kinds of components wear or become degraded over time on a casing-in machine
K3
what kinds of lubricants to use on the casing-in machine
K4
the properties of different kinds of lubricants
K5
how to replenish lubricants in dispensers and reservoirs
K6
how to find part reference numbers and order replacement parts
K7
the consequences of failing to maintain or inspect your machine in accordance with the
manufacturer's specification or any relevant code of practice
K8
legal requirements and industry guidelines for the safe handling, use and disposal of
hazardous substances
K9
the risks of handling lubricants
K10
the personal protective equipment which should be worn when handling hazardous
substances and lubricants
K11
where the principal lubrication points are on your casing-in machine
K12
to whom you should report existing and developing faults
K13
what is meant by the term 'safe system of work' and how it applies to maintenance and
lubrication activities on a casing-in machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
83
Element 330.3 Plan and implement a programme of
maintenance for casing-in machinery
Performance evidence
You must show that you plan and implement maintenance of the casing-in machine consistently,
over a period of time. Your evidence must show that:
R1
a
the machine manufacturer's recommended maintenance schedules
b
the machine manufacturer's operating manual and any other relevant documents
c
any HSE/PIAC code of practice for casing-in machinery
d
lists of consumables and parts, including those normally kept 'in stock'
e
maintenance records
f
fault reports
R2
you have a maintenance schedule for the machine, and take part in its implementation as far
as your company’s production schedules and policies allow
R3
you identify defective or deteriorating components during:
R4
84
you keep appropriate documents to enable the planning and implementation of
maintenance, such as:
a
normal machine running
b
planned maintenance work
you are able to diagnose actual or developing machine faults by:
a
examining output from the machine
b
examining the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 330.4 Keep casing-in machinery in a clean and safe
operating condition
Performance criteria
You must show that you:
1
have a 'safe system of work' and a risk assessment in place before commencing any
cleaning
2
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
3
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
4
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
5
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
6
after cleaning, check that the machine is safe to operate.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
85
Element 330.4 Keep casing-in machinery in a clean and safe
operating condition
Knowledge and understanding
You must understand:
86
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 330.4 Keep casing-in machinery in a clean and safe
operating condition
Performance evidence
You must show that you keep the casing-in machinery in a clean and safe operating condition
consistently, over a period of time. Your performance will be observed on at least four occasions.
Your evidence must show that you:
R1
R2
R3
R4
work in a tidy and safe environment and prevent the build up of debris
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
d
adhesive
check that after cleaning the machine is safe to operate:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
87
Unit 331
Introduction
Control programmatic guillotines
To achieve your unit certificate, you must show that you can:
1
Element 331.1 Set up programmatic guillotines
2
Element 331.2 Run programmatic guillotines
3
Element 331.3 Plan and implement a programme of maintenance for programmatic
guillotines
4
Element 331.4 Keep programmatic guillotines in a clean and safe operating condition
This involves:
• identifying the job requirements
• checking that the guillotine is working properly
• checking that safety devices are working properly
• running the guillotine safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
88
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 331.1 Set up programmatic guillotines
Performance criteria
You must show that you:
1
check that a current safety test certificate exists for the guillotine
2
check that the daily check-list has been completed and that guards are in place and
operating correctly
3
check that you have all the details you need for the job
4
check that you have enough materials of the right type for the job
5
promptly report to your manager, if the materials provided are not correct or sufficient
6
assess whether the work should be cut:
a
using an existing programmed cutting sequence
b
using a newly created programmed cutting sequence
c
by setting the back fence manually for each cut
(*manually means without the use of the programme)
7
set up the guillotine correctly so that:
a
the required cut size(s) is(are) produced with minimum handling
b
cuts are clean, square and accurately positioned
c
clamp pressure does not cause marking or set-off
8
produce a sample from the machine and check that it matches the required standards
9
make adjustments if necessary to enable the standards to be met
10
report promptly to your manager, if the standards cannot be met
11
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
89
Element 331.1 Set up programmatic guillotines
Knowledge and understanding
You must understand:
90
K1
what details you need for the job
K2
the principles of guillotining
K3
how to use the programmatic features of the guillotine
K4
common guillotine set-up faults, what causes them and how to prevent them
K5
the risks associated with setting up a guillotine, and how to avoid them
K6
the emergency shut-down procedures
K7
the requirements of other processes which follow cutting
K8
what is meant when printed material is produced by:
a
sheetwork
b
work and turn
c
work and tumble.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 331.1 Set up programmatic guillotines
Performance evidence
You must show that you can set up guillotines consistently over a period of time. Your performance
will be observed on at least four occasions. Your evidence must show that:
R1
R2
R3
you can create and save a cutting programme for:
a
trimming square to size
b
sub-divisional work
c
the removal of gutters imposed in the printed sheet
you can edit and save an existing programme in order to:
a
alter a programmed cutting position
b
delete a cut from the cutting sequence
c
add a cut to the cutting sequence
you can set up the guillotine for job stock which is:
a
flat printed stock
or
b
R4
made up work
and which is:
a
coated or uncoated paper
and
b
R5
coated or uncoated board
you test and adjust machinery by:
a
visual inspection
b
checking control settings
c
producing a sample from the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
91
Element 331.2 Run programmatic guillotines
Performance criteria
You must show that you:
1
92
run the guillotine:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify the causes of faults in production, which result in:
a
cut work being out of square
b
cut work being under or over size
c
cut edges not smooth
d
unacceptable size variation between top and bottom of pile
e
marking of material from clamp
5
accurately record the production and quality assurance details
6
follow the correct procedures for the removal of waste
7
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 331.2 Run programmatic guillotines
Knowledge and understanding
You must understand:
K1
your company’s quality standards
K2
the risks associated with running guillotines, and how to avoid them
K3
the emergency shut-down procedures
K4
the common guillotine running faults, what causes them and how to correct them
K5
what other faults can occur during guillotine cutting
K6
how to recognise when you should correct faults yourself, and when you should ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedure for the removal of waste from your machine
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance records you are required to keep
K12
how to deal with the cutting of pre-folded material.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
93
Element 331.2 Run programmatic guillotines
Performance evidence
You must show that you can operate guillotines consistently, over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
R2
R3
94
you operate the guillotine for:
a
trimming square to size
b
sub-divisional work
using material which is:
a
flat printed stock
b
processed work
and maintain the quality of:
a
cuts
b
the material.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 331.3 Plan and implement a programme of
maintenance for programmatic guillotines
Performance criteria
You must show that you:
1
obtain or prepare a complete schedule of maintenance for the guillotine
2
identify the recommended intervals for maintenance and lubrication
3
ensure that the maintenance plan is implemented and kept up to date as far as is possible
within the time allowed by your company for lubrication and maintenance.
4
keep records of maintenance work undertaken
5
examine the guillotine for defective components or excessive wear at intervals required by
your company
6
keep records of faults that occur or are developing and that appropriate action is taken to
deal with them either:
a
as part of the maintenance programme
b
as an urgent repair by you (if it is your job to deal with it) or
c
by reporting the problem to the relevant person in your organisation
7
are able to change the guillotine blade correctly and safely
8
are able to check and, if necessary, adjust the back-fence to deal with:
a
cutting out of square from side to side
b
cutting inaccurately from top to bottom of the stack
c
sheets becoming trapped under the back fence during forward travel
9
maintain a list of parts or consumables that are likely to require periodic replacement and
identify those parts that may be required at short notice
10
ensure that any parts or consumables identified as being required to be kept 'in stock' are
available in the required quantities.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
95
Element 331.3 Plan and implement a programme of
maintenance for programmatic guillotines
Knowledge and understanding
You must understand:
96
K1
why manufacturer's of guillotines specify a schedule of preventative maintenance
K2
what kinds of components wear or become degraded over time on a guillotine
K3
what kinds of lubricants to use on the guillotine
K4
the properties of different kinds of lubricants
K5
how to replenish lubricants in dispensers and reservoirs
K6
how to find part reference numbers and order replacement parts
K7
the HSE/PIAC recommendation and requirements relating to guillotines
K8
legal requirements and industry guidelines for the safe handling, use and disposal of
hazardous substances
K9
the risks of handling lubricants
K10
the personal protective equipment which should be worn when handling hazardous
substances and lubricants.
K11
where the principal lubrication points are on your guillotine
K12
to whom you should report existing and developing faults
K13
what is meant by the term 'safe system of work' and how it applies to maintenance and
lubrication activities on a guillotine
K14
the types of knives and cutting sticks available for guillotines and their characteristics
K15
knife grinding angles and their significance.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 331.3 Plan and implement a programme of
maintenance for programmatic guillotines
Performance evidence
You must show that you plan and implement maintenance of the guillotine consistently, over a
period of time. Your evidence must show that:
R1
you keep appropriate documents to enable the planning and implementation of
maintenance, such as:
a
the machine manufacturer's recommended maintenance schedules
b
the machine manufacturer's operating manual and any other relevant documents
c
the HSE/PIAC code of practice for paper-cutting guillotines
d
lists of consumables and parts, including those normally kept 'in stock'
e
maintenance records
f
fault reports
R2
you have a maintenance schedule for the machine, and take part in its implementation as far
as your company’s production schedules and policies allow
R3
you identify defective or deteriorating components during
R4
a
normal machine running
b
planned maintenance work
you are able to diagnose actual or developing machine faults by:
a
examining output from the machine
b
examining the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
97
Element 331.4 Keep programmatic guillotines in a clean and
safe operating condition
Performance criteria
You must show that you:
98
1
have a 'safe system of work' and a risk assessment in place before commencing any
cleaning
2
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
3
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
4
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
5
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
6
after cleaning, check that the machine is safe to operate.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 331.4 Keep programmatic guillotines in a clean and
safe operating condition
Knowledge and understanding
You must understand:
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
99
Element 331.4 Keep programmatic guillotines in a clean and
safe operating condition
Performance evidence
You must show that you keep the guillotine in a clean and safe operating condition consistently,
over a period of time. Your performance will be observed on at least four occasions. Your evidence
must show that you:
R1
R2
R3
R4
100
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
check that after cleaning the machine is safe to operate:
a
all fixed guards are in place on the machine
b
any interlocking or photo-electric guards are working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 332
Introduction
Control folding machinery
To achieve your unit certificate, you must show that you can:
1
Element 332.1 Set up folding machinery
2
Element 332.2 Run folding machinery
3
Element 332.3 Plan and implement a programme of maintenance for folding machinery
4
Element 332.4 Keep folding machinery in a clean and safe operating condition
This involves:
• identifying the job requirements
• checking that the folding machine is working properly
• checking that safety devices are working properly
• running folding machinery safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
Please note: unit 339 may not be used in conjunction with unit 332.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
101
Element 332.1 Set up folding machinery
Performance criteria
You must show that you:
102
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up folding machinery correctly, so that:
a
sheets are fed squarely and consistently, without damage or distortion
b
mis-fed sheets are detected by the machine’s device
c
sheets are folded without damage, and are free from unacceptable creasing
d
work is slit and perforated squarely and cleanly
e
sections are delivered without damage
5
produce a sample from the machine and check that it matches the required standards
6
make adjustments if necessary to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 332.1 Set up folding machinery
Knowledge and understanding
You must understand:
K1
what details you need for the job
K2
the principles of machine folding
K3
the sequence of set up tasks for the folding machine
K4
the common folding machine set-up faults, what causes them and how to prevent them
K5
the risks associated with setting up folding machines, and how to avoid them
K6
the emergency shut-down procedures
K7
the requirements of other processes which follow folding
K8
what is meant when printed material is produced by:
a
sheetwork
b
half sheetwork
c
work and turn
d
work and tumble
K9
the purpose of collating marks and signature marks
K10
how folds are made by:
K11
a
knife method
b
buckle method
how sheets are fed by:
a
pile feeders
b
continuous feeders
K12
when to use perforating discs, and when not to use them
K13
how a heavy perforation can cause problems for other processes.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
103
Element 332.1 Set up folding machinery
Performance evidence
You must show that you can set up folding machinery consistently over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
R2
R3
R3
R4
R5
104
you identify:
a
the job stock and grammage
b
supplied and finished size
c
grain direction
you check that the print layout matches:
a
the imposition
b
the required fold sequence
you can set up for the following folding schemes:
a
parallel schemes
b
right angle schemes
c
combination schemes
for sections between 4 pp and 16 pp which are:
a
portrait
b
landscape
c
lapped fore-edge
and for stock which is:
a
coated paper
b
uncoated paper
you test and adjust machinery by:
a
visual inspection
b
checking control settings
c
producing a sample from the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 332.2 Run folding machinery
Performance criteria
You must show that you:
1
run folding machinery:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify the causes of faults in production, which result in:
a
sheets sticking together
b
sheets failing to enter fold unit
c
sheets failing to leave fold unit
d
sheets folded out of square
e
slitting and perforating not parallel to sheet edge
f
unacceptable creasing of sections
g
marking of sections
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
105
Element 332.2 Run folding machinery
Knowledge and understanding
You must understand:
106
K1
your company’s quality standards
K2
the risks associated with running folding machinery, and how to avoid them
K3
the emergency shut-down procedures
K4
the common folding machine running faults, what causes them and how to correct them
K5
what other faults can occur during folding
K6
how to recognise when you should correct faults yourself, and when you ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedure for the removal of waste from your machine
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance records you are required to keep
K12
how grain direction affects the folding process
K13
which types of material are most at risk of rub marking
K14
which printed colours are most at risk of marking
K15
the purpose of pre-creasing
K16
the purpose of gluing attachments and how they work.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 332.2 Run folding machinery
Performance evidence
You must show that you can run folding machinery consistently, over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
R2
R3
R4
R5
you can fold to:
a
parallel schemes
b
right angle schemes
c
combination schemes
for sections between 4 pp and 16 pp which are:
a
portrait
b
landscape
c
lapped fore-edge
and for stock which is:
a
coated paper
b
uncoated paper
and maintain the quality of:
a
the material
b
folded sections
you decide on action to correct faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
107
Element 332.3 Plan and implement a programme of
maintenance for folding machinery
Performance criteria
You must show that you:
108
1
obtain or prepare a complete schedule of maintenance for the folding machine
2
identify the recommended intervals for maintenance and lubrication
3
ensure that the maintenance plan is implemented and kept up to date as far as is possible
within the time allowed by your company for lubrication and maintenance.
4
keep records of maintenance work undertaken
5
examine machinery for defective components or excessive wear at intervals required by
your company
6
keep records of faults that occur or are developing and that appropriate action is taken to
deal with them either:
a
as part of the maintenance programme
b
as an urgent repair by you (if it is your job to deal with it) or
c
by reporting the problem to the relevant person in your organisation
7
are able to remove and replace faulty or worn components that are your responsibility
8
maintain a list of parts or consumables that are likely to require periodic replacement and
identify those parts that may be required at short notice
9
ensure that any parts or consumables identified as being required to be kept 'in stock' are
available in the required quantities.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 332.3 Plan and implement a programme of
maintenance for folding machinery
Knowledge and understanding
You must understand:
K1
why manufacturer's of folding machinery specify a schedule of preventative maintenance
K2
what kinds of components wear or become degraded over time on folding machinery
K3
what kinds of lubricants to use on the folding machine
K4
the properties of different kinds of lubricants
K5
how to replenish lubricants in dispensers and reservoirs
K6
how to find part reference numbers and order replacement parts
K7
the consequences of failing to maintain or inspect your machine in accordance with the
manufacturer's specification or any relevant code of practice
K8
legal requirements and industry guidelines for the safe handling, use and disposal of
hazardous substances
K9
the risks of handling lubricants
K10
the personal protective equipment which should be worn when handling hazardous
substances and lubricants
K11
where the principal lubrication points are on your folding machine
K12
to whom you should report existing and developing faults
K13
what is meant by the term 'safe system of work' and how it applies to maintenance and
lubrication activities on folding machinery.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
109
Element 332.3 Plan and implement a programme of
maintenance for folding machinery
Performance evidence
You must show that you plan and implement maintenance of the guillotine consistently, over a
period of time. Your evidence must show that:
R1
a
the machine manufacturer's recommended maintenance schedules
b
the machine manufacturer's operating manual and any other relevant documents
c
the HSE/PIAC code of practice for folding machines
d
lists of consumables and parts, including those normally kept 'in stock'
e
maintenance records
f
fault reports
R2
you have a maintenance schedule for the machine, and take part in its implementation as far
as your company’s production schedules and policies allow
R3
you identify defective or deteriorating components during:
R4
110
you keep appropriate documents to enable the planning and implementation of
maintenance, including:
a
normal machine running
b
planned maintenance work
you are able to diagnose actual or developing machine faults by:
a
examining output from the machine
b
examining the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 332.4 Keep folding machinery in a clean and safe
operating condition
Performance criteria
You must show that you:
1
have a 'safe system of work' and a risk assessment in place before commencing any
cleaning
2
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
3
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
4
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
5
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
6
after cleaning, check that the machine is safe to operate.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
111
Element 332.4 Keep folding machinery in a clean and safe
operating condition
Knowledge and understanding
You must understand:
112
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 332.4 Keep folding machinery in a clean and safe
operating condition
Performance evidence
You must show that you keep the folding machinery in a clean and safe operating condition
consistently, over a period of time. Your performance will be observed on at least four occasions.
Your evidence must show that you:
R1
R2
R3
R4
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
check that after cleaning the machine is safe to operate:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
113
Unit 333
Introduction
Control in-line booklet-making machinery
To achieve your unit certificate, you must show that you can:
1
Element 333.1 Set up in-line booklet-making machinery
2
Element 333.2 Run in-line booklet-making machinery
3
Element 333.3 Plan and implement a programme of maintenance for in-line-bookletmaking machinery
4
Element 333.4 Keep in-line booklet-making machinery in a clean and safe operating
condition
This involves:
• identifying the job requirements
• checking that machinery is working properly
• checking that safety devices are working properly
• running the machine safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
Please note: unit 338 may not be used in conjunction with unit 333.
114
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 333.1 Set up in-line booklet-making machinery
Performance criteria
You must show that you:
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up the in-line machine correctly, so that:
a
flat sheets are in the correct sequence with each pile
b
showing its different, correctly-positioned printed image
c
mis-feed and double detector(s) are working properly
d
the staples are correctly positioned
e
the fold is made in the correct position
f
the fore-edge trim is correctly positioned
g
the settings are appropriate for the booklet thickness
5
produce a sample from the machine and check that it matches the required standard
6
make adjustments if necessary to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
115
Element 333.1 Set up in-line booklet-making machinery
Knowledge and understanding
You must understand:
116
K1
what details you need for the job
K2
the principles of in-line booklet-making
K3
the sequence of set up tasks for the in-line booklet-making machine
K4
the common in-line booklet-making set-up faults, what causes them and how to prevent
them
K5
the risks associated with setting in-line booklet-making machinery, and how to avoid them
K6
the emergency shut-down procedures
K7
to whom you should report set-up problems.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 333.1 Set up in-line booklet-making machinery
Performance evidence
You must show that you can set up in-line booklet-making equipment consistently over a period of
time. Your performance will be observed on at least four occasions. Your evidence must show that:
R1
you can set up the machine safely for:
a
R2
at least 2 different sheet sizes
using:
a
coated paper and board
or
b
R3
uncoated paper and board
you set up the machine for:
a
thin booklets or magazines
b
bulky booklets or magazines.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
117
Element 333.2 Run in-line booklet-making machinery
Performance criteria
You must show that you:
1
118
run the machinery:
a
at the required production speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify causes of faults in the product, which result in:
a
wire stitches or staples missing, broken or misformed
b
wire stitches/staples and fold not aligned
c
trimming faults such as out of square or wrong size
d
marking of inside or outside pages
e
pages missing or duplicated
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 333.2 Run in-line booklet-making machinery
Knowledge and understanding
You must understand:
K1
your company’s quality standards for booklet work
K2
your company’s methods for detecting defects in the product
K3
what are the common booklet-making faults, what causes them and how to correct them
K4
what other faults can occur during booklet-making
K5
how to recognise when you should correct faults yourself, and when you should ask for help
K6
to whom you should report:
a
defects in the product
b
mechanical problems
K7
where to find documents giving help in identifying the causes of faults
K8
the procedures for the removal of waste from your machine
K9
what production and quality assurance records you are required to keep
K10
your company’s method for stacking of finished work from your machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
119
Element 333.2 Run in-line booklet-making machinery
Performance evidence
You must show that you can control in-line booklet-making equipment consistently, over a period of
time. Your performance will be observed on at least four occasions. Your evidence must show that:
120
R1
you maintain the supply of materials
R2
you maintain the quality of the product and avoid waste by promptly identifying any defects
in the product and taking appropriate action
R3
and take action:
a
to adjust the machine if possible to correct the defect
b
to report machine stoppages to your manager.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 333.3 Plan and implement a programme of
maintenance for in-line booklet-making
machinery
Performance criteria
You must show that you:
1
obtain or prepare a complete schedule of maintenance for the in-line bookletmaking
machinery
2
identify the recommended intervals for maintenance and lubrication
3
ensure that the maintenance plan is implemented and kept up to date as far as is possible
within the time allowed by your company for lubrication and maintenance.
4
keep records of maintenance work undertaken
5
examine machinery for defective components or excessive wear at intervals required by
your company
6
keep records of faults that occur or are developing and that appropriate action is taken to
deal with them either:
a
as part of the maintenance programme
b
as an urgent repair by you (if it is your job to deal with it), or
c
by reporting the problem to the relevant person in your organisation
7
are able to remove and replace faulty or worn components that are your responsibility
8
maintain a list of parts or consumables that are likely to require periodic replacement and
identify those parts that may be required at short notice
9
ensure that any parts or consumables identified as being required to be kept 'in stock' are
available in the required quantities.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
121
Element 333.3 Plan and implement a programme of
maintenance for in-line booklet-making
machinery
Knowledge and understanding
You must understand:
122
K1
why manufacturers of in-line booklet-making machines specify a schedule of preventative
maintenance
K2
what kinds of components wear or become degraded over time on an inline booklet-making
machine
K3
what kinds of lubricants to use on the inline booklet-making machine
K4
the properties of different kinds of lubricants
K5
how to replenish lubricants in dispensers and reservoirs
K6
how to find part reference numbers and order replacement parts
K7
the consequences of failing to maintain or inspect your machine in accordance with the
manufacturer's specification or any relevant code of practice
K8
legal requirements and industry guidelines for the safe handling, use and disposal of
hazardous substances
K9
the risks of handling lubricants
K10
the personal protective equipment which should be worn when handling hazardous
substances and lubricants
K11
where the principal lubrication points are on your in-line booklet-making machine
K12
to whom you should report existing and developing faults
K13
what is meant by the term 'safe system of work' and how it applies to maintenance and
lubrication activities on an in-line booklet-making machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 333.3 Plan and implement a programme of
maintenance for in-line booklet-making
machinery
Performance evidence
You must show that you plan and implement maintenance of the in-line bookletmaking consistently,
over a period of time. Your evidence must show that:
R1
you keep appropriate documents to enable the planning and implementation of
maintenance, such as:
a
the machine manufacturer's recommended maintenance schedules
b
the machine manufacturer's operating manual and any other relevant documents
c
lists of consumables and parts, including those normally kept 'in stock'
d
maintenance records
e
fault reports
R2
you have a maintenance schedule for the machine, and take part in its implementation as far
as your company’s production schedules and policies allow
R3
you identify defective or deteriorating components during:
R4
a
normal machine running
b
planned maintenance work
you are able to diagnose actual or developing machine faults by:
a
examining output from the machine
b
examining the machine
R5
you are able to correctly and safely change the trimming knives
R6
you are able to strip down, clean and service the stitching heads and replace any worn parts
on them.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
123
Element 333.4 Keep in-line booklet-making machinery in a
clean and safe operating condition
Performance criteria
You must show that you:
124
1
have a 'safe system of work' and a risk assessment in place before commencing any
cleaning
2
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
3
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
4
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
5
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
6
after cleaning, check that the machine is safe to operate.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 333.4 Keep in-line booklet-making machinery in a
clean and safe operating condition
Knowledge and understanding
You must understand:
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
125
Element 333.4 Keep in-line booklet-making machinery in a
clean and safe operating condition
Performance evidence
You must show that you keep the inline booklet-making machinery in a clean and safe operating
condition consistently, over a period of time. Your performance will be observed on at least four
occasions. Your evidence must show that you:
R1
R2
R3
R4
126
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper and trimmings
b
dust, including paper dust
c
excessive lubricant
check that after cleaning the machine is safe to operate:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 334
Introduction
Control non-automatic finishing machines
To achieve your unit certificate, you must show that you can:
1
Element 334.1 Set up non-automatic finishing machines
2
Element 334.2 Run non-automatic finishing machines
3
Element 334.3 Maintain non-automatic finishing machines in clean, safe and useable
condition
This involves:
• identifying the job requirements
• checking that the non-automatic machines are working properly
• checking that safety devices are working properly
• running the non-automatic machines safely
• adjusting settings, where necessary to maintain the required standard
• checking that the work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
127
Element 334.1 Set up non-automatic finishing machines
Performance criteria
You must show that you:
128
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up the machine correctly, so that:
a
finished work meets the requirements of your job instructions
b
finished work consistently meets the quality of the approved sample
c
material is processed without damage, marking or distortion
5
produce a sample from the machine and check that it matches the required standards
6
make adjustments if necessary to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 334.1 Set up non-automatic finishing machines
Knowledge and understanding
You must understand:
K1
what details you need for the job
K2
the sequence of set up tasks for your machines
K3
the common set-up faults on your machines, what causes them and how to prevent them
K4
the risks associated with setting up your machines, and how to avoid them
K5
the requirements of any subsequent processes
K6
the emergency shut down procedures.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
129
Element 334.1 Set up non-automatic finishing machines
Performance evidence
You must show that you can set up at least two different non-automatic machines consistently over
a period of time. The two machines must be those used in your workplace. Your performance will be
observed on at least four occasions. Your evidence must show that:
R1
you can prepare machines with different functions - at least two from the following list:
Treadle operated:
R4
R6
130
a
wire stitching machines
b
drilling machines
c
punching machines
d
riveting machines
e
perforating machines
f
thread stitching machines
g
eyeletting machines
h
Rotary perforating machine
you can set up for:
a
loading
b
operating
for operations using one of the following types of job stock:
a
paper
b
board
c
plastic.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 334.2 Run non-automatic finishing machines
Performance criteria
You must show that you:
1
run non-automatic machines:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify causes of faults in production which result in:
a
marking of material during processing
b
finished product failing to match the approved sample
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
131
Element 334.2 Run non-automatic finishing machines
Knowledge and understanding
You must understand:
132
K1
your company’s quality standards
K2
the functions of your machines
K3
the risks associated with running your machines, and how to avoid them
K4
the emergency shut down procedures
K5
the common faults which can arise when running your machines, what causes them and
how to correct them
K6
how to recognise when you should correct faults yourself and when you should ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedure for the removal of waste from your machines
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance details you are required to keep.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 334.2 Run non-automatic finishing machines
Performance evidence
You must show that you run at least two non-automatic machines consistently, over a period of
time. Your performance will be observed on at least four occasions. Your evidence must show that:
R1
R2
you can maintain the supply of:
a
your company materials
b
customer materials
you can operate machines with different functions - at least two from the following list:
Treadle operated:
R3
R4
R5
a
wire stitching machines
b
drilling machines
c
punching machines
d
riveting machines
e
perforating machines
f
thread stitching machines
g
eyeletting machines
h
rotary perforating machine
for operations using one of the following types of job stock:
a
paper
b
board
c
plastic
d
metal
you decide on action to correct faults:
a
to be taken by yourself
b
to be taken by others
you maintain the quality of the product and avoid waste by promptly identifying any defects
in the product and taking appropriate action.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
133
Element 334.3 Maintain non-automatic finishing machines in
clean, safe and useable condition
Performance criteria
You must show that you:
134
1
have a 'safe system of work' before commencing any cleaning
2
obtain or prepare a schedule of cleaning, lubrication and maintenance for the machine
3
identify the recommended intervals for maintenance and lubrication
4
ensure that the schedule is implemented and kept up to date, within the time allowed by
your company for cleaning, lubrication and maintenance
5
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
6
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
7
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
8
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
9
after cleaning, check that the machine is safe to operate
10
examine machinery for defective components or excessive wear at intervals required by
your company
11
are able to remove and replace faulty or worn components that are your responsibility.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 334.3 Maintain non-automatic finishing machines in
clean, safe and useable condition
Knowledge and understanding
You must understand:
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept
K10
what kinds of components wear or become degraded over time on the non-automatic
finishing machines
K11
what kinds of lubricants to use on the non automatic finishing machines.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
135
Element 334.3 Maintain non-automatic finishing machines in
clean, safe and useable condition
Performance evidence
Your evidence must show that you:
R1
R2
R3
R4
R5
136
keep appropriate documents to enable you to ensure that cleaning, lubrication and
maintenance:
a
is kept up to date as far as is permitted within your company’s production schedule
and policy
b
takes account of the machine manufacturer's recommended cleaning, lubrication
and maintenance schedule (if available)
c
is undertaken at times required by your company
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
check that after cleaning the machine is safe to operate and that:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 335
Introduction
Control multiple hopper feeders
To achieve your unit certificate, you must show that you can:
1
Element 335.1 Set up multiple hopper feeders
2
Element 335.2 Run multiple hopper feeders
3
Element 335.3 Maintain multiple hopper feeders in clean, safe and useable condition
This involves:
• identifying the job requirements
• checking that hopper feeders are working properly
• checking that safety devices are working properly
• running the hopper feeders safely
• adjusting settings, where necessary to maintain the required standard
• checking that the work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
137
Element 335.1 Set up multiple hopper feeders
Performance criteria
You must show that you:
138
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up the hopper feeders correctly, so that:
a
sections are brought together to give the correct page sequence
b
sections are fed squarely from hoppers to the transport chain
c
separation ensures that sections are transported squarely, without damage
d
the completed work is delivered without damage, distortion or marking
e
any misfed or double-sheet detection devices function correctly
5
produce a sample from the machine and check that it matches the required standards
6
make adjustments if necessary, to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 335.1 Set up multiple hopper feeders
Knowledge and understanding
You must understand:
K1
what details you need for the job
K2
the principles of hopper feeding
K3
the sequence of set- up tasks for multiple hopper feeders
K4
the common faults in setting up hopper feeders, what causes them and how to prevent
them
K5
the risks associated with setting up hopper feeders, and how to avoid them
K6
the emergency shut-down procedures
K7
the purpose of collating marks and signature marks
K8
how to feed open and closed head sections, with and without laps
K9
how to feed sections perforated along the line of folds
K10
the purpose of perforating folds on a folding machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
139
Element 335.1 Set up multiple hopper feeders
Performance evidence
You must show that you can set up multiple hopper feeders consistently over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
you set up for:
a
R2
R3
140
multi-section work
you set up for the following types of section:
a
open head
b
closed head
c
lapped
d
non-lapped
you test and adjust equipment by:
a
visual inspection
b
checking control settings
c
producing a sample run.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 335.2 Run multiple hopper feeders
Performance criteria
You must show that you:
1
run multiple hopper feeders:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify the causes of production faults, which result in:
a
sections not gathered in the correct order
b
sections not inserted in the correct order
c
sections failing to feed and separate
d
sections feeding unevenly
e
sections tearing
f
sections marking
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
141
Element 335.2 Run multiple hopper feeders
Knowledge and understanding
You must understand:
142
K1
your company’s quality standards
K2
the risks associated with running hopper-fed units and how to avoid them
K3
the emergency shut down procedures
K4
the common hopper feeder running faults, what causes them and how to correct them
K5
what other faults can occur during hopper feeder work
K6
how to recognise when you should correct faults yourself, and when you should ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedures for the removal of waste from your machine
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance records you are required to keep
K12
what types of materials are most at risk of rub marking
K13
which printed colours are most at risk of marking.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 335.2 Run multiple hopper feeders
Performance evidence
You must show that you can run multiple hopper feeder machinery consistently, over a period of
time. Your performance will be observed on at least four occasions. Your evidence must show that:
R1
you maintain the quality of the product and avoid waste by promptly identifying any defects
in the product and taking appropriate action
R2
you run the machinery to produce:
a
R3
R4
multi-section work
for the following types of section:
a
open head
b
closed head
c
lapped
d
non-lapped
you decide on action to correct faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
143
Element 335.3 Maintain multiple hopper feeders in clean,
safe and useable condition
Performance criteria
You must show that you:
144
1
have a 'safe system of work' before commencing any cleaning
2
obtain or prepare a schedule of cleaning, lubrication and maintenance for the machine
3
identify the recommended intervals for maintenance and lubrication
4
ensure that the schedule is implemented and kept up to date, within the time allowed by
your company for cleaning, lubrication and maintenance.
5
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
6
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
7
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
8
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
9
after cleaning, check that the machine is safe to operate
10
examine machinery for defective components or excessive wear at intervals required by
your company
11
are able to remove and replace faulty or worn components that are your responsibility.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 335.3 Maintain multiple hopper feeders in clean,
safe and useable condition
Knowledge and understanding
You must understand:
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept
K10
what kinds of components wear or become degraded over time on a hopper feeder
K11
what kinds of lubricants to use on a hopper feeder.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
145
Element 335.3 Maintain multiple hopper feeders in clean,
safe and useable condition
Performance evidence
Your evidence must show that you:
R1
R2
R3
R4
R5
146
you keep appropriate documents to enable you to ensure that cleaning, lubrication and
maintenance:
a
is kept up to date as far as is permitted within your company’s production schedule
and policy
b
takes account of the machine manufacturer's recommended cleaning, lubrication
and maintenance schedule (if available)
c
is undertaken at times required by your company
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
check that after cleaning the machine is safe to operate and that:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 336
Introduction
Control auto-fed sewing machinery
To achieve your unit certificate, you must show that you can:
1
Element 336.1 Set up auto-fed sewing machinery
2
Element 336.2 Run auto-fed sewing machinery
3
Element 336.3 Maintain auto-fed sewing machinery in clean, safe and useable
condition
This involves:
• identifying the job requirements
• checking that auto-fed sewing machinery is working properly
• checking that safety devices are working properly
• running the auto-fed sewing machinery safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
147
Element 336.1 Set up auto-fed sewing machinery
Performance criteria
You must show that you:
148
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up the sewing machine correctly, so that:
a
the feeder correctly locates the centre of each section
b
sections are fed squarely and without damage into the sewing machine
c
endpapers are glued squarely and securely onto sections
d
stitch positions are spaced across spines within the finished trim size
e
stitching holds sections securely without damage or distortion
f
stitched book blocks are delivered without damage
5
produce a sample from the machine and check that it matches the required standards
6
make adjustments if necessary, to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 336.1 Set up auto-fed sewing machinery
Knowledge and understanding
You must understand:
K1
what details you need for the job
K2
the principles of mechanical sewing
K3
the sequence of set up tasks for the auto-fed sewing machine
K4
the common faults in setting up auto-fed sewing machinery, what causes them and how to
prevent them
K5
the risks associated with setting up auto-fed sewing machinery, and how to avoid them
K6
the emergency shut-down procedures
K7
the purpose of collating marks and signature marks
K8
how to feed open and closed head sections, with and without laps.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
149
Element 336.1 Set up auto-fed sewing machinery
Performance evidence
You must show that you can set up auto-fed sewing machinery consistently over a period of time.
Your performance will be observed on at least four occasions. Your evidence must show that:
R1
R2
R3
you can set up for sewing the following types of section:
a
open head
b
closed head
c
lapped fore edge
for at least one of the following types of job:
a
tipped on endpapers or plates
b
outset/wrap-around plates
c
inset plates
you identify:
a
R4
R5
150
the opening requirements per section
you can identify which of the following section opening methods are appropriate for each
job:
a
pull up
b
pull down
c
hook up
d
fore edge lap up or lap down
you test and adjust machinery by:
a
visual inspection
b
checking control settings
c
producing a sample from the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 336.2 Run auto-fed sewing machinery
Performance criteria
You must show that you:
1
run auto-fed sewing machinery:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify the causes of faults in production, which result in:
a
missed stitches
b
loose stitches
c
sections not square at head
d
glue marks on sections
e
rub marking on sections
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
151
Element 336.2 Run auto-fed sewing machinery
Knowledge and understanding
You must understand:
152
K1
your company’s quality standards
K2
the risks associated with running auto-fed sewing machines and how to avoid them
K3
the emergency shut-down procedures
K4
the common section sewing machine running faults, what causes them and how to correct
them
K5
what other faults can occur during mechanical sewing
K6
how to recognise when you should correct faults yourself, and when you should ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedures for the removal of waste from your machine
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance records you are required to keep
K12
what materials are most at risk of rub marking
K13
which printed colours are most at risk of marking.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 336.2 Run auto-fed sewing machinery
Performance evidence
You must show that you can run auto-fed sewing equipment consistently, over a period of time.
Your performance will be observed on at least four occasions. Your evidence must show that:
R1
you maintain the quality of the product and avoid waste by promptly identifying any defects
in the product and taking appropriate action
R2
you can keep up the supply of:
R3
R4
a
sections
b
thread
you maintain:
a
the position of stitches
b
the tightness of stitching
you decide on action to correct faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
153
Element 336.3 Maintain auto-fed sewing machinery in clean,
safe and useable condition
Performance criteria
You must show that you:
154
1
have a 'safe system of work' before commencing any cleaning
2
obtain or prepare a schedule of cleaning, lubrication and maintenance for the machine
3
identify the recommended intervals for maintenance and lubrication
4
ensure that the schedule is implemented and kept up to date, within the time allowed by
your company for cleaning, lubrication and maintenance
5
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
6
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
7
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
8
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
9
after cleaning, check that the machine is safe to operate
10
examine machinery for defective components or excessive wear at intervals required by
your company
11
are able to remove and replace faulty or worn components that are your responsibility.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 336.3 Maintain auto-fed sewing machinery in clean,
safe and useable condition
Knowledge and understanding
You must understand:
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept
K10
what kinds of components wear or become degraded over time on an auto-fed sewing
machine
K11
what kinds of lubricants to use on an auto-fed sewing machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
155
Element 336.3 Maintain auto-fed sewing machinery in clean,
safe and useable condition
Performance evidence
Your evidence must show that you:
R1
R2
R3
R4
R5
156
you keep appropriate documents to enable you to ensure that cleaning, lubrication and
maintenance:
a
is kept up to date as far as is permitted within your company’s production schedule
and policy
b
takes account of the machine manufacturer's recommended cleaning, lubrication
and maintenance schedule (if available)
c
complies with any HSE/PIAC code of practice for auto-fed sewing machines
d
is undertaken at times required by your company
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
check that after cleaning the machine is safe to operate and that:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 337
Introduction
Control multi-knife trimming machinery
To achieve your unit certificate, you must show that you can:
1
Element 337.1 Set up multi-knife trimming machinery
2
Element 337.2 Run multi-knife trimming machinery
3
Element 337.3 Maintain multi-knife trimming machinery in clean, safe and useable
condition
This involves:
• identifying the job requirements
• checking that multi-knife trimming machinery is working properly
• checking that safety devices are working properly
• running multi-knife trimming machinery safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
157
Element 337.1 Set up multi-knife trimming machinery
Performance criteria
You must show that you:
158
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up the multi-knife trimmer correctly, so that:
a
piles are fed squarely into the trimmer
b
the clamp holds the pile firmly without marking
c
piles are trimmed squarely and delivered without damage or distortion
d
the trimmed size is within variations permitted by your company
5
change trimmer knives correctly and safely
6
produce a sample from the machine and check that it matches the required standards
7
make adjustments if necessary to enable the standards to be met
8
report promptly to your manager, if the standards cannot be met
9
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 337.1 Set up multi-knife trimming machinery
Knowledge and understanding
You must understand:
K1
what details you need for the job
K2
the principles of multi-knife trimming
K3
the sequence of set up tasks for multi-knife trimming machinery
K4
the common multi-knife trimming machine set-up faults, what causes them and how to
prevent them
K5
the risks associated with setting up multi-knife trimming machinery, and how to avoid them
K6
the emergency shut-down procedures
K7
the procedure for trimming 2-up work
K8
how to clamp piles of uneven height securely
K9
what types of book cover materials are most at risk of marking
K10
which printed colours are most at risk of marking.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
159
Element 337.1 Set up multi-knife trimming machinery
Performance evidence
You must show that you can set up multi-knife trimming machinery consistently over a period of
time. Your performance will be observed on at least four occasions. Your evidence must show that:
R1
you set up for:
a
R2
R3
160
multi-knife trimming
... for job stock which is:
a
coated
b
uncoated
you test and adjust machinery by:
a
visual inspection
b
checking control settings
c
producing a sample from the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 337.2 Run multi-knife trimming machinery
Performance criteria
You must show that you:
1
run multi-knife trimming machinery:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify the causes of faults in production, which result in:
a
unacceptable cut size variation
b
score marks on cut surfaces
c
shiny glue marks on cut surfaces
d
ragged cut on bottom pages
e
book spines splitting at head or tail
f
books not square
g
spines creasing
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
161
Element 337.2 Run multi-knife trimming machinery
Knowledge and understanding
You must understand:
162
K1
your company’s quality standards
K2
the risks associated with running multi-knife trimming machines and how to avoid them
K3
the emergency shut-down procedures
K4
the common multi-knife trimming machine running faults, what causes them and how to
correct them
K5
what other faults can occur when running a multi-knife trimmer
K6
how to recognise when you should correct faults yourself and when you should ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedures for the removal of waste from your machine
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance details you are required to keep.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 337.2 Run multi-knife trimming machinery
Performance evidence
You must show that you can run multi-knife trimming machinery consistently, over a period of time.
Your performance will be observed on at least four occasions. Your evidence must show that:
R1
you maintain throughput on multi-knife trimming machinery
R2
... and maintain the quality of:
R3
a
cuts
b
the material
you decide on action to correct faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
163
Element 337.3 Maintain multi-knife trimming machinery in
clean, safe and useable condition
Performance criteria
You must show that you:
164
1
have a 'safe system of work' before commencing any cleaning
2
obtain or prepare a schedule of cleaning, lubrication and maintenance for the machine
3
identify the recommended intervals for maintenance and lubrication
4
ensure that the schedule is implemented and kept up to date, within the time allowed by
your company for cleaning, lubrication and maintenance
5
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
6
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
7
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
8
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
9
after cleaning, check that the machine is safe to operate
10
examine machinery for defective components or excessive wear at intervals required by
your company
11
are able to remove and replace faulty or worn components that are your responsibility.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 337.3 Maintain multi-knife trimming machinery in
clean, safe and useable condition
Knowledge and understanding
You must understand:
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept
K10
what kinds of components wear or become degraded over time on multi-knife trimming
machine
K11
what kinds of lubricants to use on a multi-knife trimming machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
165
Element 337.3 Maintain multi-knife trimming machinery in
clean, safe and useable condition
Performance evidence
You must show that you keep the multi-knife trimming machine in a clean and safe operating
condition consistently, over a period of time. Your performance will be observed on at least four
occasions. Your evidence must show that you:
R1
R2
R3
R4
R5
166
you keep appropriate documents to enable you to ensure that cleaning, lubrication and
maintenance:
a
is kept up to date as far as is permitted within your company’s production schedule
and policy
b
takes account of the machine manufacturer's recommended cleaning, lubrication
and maintenance schedule (if available)
c
complies with any HSE/PIAC code of practice for multi-knife trimming machines
d
is undertaken at times required by your company
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
check that after cleaning the machine is safe to operate and that:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 338
Introduction
Set and operate booklet-making machinery
To achieve your unit certificate, you must show that you can:
1
Element 338.1 Set up booklet-making machinery under supervision
2
Element 338.2 Operate booklet-making machinery
This involves:
• understanding the job requirements
• checking that safety devices are working properly
• setting up the collator and the stitch-fold-trim unit(s)
• operating the booklet-making equipment safely
• reporting problems
• checking that work meets the required standard
• unloading and stacking the finished product.
Note: For this unit the collator and the stitch-fold-trim unit may be separate pieces of machinery or
may be inline. However, hand collating is not acceptable; nor are booklet-makers without a
trimmer.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
Please note: unit 338 may not be used in conjunction with unit 333.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
167
Element 338.1 Set up booklet-making machinery under
supervision
Performance criteria
You must show that you:
1
check that you have the job specification
2
identify the materials you must use for the job
3
check that safety devices are working properly
4
set the collator:
5
168
a
for the size of the flat sheet
b
so that flat sheets are in the correct sequence with each pile showing its different,
correctly-positioned printed image
c
mis-feed and double detector(s) correctly
set the stitch-fold-trim unit so that:
a
the staples are correctly positioned
b
the fold is made in the correct position
c
the fore-edge trim is correctly positioned
d
the settings are appropriate for the booklet thickness
6
produce a sample from the machine and get it passed by your supervisor
7
assist your supervisor to make adjustments, if necessary, to enable the quality standards to
be met
8
report promptly to your supervisor, if the standards cannot be met
9
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 338.1 Set up booklet-making machinery under
supervision
Knowledge and understanding
You must understand:
K1
what details should be in a job specification
K2
the principles of booklet-making
K3
the behaviour of paper and board materials and how to avoid ‘cracking’
K4
the risks associated with setting booklet-making machinery, and how to avoid them
K5
the common booklet-making machine set-up faults, what causes them and how to prevent
them
K6
the emergency shut-down procedures
K7
to whom you should report set-up problems.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
169
Element 338.1 Set up booklet-making machinery under
supervision
Performance evidence
You must show that you can set up booklet-making equipment consistently over a period of time.
Your performance will be observed on at least four occasions. Your evidence must show that:
R1
you can set up the collator correctly and safely for:
a
R2
at least two different sheet sizes
... and which is:
a
coated paper and board
or
b
R3
170
uncoated paper and board
you set up the stitch-fold-trim unit for:
a
thin booklets or magazines
b
bulky booklets or magazines.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 338.2 Operate booklet-making machinery
Performance criteria
You must show that you:
1
operate the machinery:
a
at the required production speed
b
safely and efficiently
2
regularly check that your company’s quality standards are met
3
accurately identify faults in the product, which result in:
a
pages missing or duplicated
b
wire stitches or staples missing, broken or misformed
c
wire stitches/staples and fold not aligned
d
trimming faults such as out of square or wrong size
e
marking of inside or outside pages
4
promptly and accurately report faults to your manager
5
make adjustments to settings if instructed to do so by your manager
6
check that the machine is safe to operate, once faults have been corrected
7
promptly report to your manager if the machine ceases to function properly
8
accurately record production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack finished work safely using your company’s approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
171
Element 338.2 Operate booklet-making machinery
Knowledge and understanding
You must understand:
172
K1
your company’s quality standards for booklet work
K2
your company’s methods for detecting faults in the product
K3
what are the common booklet-making faults
K4
what other faults can occur during booklet-making
K5
to whom you should report:
a
defects in the product
b
mechanical problems
K6
the procedures for the removal of waste from your machine
K7
what production and quality assurance records you are required to keep
K8
your company’s method for stacking of finished work from your machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 338.2 Operate booklet-making machinery
Performance evidence
You must show that you can operate booklet-making equipment consistently, over a period of time.
Your performance will be observed on at least four occasions. Your evidence must show that:
R1
R2
R3
you maintain the quality of the product and avoid waste by promptly identifying any defects
in the product and taking appropriate action:
a
to report the problem
b
to stop the machine if necessary
you report:
a
product defects
b
mechanical problems
you take action to deal with faults if instructed to do so.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
173
Unit 339
Introduction
Control parallel folding
To achieve your unit certificate, you must show that you can:
1
Element 339.1 Set up parallel folding
2
Element 339.2 Run parallel folding
3
Element 339.3 Maintain parallel folding machines in clean, safe and useable condition
This involves:
• identifying the job requirements
• checking that the machine is working properly
• checking that safety devices are working properly
• running the machinery safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced.
Please note: unit 339 may not be used in conjunction with unit 332.
174
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 339.1 Set up parallel folding
Performance criteria
You must show that you:
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up folding machine correctly, so that:
a
sheets are fed squarely and consistently, without damage or distortion
b
mis-fed sheets are detected by the machine’s device
c
sheets are folded without damage
d
work is slit squarely and cleanly, if required
e
folded sheets are delivered without damage
5
produce a sample from the machine and check that it matches the required standard
6
make adjustments if necessary, to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
175
Element 339.1 Set up parallel folding
Knowledge and understanding
You must understand:
176
K1
what details you need for the job
K2
the principles of machine folding
K3
the sequence of set up tasks for parallel folding
K4
the requirements of other processes which follow folding
K5
what is meant when printed material is produced by:
a
sheetwork
b
work and turn
c
work and tumble
K6
how folds are made by the buckle method
K7
the risks associated with setting up folding machinery, and how to avoid them
K8
what the common folding machine faults are, what causes them and how to prevent them
K9
the emergency shut down procedures.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 339.1 Set up parallel folding
Performance evidence
You must show that you can set up parallel folding machinery consistently over a period of time.
Your performance will be observed on at least four occasions. Your evidence must show that:
R1
you identify:
a
the job stock and grammage
b
supplied and finished size
c
grain direction
R2
you check that the imposition will produce
R3
the requested fold sequence
R4
you can set up for parallel folding schemes using:
R5
a
roll folds
b
concertina folds
and for stock which is:
a
coated paper
b
uncoated paper.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
177
Element 339.2 Run parallel folding
Performance criteria
You must show that you:
1
178
run folding machinery:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that quality standards are met
4
accurately identify the cause of faults in production which result in:
a
sheets sticking together
b
sheets failing to enter fold unit
c
sheets failing to leave fold unit
d
sheets folded out of square
e
slitting not parallel to sheet edge
f
marking of sheets
5
correct mechanical faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults are corrected
8
accurately record production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 339.2 Run parallel folding
Knowledge and understanding
You must understand:
K1
your company’s quality standards for folded work
K2
how grain direction affects the folding process
K3
which types of material are most at risk of rub marking
K4
which printed colours are most at risk of marking
K5
the purpose of gluing attachments and how they work
K6
the risks associated with running folding machinery and how to avoid them
K7
the emergency shut down procedures
K8
the common folding machine faults, what causes them and how to correct them
K9
what other faults can occur during folding
K10
how to recognise when you should correct faults yourself and when you should ask for help
K11
to whom you must report faults
K12
where to find documents giving help in identifying the causes of faults
K13
the procedures for the removal of waste from your machine
K14
what production and quality assurance details you are required to keep.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
179
Element 339.2 Run parallel folding
Performance evidence
You must show that you can run folding machinery consistently, over a period of time. Your
performance will be observed on at least four occasions. Your evidence must show that:
R1
you maintain the quality of the product and avoid waste by promptly identifying any defects
in the product and taking appropriate action
R2
you can produce:
R3
R4
180
a
roll folds
b
concertina folds
and for stock which is:
a
coated paper
b
uncoated paper
you decide on action to remedy faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 339.3 Maintain parallel folding machines in clean,
safe and useable condition
Performance criteria
You must show that you:
1
have a 'safe system of work' before commencing any cleaning
2
obtain or prepare a schedule of cleaning, lubrication and maintenance for the machine
3
identify the recommended intervals for maintenance and lubrication
4
ensure that the schedule is implemented and kept up to date, within the time allowed by
your company for cleaning, lubrication and maintenance
5
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
6
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
7
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
8
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
9
after cleaning, check that the machine is safe to operate
10
examine machinery for defective components or excessive wear at intervals required by
your company
11
are able to remove and replace faulty or worn components that are your responsibility.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
181
Element 339.3 Maintain parallel folding machines in clean,
safe and useable condition
Knowledge and understanding
You must understand:
182
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept
K10
what kinds of components wear or become degraded over time on a parallel folding
machine
K11
what kinds of lubricants to use on a parallel folding machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 339.3 Maintain parallel folding machines in clean,
safe and useable condition
Performance evidence
Your evidence must show that you:
R1
R2
R3
R4
R5
you keep appropriate documents to enable you to ensure that cleaning, lubrication and
maintenance:
a
is kept up to date as far as is permitted within your company’s production schedule
and policy
b
takes account of the machine manufacturer's recommended cleaning, lubrication
and maintenance schedule (if available)
c
complies with any HSE/PIAC code of practice for folding machines
d
is undertaken at times required by your company
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
check that after cleaning the machine is safe to operate and that:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
183
Unit 340
Introduction
Run and monitor adhesive binding machinery
To achieve your unit certificate, you must show that you can:
1
Element 340.1 Run adhesive binding machine under supervision
2
Element 340.2 Monitor quality of adhesive binding
This involves:
• understanding the job requirements
• checking that safety devices are working properly
• starting up the adhesive binding machine
• running the adhesive binding machine safely
• reporting problems
• checking that work meets the required standard
• unloading and stacking the finished product.
Note: This unit may be used for inline adhesive binding machinery or off-line.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced
• samples of running faults as they arise.
Please note: unit 340 may not be used in conjunction with unit 328.
184
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 340.1 Run adhesive binding machine under
supervision
Performance criteria
You must show that you:
1
check that you have the job specification
2
identify the materials you must use for the job
3
check that safety devices are working properly
4
check that your work area is safe and ready for production
5
correctly start up the adhesive binding machine
6
run the adhesive binding machine:
7
a
at the required speed
b
safely and efficiently
promptly report to your manager if:
a
the machine ceases to function properly
b
you are running out of correct materials
8
accurately record the production details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
185
Element 340.1 Run adhesive binding machine under
supervision
Knowledge and understanding
You must understand:
186
K1
what details should be in a job specification
K2
the principles of adhesive binding
K3
the risks associated with running adhesive binding machinery, and how to avoid them
K4
the emergency shut-down procedures
K5
the purpose of collating marks
K6
what types of problems can occur when running adhesive binding machinery
K7
to whom you should report problems
K8
what production records you are required to keep
K9
the procedures for the removal of waste from your machine
K10
your company’s method for stacking of finished work from your machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 340.1 Run adhesive binding machine under
supervision
Performance evidence
You must show that you can run adhesive binding machinery under supervision consistently over a
period of time. Your performance will be observed on at least four occasions. Your evidence must
show that:
R1
R2
R3
R4
you start and run the machine:
a
safely
b
efficiently
you can run the adhesive binding machine for the following:
a
sewn or unsewn sections
b
board covers
c
thin books
d
bulky books
you promptly report problems:
a
relating to mechanical faults
b
of materials supply
you correctly follow procedures for:
a
keeping records of production
b
removal of waste
c
safe stacking.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
187
Element 340.2 Monitor quality of adhesive binding
Performance criteria
You must show that you:
188
1
regularly check that your company’s quality standards are met
2
accurately identify faults in the product, which result in:
a
cracking of the surface along score lines
b
print being out of square on the front cover and spine
c
rounding of spines
d
too much and too little glue penetration
e
poor page-pull strength
f
covers not registering correctly with book blocks
3
promptly and accurately report quality defects to your manager
4
check that the machine is safe to operate, once quality defects are corrected
5
accurately record the quality assurance details.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 340.2 Monitor quality of adhesive binding
Knowledge and understanding
You must understand:
K1
your company’s quality standards for adhesive binding work
K2
your company’s methods for detecting defects in the product
K3
the common adhesive binding faults
K4
what other faults can occur during adhesive binding
K5
to whom you should report faults
K6
what quality assurance records you are required to keep
K7
which types of material are most at risk of rub marking
K8
which printed colours are most at risk of marking.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
189
Element 340.2 Monitor quality of adhesive binding
Performance evidence
You must show that you can monitor the quality of adhesive binding consistently, over a period of
time. Your performance will be observed on at least four occasions. Your evidence must show that:
R1
190
you maintain the quality of the product and avoid waste by promptly identifying any defects
in the product and taking appropriate action:
a
to report the problem
b
to stop the machine if necessary.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 341
Control in-line insetting-stitching-trimming
machinery
Introduction
To achieve your unit certificate, you must show that you can:
1
Element 341.1 Set up in-line insetting-stitching-trimming machinery
2
Element 341.2 Run in-line insetting-stitching-trimming machinery
3
Element 341.3 Plan and implement a programme of maintenance for in-line insettingstitching-trimming machinery
4
Element 341.4 Keep in-line insetting-stitching-trimming machinery in a clean and safe
operating condition
This involves:
• identifying the job requirements
• checking that the in-line insetting-stitching-trimming machine is working properly
• checking that safety devices are working properly
• running the machine safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced
• how you maintained the speed of output and quality of the product throughout the line.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
191
Element 341.1 Set up in-line insetting-stitching-trimming
machinery
Performance criteria
You must show that you:
192
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up the line correctly, so that:
a
sections are inserted to give the correct page sequence
b
sections and covers are fed into the stitcher squarely and without damage
c
stitched books hold firmly, and are securely clenched
d
stitched books are fed into the trimmer squarely and without damage
e
books are trimmed evenly and squarely to the correct size, without marking
f
books are delivered without damage or distortion
5
produce a sample from the machine and check that it matches the required standards
6
make adjustments if necessary to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 341.1 Set up in-line insetting-stitching-trimming
machinery
Knowledge and understanding
You must understand:
K1
what details you need for the job
K2
the principles of insetting-stitching-trimming
K3
the sequence of set up tasks for insetting-stitching-trimming machinery
K4
the common in-line insetting-stitching-trimming set-up faults, what causes them and how to
prevent them
K5
the risks associated with setting up insetting-stitching-trimming machinery, and how to
avoid them
K6
the emergency shut-down procedures
K7
the procedures for dealing with 2-up work
K8
how attachments work for feeding glued inserts into the book
K9
how to select wire of the appropriate shape and thickness for the job
K10
the purpose of signature marks
K11
which types of material are most at risk of rub marking
K12
which printed colours are most at risk of marking
K13
the danger to the book user of wires inadequately clenched.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
193
Element 341.1 Set up in-line insetting-stitching-trimming
machinery
Performance evidence
You must show that you can set up in-line insetting-stitching-trimming machinery consistently over a
period of time. Your performance will be observed on at least four occasions. Your evidence must
show that:
R1
R2
you identify from your examination of materials:
a
the section make-up
b
type of section
c
section sequence
d
trim positions
e
signature marks
you set up for:
a
R3
R4
R5
194
multi-section work including cover
for sections which are:
a
open head
b
closed head
c
lapped
d
non-lapped
using:
a
coated paper
b
uncoated paper
you test and adjust machinery by:
a
visual inspection
b
checking control settings
c
producing a sample from the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 341.2 Run in-line insetting-stitching-trimming
machinery
Performance criteria
You must show that you:
1
run in-line insetting-stitching-trimming machinery:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify the causes of production faults, which result in:
a
stitch legs of unequal length
b
stitch legs not closed
c
stitches missing
d
marks on book spines
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
195
Element 341.2 Run in-line insetting-stitching-trimming
machinery
Knowledge and understanding
You must understand
196
K1
your company’s quality standards
K2
the risks associated with running in-line insetting-stitching-trimming machinery and how to
avoid them
K3
the emergency shut-down procedures
K4
the common in-line insetting-stitching-trimming running faults, what causes them and how
to correct them
K5
what other faults can occur during insetting-stitching-trimming work
K6
how to recognise when you should correct faults yourself and when you should ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedures for the removal of waste from your machine
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance details you are required to keep
K12
why trimmer knives should be kept sharp and free from chips.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 341.2 Run in-line insetting-stitching-trimming
machinery
Performance evidence
You must show that you can run in-line insetting-stitching-trimming machinery consistently, over a
period of time. Your performance will be observed on at least four occasions. Your evidence must
show that:
R1
R2
R3
you can run the machine to produce:
a
single section work inclusive of cover
b
multi-section work including cover
and maintain the quality of:
a
insetting
b
stitches
c
trims
d
the material
you decide on action to correct faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
197
Element 341.3 Plan and implement a programme of
maintenance for in-line insetting-stitchingtrimming machinery
Performance criteria
You must show that you:
198
1
obtain or prepare a complete schedule of maintenance for in-line insetting-stitchingtrimming machinery
2
identify the recommended intervals for maintenance and lubrication
3
ensure that the maintenance plan is implemented and kept up to date as far as is possible
within the time allowed by your company for lubrication and maintenance
4
keep records of maintenance work undertaken
5
examine machinery for defective components or excessive wear at intervals required by
your company
6
keep records of faults that occur or are developing and that appropriate action is taken to
deal with them either:
a
as part of the maintenance programme
b
as an urgent repair by you (if it is your job to deal with it) or
c
by reporting the problem to the relevant person in your organisation
7
are able to remove and replace faulty or worn components that are your responsibility
8
maintain a list of parts or consumables that are likely to require periodic replacement and
identify those parts that may be required at short notice
9
ensure that any parts or consumables identified as being required to be kept 'in stock' are
available in the required quantities.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 341.3 Plan and implement a programme of
maintenance for in-line insetting-stitchingtrimming machinery
Knowledge and understanding
You must understand:
K1
why manufacturer's of in-line insetting-stitching-trimming machines specify a schedule of
preventative maintenance
K2
what kinds of components wear or become degraded over time on in-line insetting-stitchingtrimming machinery
K3
what kinds of lubricants to use on the in-line insetting-stitching-trimming machinery
K4
the properties of different kinds of lubricants
K5
how to replenish lubricants in dispensers and reservoirs
K6
how to find part reference numbers and order replacement parts
K7
the consequences of failing to maintain or inspect your machine in accordance with the
manufacturer's specification or any relevant code of practice
K8
legal requirements and industry guidelines for the safe handling, use and disposal of
hazardous substances
K9
the risks of handling lubricants
K10
the personal protective equipment which should be worn when handling hazardous
substances and lubricants.
K11
where the principal lubrication points are on your in-line insetting-stitching-trimming
machinery
K12
to whom you should report existing and developing faults
K13
what is meant by the term 'safe system of work' and how it applies to maintenance and
lubrication activities on an in-line insetting-stitching-trimming machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
199
Element 341.3 Plan and implement a programme of
maintenance for in-line insetting-stitchingtrimming machinery
Performance evidence
You must show that you plan and implement maintenance of the adhesive binder consistently, over
a period of time. Your evidence must show that:
R1
a
the machine manufacturer's recommended maintenance schedules
b
the machine manufacturer's operating manual and any other relevant documents
c
any HSE/PIAC code of practice for inline insetting-stitching-trimming machines
d
lists of consumables and parts, including those normally kept 'in stock'
e
maintenance records
f
fault reports
R2
you have a maintenance schedule for the machine, and take part in its implementation as far
as your company’s production schedules and policies allow
R3
you identify defective or deteriorating components during:
R4
200
you keep appropriate documents to enable the planning and implementation of
maintenance, such as:
a
normal machine running
b
planned maintenance work
you are able to diagnose actual or developing machine faults by:
a
examining output from the machine
b
examining the machine
R5
you are able to correctly and safely change the trimming knives
R6
you are able to strip down, clean and service the stitching heads and replace any worn parts
on them.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 341.4 Keep in-line insetting-stitching-trimming
machinery in a clean and safe operating
condition
Performance criteria
You must show that you:
1
have a 'safe system of work' and a risk assessment in place before commencing any
cleaning
2
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
3
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
4
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
5
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
6
after cleaning, check that the machine is safe to operate.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
201
Element 341.4 Keep in-line insetting-stitching-trimming
machinery in a clean and safe operating
condition
Knowledge and understanding
You must understand:
202
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 341.4 Keep in-line insetting-stitching-trimming
machinery in a clean and safe operating
condition
Performance evidence
You must show that you keep the inline insetting-stitching-trimming machine in a clean and safe
operating condition consistently, over a period of time. Your performance will be observed on at
least four occasions. Your evidence must show that you:
R1
R2
R3
R4
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
d
spent adhesive
check that after cleaning the machine is safe to operate:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
203
Unit 342
Control in-line gathering-adhesive bindingtrimming machinery
Introduction
To achieve your unit certificate, you must show that you can:
1
Element 342.1 Set up in-line gathering-adhesive binding-trimming machinery
2
Element 342.2 Run in-line gathering-adhesive binding-trimming machinery
3
Element 342.3 Plan and implement a programme of maintenance for in-line gatheringadhesive binding-trimming machinery
4
Element 342.4 Keep in-line gathering-adhesive binding-trimming machinery in a clean
and safe operating condition
This involves:
• identifying the job requirements
• checking that the in-line gathering-adhesive binding-trimming machine is working properly
• checking that safety devices are working properly
• running in-line gathering-adhesive binding-trimming machinery safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced
• how you maintained the speed of output and quality of the product throughout the line.
204
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 342.1 Set up in-line gathering-adhesive bindingtrimming machinery
Performance criteria
You must show that you:
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up the in-line gathering-adhesive binding-trimming machinery correctly, so that:
a
sections are gathered to give the correct page sequence
b
sections are fed squarely from hoppers to the transport chain
c
book blocks are fed into the binder squarely and without damage
d
spine preparation gives the correct glue penetration of the paper
e
glue is applied evenly at the correct temperature
f
covers are fed squarely
g
score lines do not break the cover surface
h
books are fed into the trimmer squarely and without damage
i
clamp holds pile firmly without marking
j
piles are trimmed squarely and delivered without damage or distortion
k
the trimmed size is within the variation permitted by your company
5
produce a sample from the machine and check that it matches the required standard
6
make adjustments if necessary to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
205
Element 342.1 Set up in-line gathering-adhesive bindingtrimming machinery
Knowledge and understanding
You must understand:
206
K1
what details you need for the job
K2
the principles of in line gathering-adhesive binding-trimming
K3
the sequence of set up tasks for gathering-adhesive binding-trimming machinery
K4
the common gathering-adhesive binding-trimming set-up faults, what causes them and how
to prevent them
K5
the risks associated with setting-up gathering-adhesive binding-trimming machinery, and
how to avoid them
K6
the emergency shut-down procedures
K7
the purpose of collating marks and signature marks
K8
how the grain direction of materials affect binding quality
K9
the binding requirements of:
a
unsewn and sewn sections
b
covers with two and four scores
c
coated and uncoated papers
d
2-up work
K10
how to gather open and closed head sections, with and without laps
K11
how to gather sections perforated along the line of a fold
K12
the purpose of perforating sections on a folding machine
K13
which types of material are most at risk of rub marking
K14
which printed colours are most at risk of marking
K15
the differences between binding with Hot Melt and Emulsion adhesives
K16
how to securely clamp piles of uneven height for trimming.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 342.1 Set up in-line gathering-adhesive bindingtrimming machinery
Performance evidence
You must show that you can set up in-line gathering-adhesive binding-trimming machinery
consistently over a period of time. Your performance will be observed on at least four occasions.
Your evidence must show that:
R1
R2
R3
R4
R5
you set up for the following types of section:
a
open head
b
closed head
c
lapped
d
non-lapped
... and these types of stock:
a
coated paper
b
uncoated paper
... when the job style is:
a
landscape
b
portrait
... and for jobs which include:
a
outset/wraparound plates
b
sections with insetted folded inserts
c
single leaf tipped on plates
you test and adjust machinery by:
a
visual inspection
b
checking control settings
c
producing a sample run.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
207
Element 342.2 Run in-line gathering-adhesive bindingtrimming machinery
Performance criteria
You must show that you:
1
208
run in-line gathering-adhesive binding machinery:
a
at the required speed
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that your company’s quality standards are met
4
accurately identify the causes of production faults, which result in:
a
sections not in the correct order
b
cracking of the cover surface on front cover and spine
c
rounding of spines
d
too much and too little glue penetration
e
poor page-pull strength
f
covers not registering correctly with book blocks
g
unacceptable cut size variation
h
score marks on cut surfaces
I
ragged cut on bottom pages
j
book spines splitting at head and tail
k
books not square
l
spines creasing
5
correct faults which it is your job to remedy
6
promptly report faults which it is not your job to correct
7
check that the machine is safe to operate, once faults have been corrected
8
accurately record the production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 342.2 Run in-line gathering-adhesive bindingtrimming machinery
Knowledge and understanding
You must understand:
K1
your company’s quality standards
K2
the risks associated with running in-line gathering-adhesive binding-trimming machinery and
how to avoid them
K3
the emergency shut-down procedures
K4
the common in-line gathering-adhesive binding-trimming running faults, what causes them
and how to correct them
K5
what other faults can occur during gathering-adhesive binding-trimming production
K6
how to recognise when you should correct faults and when you should ask for help
K7
to whom you should report faults
K8
where to find documents giving help in identifying the causes of faults
K9
the procedures for the removal of waste from your machine
K10
your company’s methods for stacking finished work from your machine
K11
what production and quality assurance details you are required to keep
K12
why trimmer knives should be kept sharp and free from chips
K13
the factors what will dictate the height of piles for trimming.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
209
Element 342.2 Run in-line gathering-adhesive bindingtrimming machinery
Performance evidence
You must show that you can run in-line gathering-adhesive binding-trimming machinery
consistently, over a period of time. Your performance will be observed on at least four occasions.
Your evidence must show that:
R1
R2
you run the machinery from sections which are:
a
open head or closed head
b
lapped or non-lapped
… and these types of stock:
a
R3
and maintain the quality of:
a
R4
210
coated paper and uncoated paper
gathering, bond strength and trims
you decide on action to correct faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 342.3 Plan and implement a programme of
maintenance in-line gathering-adhesive
binding-trimming machinery
Performance criteria
You must show that you:
1
obtain or prepare a complete schedule of maintenance for the in-line gathering adhesive
binding-trimming machinery
2
identify the recommended intervals for maintenance and lubrication
3
ensure that the maintenance plan is implemented and kept up to date as far as is possible
within the time allowed by your company for lubrication and maintenance
4
keep records of maintenance work undertaken
5
examine machinery for defective components or excessive wear at intervals required by
your company
6
keep records of faults that occur or are developing and that appropriate action is taken to
deal with them either:
a
as part of the maintenance programme
b
as an urgent repair by you (if it is your job to deal with it), or
c
by reporting the problem to the relevant person in your organisation
7
are able to remove and replace faulty or worn components that are your responsibility
8
maintain a list of parts or consumables that are likely to require periodic replacement and
identify those parts that may be required at short notice
9
ensure that any parts or consumables identified as being required to be kept 'in stock' are
available in the required quantities.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
211
Element 342.3 Plan and implement a programme of
maintenance in-line gathering-adhesive
binding-trimming machinery
Knowledge and understanding
You must understand:
212
K1
why manufacturer's of in-line gathering-adhesive binding-trimming machinery specify a
schedule of preventative maintenance
K2
what kinds of components wear or become degraded over time on in-line gatheringadhesive binding-trimming machinery
K3
what kinds of lubricants to use on the in-line gathering-adhesive binding-trimming machinery
K4
the properties of different kinds of lubricants
K5
how to replenish lubricants in dispensers and reservoirs
K6
how to find part reference numbers and order replacement parts
K7
the consequences of failing to maintain or inspect your machine in accordance with the
manufacturer's specification or any relevant code of practice
K8
legal requirements and industry guidelines for the safe handling, use and disposal of
hazardous substances
K9
the risks of handling lubricants
K10
the personal protective equipment which should be worn when handling hazardous
substances and lubricants.
K11
where the principal lubrication points are on your in-line gathering-adhesive bindingtrimming machinery
K12
to whom you should report existing and developing faults
K13
what is meant by the term 'safe system of work' and how it applies to maintenance and
lubrication activities on an in-line gathering-adhesive binding-trimming machinery.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 342.3 Plan and implement a programme of
maintenance in-line gathering-adhesive
binding-trimming machinery
Performance evidence
You must show that you plan and implement maintenance of the in-line gathering adhesive
binding-trimming machinery consistently, over a period of time.
Your evidence must show that:
R1
you keep appropriate documents to enable the planning and implementation of
maintenance, such as:
a
the machine manufacturer's recommended maintenance schedules
b
the machine manufacturer's operating manual and any other relevant documents
c
any HSE/PIAC code of practice for in-line gathering-adhesive binding-trimming
machinery
d
lists of consumables and parts, including those normally kept 'in stock'
e
maintenance records
f
fault reports
R2
you have a maintenance schedule for the machine, and take part in its implementation as far
as your company’s production schedules and policies allow
R3
you identify defective or deteriorating components during:
R4
R5
a
normal machine running
b
planned maintenance work
you are able to diagnose actual or developing machine faults by:
a
examining output from the machine
b
examining the machine
you are able to change the trimming knives safely and correctly.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
213
Element 342.4 Keep in-line gathering-adhesive bindingtrimming machinery in a clean and safe
operating condition
Performance criteria
You must show that you:
214
1
have a 'safe system of work' and a risk assessment in place before commencing any
cleaning
2
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
3
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
4
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
5
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
6
after cleaning, check that the machine is safe to operate.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 342.4 Keep in-line gathering-adhesive bindingtrimming machinery in a clean and safe
operating condition
Knowledge and understanding
You must understand:
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
215
Element 342.4 Keep in-line gathering-adhesive bindingtrimming machinery in a clean and safe
operating condition
Performance evidence
You must show that you keep the in-line gathering-adhesive binding-trimming machinery in a clean
and safe operating condition consistently, over a period of time. Your performance will be observed
on at least four occasions. Your evidence must show that you:
R1
R2
R3
R4
216
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
d
spent adhesive
check that after cleaning the machine is safe to operate:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
c
any guards designed to give protection from the milling station and the glue tank are
fitted and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Unit 343
Control in-line block feeding-forwarding- case
binding machinery
Introduction
To achieve your unit certificate, you must show that you can:
1
Element 343.1 Set up in-line block feeding-forwarding- case binding machinery
2
Element 343.2 Run in-line block feeding-forwarding- case binding machinery
3
Element 343.3 Plan and implement a programme of maintenance for in- block feedingforwarding- case binding machinery
4
Element 343.4 Keep in-line block feeding-forwarding- case binding machinery in a clean
and safe operating condition
This involves:
• identifying the job requirements
• checking that the in-line block feeding-forwarding-binding machine is working properly
• checking that safety devices are working properly
• running in-line block feeding-forwarding-binding machinery safely
• adjusting settings, where necessary to maintain the required standard
• checking that work meets the required standard
• identifying faults and taking action to deal with them
• unloading and stacking the finished product.
Collecting the evidence for this unit
Your performance evidence must show that you have covered all of the statements in each
element, and must be the result of real work activities in actual production situations. Simulation is
not acceptable for this unit. Video recording evidence is ideal.
Your assessor will need to be satisfied that you have the necessary understanding specified in each
‘K’ list. Where this is not evident from your performance, you may be asked oral or written
questions, or to write a short report.
You may need to provide other information to support your performance evidence or be able to
point to where such evidence may be found within your company. Here are some examples:
• job instructions
• samples of finished jobs
• samples of finished jobs
• production records showing the time taken to produce the job and/or the quantity produced
• how you maintained the speed and quality of the throughput on the line.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
217
Element 343.1 Set up in-line block feeding-forwarding-case
binding machinery
Performance criteria
You must show that you:
218
1
check that you have all the details you need for the job
2
check that you have enough materials of the right type for the job
3
promptly report to your manager, if the materials provided are not correct or sufficient
4
set up the line correctly, so that:
a
book blocks are fed into forwarding units squarely and without damage
b
forwarding processes match the specification
c
finished blocks are fed into the case binder squarely, and without damage
d
cases are fed squarely, evenly and without distortion
e
adhesive is applied evenly to the book joints and endpapers
f
book blocks are securely and cleanly attached to cases
g
the size of squares are equal all round
h
books are delivered without damage or distortion
5
produce a sample from the machine and check that it matches the required standards
6
make adjustments if necessary, to enable the standards to be met
7
report promptly to your manager, if the standards cannot be met
8
check that your work area is safe and ready for production.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 343.1 Set up in-line block feeding-forwarding-case
binding machinery
Knowledge and understanding
You must understand:
K1
what details you need for the job
K2
the principles of in line block feeding-forwarding-binding
K3
the sequence of set up tasks for block feeding-forwarding-binding machinery
K4
the different binding requirements of:
a
square backed books
b
rounded and backed books
K5
which glues are suitable for forwarding and casing-in processes
K6
how the grain direction of boards and book blocks affects binding quality
K7
the degree of warping produced by gluing different types of boards and papers
K8
the risks associated with setting up in line block feeding-forwarding-binding machinery, and
how to avoid them
K9
what the common in line block feeding-forwarding-binding machine faults are, what causes
them and how to prevent them
K10
the emergency shut down procedures.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
219
Element 343.1 Set up in-line block feeding-forwarding-case
binding machinery
Performance evidence
You must show that you can set up in-line block feeding-forwarding-case binding machinery
consistently over a period of time. Your performance will be observed on at least four occasions.
Your evidence must show that:
R1
you set up for:
a
R2
R3
R4
... for jobs including:
a
multi book back linings
b
head and tail bands
... when the types of cases are:
a
plastic or coated
b
cloth and paper
... and the following types of hollow lining are required:
a
R5
220
case bound rounded and backed, and square back books
paper and board
you test and adjust machinery by:
a
visual inspection
b
checking control settings
c
producing a sample run.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 343.2 Run in-line block feeding-forwarding-case
binding machinery
Performance criteria
You must show that you:
1
run in-line block feeding-forwarding-binding machinery:
a
at the required speed to produce the output
b
safely and efficiently
2
keep up the supply of materials throughout the run
3
regularly check that quality standards are met
4
accurately identify the cause of production faults, which result in:
a
out of square with case head and tail bands incorrectly positioned on the spine
b
lining off-centre to the spine
c
shape of spines distorted
d
over and under penetration of glue
e
shoulders of joints poorly formed
f
book blocks
5
correct mechanical faults which it is your job to remedy
6
promptly report mechanical faults which it is not your job to correct
7
check that the machine is safe to operate, once faults are corrected
8
accurately record production and quality assurance details
9
follow the correct procedures for the removal of waste
10
stack work safely using the approved method.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
221
Element 343.2 Run in-line block feeding-forwarding-case
binding machinery
Knowledge and understanding
You must understand:
222
K1
your company’s quality standards
K2
the principles of in line block feeding-forwarding-binding
K3
the risks associated with running in line block feeding-forwarding-binding machinery and
how to avoid them
K4
the emergency shut down procedures
K5
the common in line block feeding-forwarding-binding machine faults, what causes them and
how to correct them
K6
what other faults can occur during block feeding-forwarding-binding work
K7
how to recognise when you should correct faults yourself and when you should ask for help
K8
to whom you must report faults
K9
where to find documents giving help in identifying the causes of faults
K10
the procedures for the removal of waste from your machine
K11
what production and quality assurance details you are required to keep.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 343.2 Run in-line block feeding-forwarding-case
binding machinery
Performance evidence
You must show that you can run in-line block feeding-forwarding-case binding machinery
consistently, over a period of time. Your performance will be observed on at least four occasions.
Your evidence must show that:
R1
R2
R3
R4
you run the machine for jobs which include:
a
tape sewn sections
b
multi book back linings
c
head and tail bands
… when the types of cases are:
a
plastic or coated
b
cloth
c
paper
…and maintain the quality of:
a
case position
b
spine shape
c
bond strength
you determine action to remedy faults:
a
to be taken by yourself
b
to be taken by others.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
223
Element 343.3 Plan and implement a programme of
maintenance for in-line block feedingforwarding-case binding machinery
Performance criteria
You must show that you:
224
1
obtain or prepare a complete schedule of maintenance for the in-line block feedingforwarding-case binding machinery
2
identify the recommended intervals for maintenance and lubrication
3
ensure that the maintenance plan is implemented and kept up to date as far as is possible
within the time allowed by your company for lubrication and maintenance.
4
keep records of maintenance work undertaken
5
examine machinery for defective components or excessive wear at intervals required by
your company
6
keep records of faults that occur or are developing and that appropriate action is taken to
deal with them either:
a
as part of the maintenance programme
b
as an urgent repair by you (if it is your job to deal with it) or
c
by reporting the problem to the relevant person in your organisation
7
are able to remove and replace faulty or worn components that are your responsibility
8
maintain a list of parts or consumables that are likely to require periodic replacement and
identify those parts that may be required at short notice
9
ensure that any parts or consumables identified as being required to be kept 'in stock' are
available in the required quantities.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 343.3 Plan and implement a programme of
maintenance for in-line block feedingforwarding-case binding machinery
Knowledge and understanding
You must understand:
K1
why manufacturer's of in-line block feeding-forwarding-case binding machinery specify a
schedule of preventative maintenance
K2
what kinds of components wear or become degraded over time on in-line block feedingforwarding-case binding machinery
K3
what kinds of lubricants to use on the in-line block feeding-forwarding-case binding
machinery
K4
the properties of different kinds of lubricants
K5
how to replenish lubricants in dispensers and reservoirs
K6
how to find part reference numbers and order replacement parts
K7
the consequences of failing to maintain or inspect your machine in accordance with the
manufacturer's specification or any relevant code of practice
K8
legal requirements and industry guidelines for the safe handling, use and disposal of
hazardous substances
K9
the risks of handling lubricants
K10
the personal protective equipment which should be worn when handling hazardous
substances and lubricants.
K11
where the principal lubrication points are on your in-line block feeding-forwarding-case
binding machinery
K12
to whom you should report existing and developing faults
K13
what is meant by the term 'safe system of work' and how it applies to maintenance and
lubrication activities on an in-line block feeding-forwarding-case binding machinery.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
225
Element 343.3 Plan and implement a programme of
maintenance for in-line block feedingforwarding-case binding machinery
Performance evidence
You must show that you plan and implement maintenance of the adhesive binder consistently, over
a period of time. Your evidence must show that:
R1
a
the machine manufacturer's recommended maintenance schedules
b
the machine manufacturer's operating manual and any other relevant documents
c
any HSE/PIAC code of practice for in-line block feeding-forwarding-case binding
machinery
d
lists of consumables and parts, including those normally kept 'in stock'
e
maintenance records
f
fault reports
R2
you have a maintenance schedule for the machine, and take part in its implementation as far
as your company’s production schedules and policies allow
R3
you identify defective or deteriorating components during:
R4
226
you keep appropriate documents to enable the planning and implementation of
maintenance, such as:
a
normal machine running
b
planned maintenance work
you are able to diagnose actual or developing machine faults by:
a
examining output from the machine
b
examining the machine.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 343.4 Keep in-line block feeding-forwarding-case
binding machinery in a clean and safe
operating condition
Performance criteria
You must show that you:
1
have a 'safe system of work' and a risk assessment in place before commencing any
cleaning
2
use cleaning methods which are safe, avoid harm to the environment and which follow the
manufacturer's instructions
3
dispose of used cleaning agents and waste materials safely and in accordance with
environment/waste disposal legislation
4
prevent any build up of debris in or around the machine by regularly removing it and
cleaning the machine
5
regularly check that the machine is clean enough to prevent marking or damage to the
product during normal operation
6
after cleaning, check that the machine is safe to operate.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
227
Element 343.4 Keep in-line block feeding-forwarding-case
binding machinery in a clean and safe
operating condition
Knowledge and understanding
You must understand:
228
K1
what 'safe systems of work' and 'risk assessments' are
K2
the current legal requirements and industry guidelines for the safe handling and use of
hazardous substances
K3
the risks of handling cleaning materials
K4
what the production schedule is and how this affects cleaning operations
K5
why it is important to use cleaning methods which are safe, avoid harming the environment
and meet manufacturers' requirements
K6
what cleaning agents are suitable for use
K7
your company's procedures for the safe disposal of waste
K8
what you must do to comply with environmental and waste legislation
K9
what records need to be kept.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Element 343.4 Keep in-line block feeding-forwarding-case
binding machinery in a clean and safe
operating condition
Performance evidence
You must show that you keep the in-line block feeding-forwarding-case binding machinery in a clean
and safe operating condition consistently, over a period of time. Your performance will be observed
on at least four occasions. Your evidence must show that you:
R1
R2
R3
R4
work in a tidy and safe environment and prevent the build up of debris:
a
inside or on the machine
b
around the machine
keep the machine and surrounding area free from:
a
scrap paper
b
dust, including paper dust
c
excessive lubricant
d
spent adhesive
check that after cleaning the machine is safe to operate:
a
all fixed guards are in place on the machine
b
any interlocking guards are in place and working correctly
dispose of the following waste materials properly:
a
used cleaning agents
b
solvents and lubricants
c
production debris
d
soiled materials.
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
229
Appendix 1
Accreditation, national frameworks and
qualification level descriptors
Please visit the following websites to find information on accreditation, national frameworks and
qualification level descriptors in each country.
230
Nation
Who to contact
Website
England
The Qualifications and Curriculum Authority
www.qca.org.uk
Scotland
The Scottish Qualifications Authority
www.sqa.org.uk
Wales
The Department for Education, Lifelong Learning
and Skills Wales
www.new.wales.gov.uk
Northern
Ireland
The Council for Curriculum, Examinations and
Assessment
www.ccea.org.uk
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Appendix 2
The qualification structure
This section of the document outlines the qualification structure for the full suite of Printing NVQs at
Levels 2 and 3. Please refer to the tables on the following pages.
Qualification
Complex
QCA reference
Level 2 NVQ in Digital Print Production
5158-20 and -80
500/1488/2
Level 2 NVQ in Machine Printing
5158-21 and -81
500/1483/3
Level 2 NVQ in Mechanised Print Finishing and Binding
5158-22 and -82
500/1479/1
Level 2 NVQ in Envelope Manufacture
5158-23 and -83
500/1476/6
Level 3 NVQ in Digital Print Production
5158-30 and -90
500/1469/9
Level 3 NVQ in Machine Printing
5158-31 and -91
500/1491/2
Level 3 NVQ in Mechanised Print Finishing and Binding
5158-32 and -92
500/1475/4
Level 3 NVQ in Envelope Manufacture
5158-33 and -93
500/1487/0
Level 3 NVQ in Hand Binding
5158-34 and -94
500/1477/8
Level 3 NVQ in Carton Manufacture
5158-35 and -95
500/1478/X
Level 3 NVQ in Print Administration
5158-36 and -96
500/1472/9
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
231
Level 2 NVQ in Digital Print Production
Mandatory common units
201
Comply with Health and Safety Requirements in the Workplace
202
Improve your performance at work
203
Plan your work to meet production requirements
204
Capture images from specified sources
Mandatory Technical Units
Group A – Digital Artwork for Print
Group B – Pre-Press
Group C – Digital Printing
205
206
207
Create digital colour artwork for print
Produce imposed separations for printing
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Operate digital printing machines
232
Level 2 NVQ in Machine Printing
Mandatory common units
201
Comply with Health and Safety Requirements in the Workplace
202
Improve your performance at work
208
Contribute to maintaining equipment in working order
Mandatory technical units (Groups A-G) – complete two units from same pathway
Group A Lithography
Group B Web Offset
Group C Flexography
Group D Screen
Group E Gravure
Group F Pad printing
Group G Dye Stamping
209 Prepare
machines for
sheet fed
lithographic
printing
217 Prepare
machines for
web offset
printing
221 Prepare
machines for
flexographic
printing
226 Prepare
equipment and
machines for
screen printing
229 Prepare
machines for
gravure
printing
232 Prepare
machines for
pad printing
262 Prepare dye
stamping
machines for
printing
210 Operate sheet
fed lithographic
printing
machines
218 Operate web
offset printing
machines
222 Operate
flexographic
printing
machines
227 Operate screen
printing
machines
230 Operate
gravure
printing
machines
233 Operate pad
printing
machines
263 Operate dye
stamping
machines
211 Operate in-line
converting
equipment
212 Operate ink
drying
equipment
211 Operate in-line
converting
equipment
213 Prepare inks
213 Prepare inks
Optional technical units – complete one unit from chosen pathway
211 Operate in-line
converting
equipment
211 Operate in-line
converting
equipment
211 Operate in-line
converting
equipment
211 Operate in-line
converting
equipment
212 Operate ink
drying
equipment
212 Operate ink
drying
equipment
212 Operate ink
drying
equipment
212 Operate ink
212 Operate ink
drying
drying
equipment
equipment
Continued on next page
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
233
213 Prepare inks
214 Set up and
operate
auxiliary
equipment
213 Prepare inks
213 Prepare inks
220 Operate reel
handling
equipment
214 Set up and
operate
auxiliary
equipment
219 Operate in-line
printing units
214 Set up and
operate
auxiliary
equipment
228 Prepare
stencils for
printing
231 Mix, dry and
cure inks
215 Maintain the
condition of
plates for
printing
220 Operate reel
handling
equipment
215 Maintain the
condition of
plates for
printing
216 Prepare and
produce wet
proofs
234 Maintain the
condition of
consumables
for printing
214 Set up and
operate
auxiliary
equipment
216 Prepare and
produce wet
proofs
220 Operate reel
handling
equipment
223 Operate and
monitor bar
code printing
224 Control colour
throughout the
run
225 Maintain anilox
roll conditions
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
234
Level 2 NVQ in Mechanised Print Finishing and Binding
Mandatory common units
201
Comply with Health and Safety Requirements in the Workplace
202
Improve your performance at work
208
Contribute to maintaining equipment in working order
Optional technical units (Groups A-B) – complete two optional from chosen pathway
Group A – General Print
Group B – Newspapers and Periodicals
235
Run and monitor guillotines
249 Operate automated inserting equipment for newspapers and periodicals
production
236
Run and monitor adhesive binding machinery
250 Operate automated stitch and trim equipment for newspapers and periodicals
production
237 Run and monitor case making machinery
251 Set up machines for automated newspapers and periodicals print finishing
238 Run and monitor casing-in machinery
252 Move materials for newspaper and periodical production
239 Run and monitor folding machinery
253 Repair and maintain feeder machinery
240 Set and operate booklet-making machinery
254 Control publishing equipment for newspaper and periodicals production
241 Set and operate mail processing machinery
255 Control auto-palletising equipment for newspaper and periodicals production
242 Set and operate multi-knife trimming machinery
243 Set and operate multiple hopper feeders
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
Continued on next page
235
244 Set and operate auto-fed sewing machinery
245 Control auto punching and cutting machinery
246 Control foil blocking machinery
247 Control twin loop wire binding machinery
248 Control parallel folding
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
236
Level 2 NVQ in Envelope Manufacture
Mandatory common units
201
Comply with Health and Safety Requirements in the Workplace
202
Improve your performance at work
208
Contribute to maintaining equipment in working order
256
Monitor and run envelope manufacturing machines
Optional Technical units – complete one optional
257
Prepare and set printing units
258
Prepare and set window cutting and patching units for envelope manufacture
259
Prepare and set scoring, folding and gumming units for envelope manufacturing
260
Prepare and set profile cutting units for envelope manufacture
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
237
Level 3 NVQ in Digital Print Production
Mandatory Common Units
203
Plan work to meet production requirements
261
Send and receive digital files
301
Ensure your own actions reduce risks to health and safety in the workplace
302
Improve Individual and Organisational Performance
303
Plan and capture digital images
304
Maintain digital systems in working order
305
Design and produce creative digital colour artwork for print
Mandatory Technical Units (Groups A-B) – complete one units from chosen pathway
Group A - Digital Artwork for Print
Group B - Pre-press
206
Produce imposed separations for printing
228
Prepare stencils for printing
207
Operate digital printing machines
306
Plan and produce edited images
306
Plan and produce edited images
307
Manage colour reproduction in digital pre-press
307
Manage colour reproduction in digital pre-press
308
Produce approved proofs from digital artwork
308
Produce approved proofs from digital artwork
309
Produce computer generated image carriers
310
Make photopolymer plates for flexographic printing
311
Make plates for lithographic printing
312
Make gravure cylinders
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
238
Level 3 NVQ in Machine Printing
Mandatory common units
301
Ensure your own actions reduce risks to health and safety in the workplace
302
Improve Individual and Organisational Performance
348
Maintain equipment in working order
Mandatory technical units
Group A –
Lithography
Group B – Web Offset
Group C –
Flexography
Group D - Screen
315 Control sheet-fed
multi unit
lithographic
printing machines
319 Control web offset
printing machines
323 Control
flexographic
printing machines
325 Control screen
326 Control gravure
printing machines
printing machines
Group E - Gravure
Group F - Pad Printing
327 Control pad
printing machines
Optional Technical Units (Groups A-F) – complete two units from chosen pathway
Group A –
Lithography
Group B – Web Offset
Group C –
Flexography
Group D - Screen
Group E - Gravure
Group F - Pad Printing
215 Maintain the
condition of plates
for printing
316 Control in-line
converting
machinery
215 Maintain the
condition of plates
for printing
213
Prepare inks
316 Control in-line
converting
machinery
213 Prepare inks
311 Make plates for
lithographic
printing
317 Control ink drying
machinery
316 Control in-line
converting
machinery
228
Prepare stencils
for printing
317 Control ink drying
machinery
234 Maintain the
condition of
consumables for
printing
Continued on next page
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
239
316 Control in-line
converting
machinery
318 Control auxiliary
equipment
317 Control ink drying
machinery
316
Control in-line
converting
machinery
318 Control auxiliary
equipment
317 Control ink drying
machinery
320 Control in-line
printing units
318 Control auxiliary
equipment
317
Control ink drying
machinery
321 Control reel
handling
equipment
318 Control auxiliary
equipment
321 Control reel
handling
equipment
321 Control reel
handling
equipment
322 Control in-line
folding units
324 Test flexographic
printing machines
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
317 Control ink drying
machinery
322 Control in-line
folding units
240
Level 3 NVQ in Mechanised Print Finishing and Binding
Mandatory common units
301 Ensure your own actions reduce risks to health and safety in the workplace
302 Improve Individual and Organisational Performance
Optional technical units (Groups A-B) – complete one optional from chosen pathway
Group A – General Print
Group B – Newspapers and Periodicals
Optional technical units – complete two units
Mandatory technical units – complete one unit
328 3 Control adhesive binding machinery
348
329
Optional Technical units complete two units
Control case making machinery
Maintain equipment in working order
330 Control casing-in machinery
253
Repair and maintain feeder machinery
331 Control programmatic guillotines
344 Control automated inserting processes for
newspapers and periodicals print
332 2 Control folding machinery
345 Control automated stitch and trim processes for
newspaper and periodicals print
333 1 Control in-line booklet making machinery
346 Control the set up of machines for newspaper and
periodicals print finishing
Optional Technical units complete one unit
347 Control materials handling for newspaper and
periodicals print finishing
Continued on next page
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
241
246 Control foil blocking machinery
334 Control non-automatic finishing machines
335 Control multiple hopper feeders
336 Control auto-fed sewing machinery
337 Control multi-knife trimming machinery
338 1 Set and operate booklet-making machinery
339 2 Control parallel folding
340 3 Run and monitor adhesive binding machinery
341 Control inline insetting-stitching-trimming machines
342 Control inline gathering-adhesive-binding-trimming machinery
343 Control inline block-feeding-forwarding-case binding machinery
Notes
1
Unit 338 may not be used in conjunction with Unit 333
2
Unit 339 may not be used in conjunction with Unit 332
3
Unit 340 may not be used in conjunction with Unit 328
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
242
Level 3 NVQ in Envelope Manufacture
Mandatory common Units
301 Ensure your own actions reduce risks to health and safety in the workplace
302 Improve Individual and Organisational Performance
314 Identify and organise the requirements for production
348 Maintain equipment in working order
349 Control envelope manufacturing machinery
Optional technical units – complete one optional
350 Support the efficient use of resources (MCI)
351 Manage yourself (MCI)
352 Contribute to the development of teams and individuals (MCI)
353 Lead the work of teams and individuals to achieve their objectives (MCI)
354 Train new operators
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
243
Level 3 NVQ in Hand Binding
Mandatory common units
301 Ensure your own actions reduce risks to health and safety in the workplace
302 Improve Individual and Organisational Performance
355 Prepare for hand binding operations
356 Bind books by hand
357 Cut page edges and binding materials by guillotine
Optional technical units – complete one optional
351 Manage yourself (MCI)
352 Contribute to the development of teams and individuals (MCI)
353 Lead the work of teams and individuals to achieve their objectives (MCI)
354 Train new operators
358 Decorate cases
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
244
Level 3 NVQ in Carton Manufacture
Mandatory common units
301 Ensure your own actions reduce risks to health and safety in the workplace
302 Improve Individual and Organisational Performance
348 Maintain equipment in working order
Optional technical units – complete one optional
359 Control cutting and creasing machinery
360 Control multi-folding and gluing machinery
361 Produce dyes and tooling
Optional technical units – complete one optional
314 Identify and organise the requirements for production
350 Support the efficient use of resources (MCI)
351 Manage yourself (MCI)
352 Contribute to the development of teams and individuals (MCI)
353 Lead the work of teams and individuals to achieve their objectives (MCI)
354 Train new operators
Additional technical unit
362 Control carton enhancing machinery
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
245
Level 3 NVQ in Print Administration
Mandatory common units
301 Ensure your own actions reduce risks to health and safety in the workplace
302 Improve Individual and Organisational Performance
261 Send and receive digital files
Optional technical units – complete three optional
363 Produce estimates from customer requirements
364 Prepare job cost information and produce invoices
365 Agree job specification and prepare production schedules
366 Control Production
367 Purchase materials and services for production
368 Service customer accounts
Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
246
Published by City & Guilds
1 Giltspur Street
London
EC1A 9DD
T +44 (0)20 7294 2800
F +44 (0)20 7294 2400
www.cityandguilds.com
City & Guilds is a registered charity
established to promote education
and training
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Level 3 NVQ in Mechanised Print Finishing and Binding - General Print (5158-32)
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