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Title / Operate a flexo folder gluer for repeat work in the corrugated packaging industry
Level / 4 / Credits / 30
Purpose / People credited with this unit standard are able to: plan ahead, to avoid delays during make ready and during production running; communicate to ensure that job requirements are met; make ready the machine to make printed, folded, and glued product without avoidable delays; run the machine, in accordance with workplace practices, to make printed, folded and glued product to meet job requirements; and follow safety requirements to for the machine being operated.
Classification / Fibreboard Packaging > Corrugated Case Converting
Available grade / Achieved
Entry information
Critical health and safety prerequisites / Unit 340, Demonstrate knowledge of safe working practices in the printing and graphic pre-press industries, or demonstrate equivalent knowledge and skills.
Recommended skills and knowledge / Unit 21723, Make ready and run an automatic straight line folder gluer in the corrugated packaging industry; Unit 10108, Produce two colour printed board in the corrugated packaging industry; Unit 10113, Set up and run a hopper feeder for high speed machinery in the corrugated packaging industry; Unit 10140, Produce slotted and creased board in the corrugated packaging industry; Unit 10154, Use load forming and strapping equipment in the corrugated packaging industry; andUnit 10142, Use squaring and counting equipment in the corrugated packaging industry;or demonstrate equivalent knowledge and skills.
Explanatory notes
1All workplace practices must meet any applicable and recognised codes of practice, and documented workplace health, safety, and environmental procedures for personal, product, workplace health, safety, and environmental matters, and the obligations required under current law including the Health and Safety in Employment Act 1992, Hazardous Substances and New Organisms Act 1996, Resource Management Act 1991, Privacy Act 1993 and their subsequent amendments.
2Workplace practices refer to the documented procedures for the machine and/or workplace.
3Board warped in excess of 2% is not to be used during assessment. The process for defining and calculating warp percentage is as follows: when a warped board is laid on a level surface so as to form a shallow arch, the maximum vertical deviation from the horizontal is expressed as a percentage of the board dimension that forms the arch.
4Assessments must be conducted where board sheet size is 20% above the machine’s specified minimum limit and 20% below the machine’s specified maximum limit.
5Competence in this unit standard must be assessed for a repeat production task at any flexo folder gluer with two or more print stations.
6Competence must be demonstrated in printing two colours in a single pass with a registration requirement and a requirement for either trapping or alignment.
7Competence in the use of any form of rotary die cutting machine configured need not be demonstrated for this unit standard.
Outcomes and evidence requirements
Outcome 1
Plan ahead, to avoid delays during make ready and during production running.
Evidence requirements
1.1Procedures for the handling of priority orders where special job prioritisation is scheduled are described and followed in accordance with workplace practices.
1.2Before make ready work begins, production order documentation is confirmed as the documentation required for the next job scheduled.
1.3Identification for the initial pallet load or slip sheet load is prepared in advance of production running in accordance with workplace practices.
1.4All required materials and documentation are confirmed as available prior to make ready.
Rangematerials may include, but are not limited to – glue, glue heads, stereos, samples, inks, colour swatches, lay cards, overlays, slip sheets, pallets, tools, board to be run, documentation, load identification.
Outcome 2
Communicate to ensure that job requirements are met.
Evidence requirements
2.1Any forward rescheduling to match up similar jobs is agreed with other staff in accordance with workplace practices.
Rangesupervisor, manager, planning department.
2.2Staff responsible for delivering materials for the next job are clearly advised of the requirements in accordance with workplace practices ensuring that no avoidable delays occur.
Rangeforkhoist operators, pre-press, own machine crew.
2.3Machine crew confirm that they understand the specific make ready and production tasks they are responsible for.
Rangetask responsibilities – stripping down machine from the previous job, setting up for the next job, checks at feed end, checks to be made at take off.
2.4Potential problems during make ready and production, and any special production needs are identified, and their requirements are met through clear communication with crew members.
Outcome 3
Make ready the machine to make printed, folded and glued product without avoidable delays.
Evidence requirements
3.1Make ready is completed in accordance with workplace practices and to meet job requirements.
Rangetime allowed, board condition;
job requirements which may include – run length, print specifications, take off requirements.
Outcome 4
Run the machine, in accordance with workplace practices, to make printed, folded and glued product to meet job requirements.
Evidence requirements
4.1Production running speed is maintained ensuring that required quality and production standards are met.
4.2Checks for faults are carried out during production running.
4.3Action is immediately taken to identify and rectify any faults, and fault-free production running is successfully resumed.
4.4Proactive measures to reduce the likelihood of faults occurring during production are followed.
Rangeproactive measures may include but are not limited to checks on – machine settings and machine running, condition of board being input, condition of finished product at take off.
4.5Actions available to counter the effect of board warp exceeding 2% are explained in terms of workplace practices.
4.6Load identification requirements are carried out.
4.7Print position and registration of all print meets workplace practices within the first five sheets.
4.8Colour shades are confirmed as meeting the requirements of the job.
4.9Viscosity adjustments are made to rectify any incorrect colour shade caused by viscosity outside specifications.
4.10All impression faults are recognised and rectified.
Rangeimpression faults may include – light and/or missing print, distorted print, board crush, halo, print fill in.
4.11Slotting, creasing, folding, gluing, and squaring are achieved to meet job requirements.
Rangefaults may include – skewing, fishtailing, failure of board to fold at crease lines, failure to achieve continuous and unbroken glue application, excessive glue squeezed out, glue applied out of position, ragged slots, liner slit at creases, slots and creases more than 1mm from specified position, alignment of creases to slots exceeding 0.5mm.
4.12Bonding of product is achieved to meet job requirements.
Rangebonding problems may include – failure to bond from inadequate compression, or the occurrence of flat crush from excessive compression.
4.13Load format and load identification are carried out.
Rangeload format may include – specific requirements for counts, bundling, strapping, unitising, palletising.
4.14Documentation is completed.
Rangemay include but is not limited to – internal fault error sheets, time sheets, record of waste, production order data, quality control data, machine fault reports, feed stock sheets, maintenance sheets, load identification, provision of product sample(s), final count confirmation, information required for the next time the job is run.
Outcome 5
Follow safety requirements for the machine being used.
Rangeoperating manual, workplace practices.
Evidence requirements
5.1Machine start up, shutdown and emergency procedures in the workplace are explained.
5.2Hazard control measures, as circulated by the company, are described and followed.
5.3Hazards or potential hazards in the workplace are identified and reported in accordance with workplace practices.
Replacement information / This unit standard, unit standard 3682, unit standard 10146, unit standard 10147, unit standard 10157, unit standard 10158, unit standard 10159, and unit standard 18245 have been replaced by unit standard 27799.This unit standard is expiring. Assessment against the standard must take place by the last date for assessment set out below.
Status information and last date for assessment for superseded versions
Process / Version / Date / Last Date for AssessmentRegistration / 1 / 18 February 1998 / 31 December 2015
Revision / 2 / 27 March 2001 / 31 December 2015
Review / 3 / 27 April 2005 / 31 December 2015
Rollover / 4 / 12 December 2008 / 31 December 2015
Review / 5 / 20 September 2012 / 31 December 2019
Rollover / 6 / 10 December 2015 / 31 December 2019
Consent and Moderation Requirements (CMR) reference / 0005
This CMR can be accessed at
Please note
Providers must be granted consent to assess against standards (accredited) by NZQA, before they can report credits from assessment against unit standards or deliver courses of study leading to that assessment.
Industry Training Organisations must be granted consent to assess against standards by NZQA before they can register credits from assessment against unit standards.
Providers and Industry Training Organisations, which have been granted consent and which are assessing against unit standards must engage with the moderation system that applies to those standards.
Requirements for consent to assess and an outline of the moderation system that applies to this standard are outlined in the Consent and Moderation Requirements (CMR). The CMR also includes useful information about special requirements for organisations wishing to develop education and training programmes, such as minimum qualifications for tutors and assessors, and special resource requirements.
CompetenzSSB Code 101571 / New Zealand Qualifications Authority 2018 / / New Zealand Qualifications Aut