Level 3 Certificate in Printing and Graphic Communications (5261)

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1 Level 3 Certificate in Printing and Graphic Communications (5261) Scheme handbook

2 Publications and enquiries City & Guilds publications are available from Publications Sales City & Guilds 1 Giltspur Street London EC1A 9DD T +44 (0) F +44 (0) General information about City & Guilds is available on our website or may be obtained from Customer Relations at the above address, or by telephoning ,or by ing Equal opportunities City & Guilds fully supports the principle of equal opportunities and we are committed to satisfying this principle in all our activities and published material. A copy of our Equal Opportunities Policy statement Access to assessment is available on our website or from Customer Relations. Every effort has been made to ensure that the information contained in this publication is true and correct at the time of going to press. However, City & Guilds products and services are subject to continuous development and improvement and the right is reserved to change products and services from time to time. City & Guilds cannot accept liability for loss or damage arising from the use of information in this publication The City and Guilds of London Institute. All rights reserved. City & Guilds is a trademark of the City and Guilds of London Institute. 1 Giltspur Street London EC1A 9DD T +44 (0) F +44 (0)

3 Level 3 Certificate in Printing and Graphic Communications (5261) Scheme handbook September 2003 ST81453/09.03/F

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5 Contents page Introduction 5 General information and structure of award 8 Assessment and quality assurance 8 Modern apprenticeships and technical certificates 9 Course design 10 Centre and scheme approval 10 Summary of requirements 12 Registration and certification 13 Test specification(s) 14 Relationship to NVQ units 55 Key Skills signposting 66 Opportunities for Health and Safety, Spiritual, Environmental, 67 European Developments Units: Unit 301 Working in the printing and graphic communications industry 68 Unit 302 Productivity and quality assurance in desktop publishing 86 (DTP) and pre-press Unit 303 Productivity, quality assurance and maintenance in machine 95 printing and print finishing Unit 304 Digital pre-press processes 108 Unit 305 Desktop publishing (DTP) 120 Unit 306 Machine printing (Sheet fed lithography) 136 Unit 307 Machine printing (Web fed lithography) 154 Unit 308 Machine printing (Flexography) 172 Unit 309 Machine printing (Gravure) 190 Unit 310 Machine printing (Screen) 208 Unit 311 Mechanised print finishing and binding 224 Unit 312 Carton manufacturing processes 236 Unit 313 ICT for print administration 248 Unit 314 Estimating and costing 254 Unit 315 Production planning and control 263 Unit 316 Service customer accounts 273 3

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7 Level 3 Certificate in Printing and Graphic Communications ( ) Introduction This award is aimed at candidates who wish for career progression within the sector require evidence towards the underpinning knowledge of the N/SVQ are looking for progression into City & Guilds Level 3 NVQ Printing (5157) do not have access to an N/SVQ The award is suitable for school leavers or for adults looking for a change in career. This award is designed to contribute towards the knowledge and understanding for the N/SVQ(s) in Printing (City & Guilds scheme number 5157), while containing additional skills and knowledge which go beyond the scope of the National Occupational Standards. It provides a valuable alternative for those candidates who do not have access to the N/SVQ. Vocationally Related Qualifications are available in a range of vocational areas, please contact Customer Services Enquiry unit at City & Guilds for further information. This qualification provides progression for candidates who have the level 2 Certificate in Printing and Graphic Communications. The 5261 level 3 Certificate in Printing and Graphic Communications is recognised as a Technical Certificate for the Advanced Modern Apprenticeship in Print and Print Packaging. There is one common mandatory unit for each pathway: Common mandatory unit 301 Working in the printing and graphic communications industry The six distinct pathways within this award are as follows: Pre-press pathway 302 Productivity and quality assurance in desktop publishing (DTP) and pre-press 304 Digital pre-press processes Desktop Publishing pathway 302 Productivity and quality assurance in desktop publishing (DTP) and pre-press 305 Desktop Publishing (DTP) Machine Printing pathway 303 Productivity, quality assurance and maintenance in machine printing and print finishing plus one from 306 Machine printing (Sheet fed lithography) 307 Machine printing (Web fed lithography) 5

8 308 Machine printing (Flexography) 309 Machine printing (Gravure) 310 Machine printing (Screen) Mechanised Print Finishing and Binding pathway 303 Productivity, quality assurance and maintenance in machine printing and print finishing 311 Mechanised print finishing and binding Carton Manufacture pathway 303 Productivity, quality assurance and maintenance in machine printing and print finishing 312 Carton manufacturing processes Print Administration pathway 313 ICT for print administration 314 Estimating and costing plus one from 315 Production planning and control 316 Service customer accounts 6

9 Pre-press Desktop Publishing Machine Printing Mechanised Print Finishing and Binding Carton Manufacture Print Administration Common Mandatory Unit 301 Working in the printing and graphic communications industry Pathway Units 302 Productivity and quality assurance in desktop publishing (DTP) and pre-press 303 Productivity, quality assurance and maintenance in Plus one from: 306 Machine printing (Sheet fed lithography) machine printing and print finishing 313 ICT for print administration 314 Estimating and costing Plus one from: 304 Digital pre-press processes 305 Desktop publishing (DTP) 307 Machine printing (Web fed lithography) 308 Machine printing 311 Mechanised print finishing and binding 312 Carton manufacturing processes 315 Production planning and control (Flexography) Machine printing Service customer (Gravure) accounts 310 Machine printing (Screen) 7

10 General information These vocationally related awards have been designed by City & Guilds to support government initiatives towards the National Qualifications Framework. They can contribute towards the knowledge and understanding required for the related N/SVQ while not requiring or proving evidence of occupational competence. General structure The awards are made up of units expressed in a standard format. Each unit is preceded by details of the structure of the unit the aims and general coverage of the unit the relationship of the unit to the appropriate N/SVQ/ National Occupational Standards the outcomes the assessment methods signposting of opportunities to generate evidence for Key Skills. Assessment and quality assurance National standards and rigorous quality assurance are maintained by the use of City & Guilds set and marked written short answer tests for the core unit, and City and Guild set and centre marked externally verified tests for the pathway units. A short answer test which assesses knowledge and understanding will be set by City & Guilds for each unit. The short answer test for the common mandatory unit will be externally marked by City & Guilds. The short answer tests for the pathway units will be marked locally by centres according to criteria set by City & Guilds. All tests will be grades as pass or fail. For candidates with particular requirements, centres should refer to City & Guilds policy document Access to assessment, candidates with particular requirements. External verifiers act on behalf of City & Guilds to ensure that national standards are maintained. Full details of their role can be found in Providing City & Guilds Qualifications a guide to centre and scheme approval. Health and safety The requirements to follow safe working practices is an integral part of all City and Guilds qualifications and assessments, and it is the responsibility of centres to ensure that all relevant health and safety requirement s are in place. 8

11 Modern apprenticeships and technical certificates Modern Apprenticeships are a mixture of work-based training and education. There are two types of Modern Apprenticeship, Foundation and Advanced. The different levels of attainment between the Foundation and Advanced Modern Apprenticeships are reflected by the competencies required and qualifications gained. The revised Modern Apprenticeships are a mixture of work-based training and education, which include the following basic elements: a National Vocational Qualification (NVQ) Key Skills, e.g. communication and application of number a technical certificate other mandatory or optional elements as specified by the particular occupation. Technical certificates are qualifications testing specific occupational knowledge. They are delivered through a taught programme of off-the-job training, unlike NVQs, which are delivered through on-the-job training. This 5261 Level 3 Certificate in Printing and Graphic Communications is recognised as a Technical Certificate for Advanced Modern Apprenticeship in Print and Print Packaging. 9

12 Course Design Tutors should familiarise themselves with the structure and content of the award before designing an appropriate course; in particular they are advised to consider the knowledge and understanding requirements of the relevant N/SVQ. City & Guilds does not itself provide courses of instruction or specify entry requirements. As long as the requirements for the award are met, tutors may design courses of study in any way that they feel best meets the needs and capabilities of the candidates. It is recommended that centres cover the following in the delivery of the course, where appropriate: Key Skills (such as Communication, Application of number, Information technology, Working with others, Improving own learning and performance, Problem solving) Health and safety considerations, in particular the need to impress to candidates that they must preserve the health and safety of others as well as themselves Spiritual, moral, social and cultural issues Environmental education European dimension. Guided learning hours are an estimate of the amount of time needed to complete this qualification. It includes direct teaching, assessment and directed or supported study. It is recommended that 300 guided learning hours should be allocated for the Level 3 qualification. No specific prior qualifications, learning or experience are required for candidates undertaking the qualification. However, due to the technical nature and level of these qualifications it is recommended that candidates should have an interest in the printing and graphic communications sector. The nature of both the learning and assessment required for the qualification is such that candidates will need basic literacy and numeracy skills: i.e. the ability to read and interpret written tasks and to write answers in a legible and understandable form. Candidates will also need to be able to organise written information clearly and coherently, although they will not be assessed for spelling or grammatical accuracy unless this is part of the assessment criteria. Centres will need to make an initial assessment of each candidate and decide on the most appropriate level of qualification. Centre and scheme approval Centres wishing to offer City & Guilds qualifications must gain approval. New centres must apply for centre and scheme approval. Existing City & Guilds centres will need to get specific scheme approval to run this award. 10

13 Full details of the process for both centre and scheme approval are given in Providing City & Guilds Qualifications a guide to centre and scheme approval, which is available from City & Guilds' regional offices. City & Guilds reserves the right to suspend an approved centre, or withdraw its approval from an approved centre, to conduct a particular City & Guilds scheme or particular City & Guilds schemes, for reasons of debt, malpractice or for any reason that may be detrimental to the maintenance of authentic, reliable and valid qualifications or that may prejudice the name of City & Guilds. 11

14 Summary of requirements General structure 5621 Level 3 Certificate in Printing and Graphic Communications For the Level 3 Award in Printing and Graphic Communications the units are: Common mandatory unit 301 Working in the printing and graphic communications industry The five distinct pathways within this award are as follows: Pre-press pathway 302 Productivity and quality assurance in desktop publishing (DTP) and pre-press 304 Digital pre-press processes Desktop Publishing pathway 302 Productivity and quality assurance in desktop publishing (DTP) and pre-press 305 Desktop publishing (DTP) Machine Printing pathway 303 Productivity, quality assurance and maintenance in machine printing and print finishing plus one from 306 Machine printing (Sheet fed lithography) 307 Machine printing (Web fed lithography) 308 Machine printing (Flexography) 309 Machine printing (Gravure) 310 Machine printing (Screen) Mechanised Print Finishing and Binding pathway 303 Productivity, quality assurance and maintenance in machine printing and print finishing 311 Mechanised print finishing and binding Carton Manufacture pathway 303 Productivity, quality assurance and maintenance in machine printing and print finishing 312 Carton manufacturing processes Print Administration pathway 313 ICT for print administration 314 Estimating and costing plus one from 315 Production planning and control 316 Service customer accounts 12

15 Registration and certification For the award of a certificate, candidates must successfully complete the written test for the common mandatory unit and the units of their chosen pathway. Units Assessment components required Unit 301 Working in the printing and graphic communications industry Written test (short answer) Unit 302 Productivity and quality assurance in desktop publishing (DTP) and pre-press Written test (short answer) Unit 303 Productivity, quality assurance and maintenance in machine printing and print Written test (short answer) finishing Unit 304 Digital pre-press processes Written test (short answer) Unit 305 Desktop publishing (DTP) Written test (short answer) Unit 306 Machine printing (Sheet fed lithography) Written test (short answer) Unit 307 Machine printing (Web fed lithography) Written test (short answer) Unit 308 Machine printing (Flexography) Written test (short answer) Unit 309 Machine printing (Gravure) Written test (short answer) Unit 310 Machine printing (Screen) Written test (short answer) Unit 311 Mechanised print finishing and binding Written test (short answer) Unit 312 Carton manufacturing processes Written test (short answer) Unit 313 ICT for print administration Written test (short answer) Unit 314 Estimating and costing Written test (short answer) Unit 315 Production planning and control Written test (short answer) Unit 316 Service customer accounts Written test (short answer) Candidates must be registered at the beginning of their course. Centres should submit registrations using Form S (Registration), under scheme/complex no When locally marked short answer tests have been successfully completed, candidate results should be submitted on Form S (Results submission). Centres should note that results will NOT be processed by City & Guilds until verification records are complete. 13

16 The written core test is available three times each year during February, May and November. Candidates must be entered for written (timetabled) assessment components using Form S (and examination month entered in the 'dated entry' box). Candidates achieving one or more assessment components will receive a Certificate of Unit Credit listing the assessment components achieved together with the appropriate grade. Candidates achieving the number and combination of assessment components required for the Certificate will, in addition, be issued a Certificate. Full details on all the above procedures, together with dates and times of written tests will be found in the Directory of Vocational Awards published annually by City & Guilds. This information also appears on City & Guilds Web site 14

17 Printing and Graphic Communications Level 3 Title: Unit 301 Working in the Printing and Graphic Communications Industry. Assignment type - Written (short answer) Test duration 2 hours Total number of questions: 25 Outcome Describe the responsibility of an employee for 1 health and safety under the Health and Safety at Work Act Describe the health and safety risks 2 associated with equipment and processes in the workplace. Describe the use of safety clothing, footwear 3 and equipment in the workplace. Describe how to create and maintain effective 4 working relationships. Identify the principles of personal 5 development, planning and training. Describe the principles and techniques of 6 communicating with others. 7 Identify the printing processes and their common applications. 8 Describe the stages in the printing process from pre-press to finished printed product. 9 Identify types of representative organisations and other associations. 10 Describe the key job functions within the printing and graphic communications industry and their main purposes. 11 Identify legal issues concerning employment and working in the printing and graphic communications industry. No of Questions No of Marks %

18 Printing and Graphic Communications Level 3 Title: Unit 302 Productivity and Quality Assurance in Desktop Publishing (DTP) and Pre-Press Assignment type - Written (short answer) Test duration 1 hour 45 minutes Total number of questions: Outcome Identify the issues which affect profitable production and productivity, and the reasons why these are important in the graphic communications industry. Identify the main features of quality assurance and quality control systems. Identify the activities and processes within DTP and pre-press areas and plan the workflow. Identify the administrative control procedures in DTP and pre-press areas. Describe the different methods of producing proofs and the strengths and weaknesses of each. Describe the methods used to archive DTP and pre-press work. No of Questions No of Marks %

19 Printing and Graphic Communications Level 3 Title: Unit 303 Productivity, Quality Assurance and Maintenance in Machine Printing and Print Finishing. Assignment type - Written (short answer) Test duration 1 hour 45mins Total number of questions: 20 Outcome Identify the issues which affect profitable 1 production and productivity, and the reasons why these are important in the printing and graphic communications industry. Identify the main features of quality assurance 2 and quality control systems. Identify the systems and documentation 3 usually used in the printing and graphic communications industry to organise and control production. Explain the roles and responsibilities for 4 cleaning, lubricating and preventative maintenance and for reporting and recording machine faults. Explain the principle activities involved with 5 machine cleaning, lubricating and component replacement as part of a preventative maintenance programme. Identify machine faults and how they can be 6 rectified. 7 Identify procedures for the safe use of chemicals and the disposal of waste. No of Questions No of Marks %

20 Printing and Graphic Communications Level 3 Title: Unit 304 Digital Pre-Press Processes Assignment type - Written (short answer) Test duration 1 hour 45 minutes Total number of questions: Outcome Describe the operation of hardware and software systems typically used in pre-press. Explain the systems and processes for converting originals into digital files. Explain the principles of layout and imposition including the use and placement of marks and control guides. Describe the principles for the production of the image carriers. Describe the principles for the production of digital proofs. Identify the procedures for pre-flighting and ripping files in digital pre-press. No of Questions No of Marks %

21 Printing and Graphic Communications Level 3 Title: Unit 305 Desktop Publishing (DTP) Assignment type - Written (short answer) Test Duration: 1 hour 45 minutes Total number of questions: 20 Explain the principles involved in planning and 1 designing DTP documents to meet customer requirements. Describe the operating of hardware and 2 software systems typically used in DTP. Describe the digital fonts, their attributes and 3 application in DTP. Describe the systems and processes for the 4 creation, editing and use of digital images in DTP documents. Explain the principle issues involved in 5 defining, viewing and outputting colour in DTP documents. Identify the principles of setting up and laying 6 out documents in DTP. 7 Describe the use of proofs during the design and production of DTP documents, and the pre-flighting and handover of approved documents for print or publishing. No of Questions No of Marks %

22 Printing and Graphic Communications Level 3 Title: Unit 306 Machine Printing (Sheet Fed Lithography) Assignment type - Written (short answer) Test duration 1 hour 45mins Total number of questions: 20 Outcome Identify the printed products associated with 1 the various printing processes and reasons for selecting one over another. Describe the types and characteristics of 2 paper and board. Identify the procedures for controlling the 3 inking, coatings drying systems commonly used in machine printing. Describe the properties, structures and 4 manufacture of the materials commonly used in machine printing. Identify the principal types of proof used and 5 their role in the printing process. Identify and explain the use of 6 microprocessors and computers commonly found in machine printing. 7 Describe the make-ready and operating procedures for sheet fed lithography. 8 Identify the procedures for controlling quality in machine printing including sampling and inspection regimes. No of Questions No of Marks %

23 Printing and Graphic Communications Level 3 Title: Unit 307 Machine Printing (Web Fed Lithography) Assignment type - Written (short answer) Test duration 1 hour 45 minutes Total number of questions: 20 Outcome Identify the printed products associated with 1 the various printing processes and reasons for selecting one over another. Describe the types and characteristics of 2 paper and board. Identify the procedures for controlling the 3 inking, coatings and drying systems commonly used in machine printing. Describe the properties, structures and 4 manufacture of the materials commonly used in machine printing Identify the principal types of proof used and 5 their role in the printing process. Identify and explain the use of 6 microprocessors and computers commonly found in machine printing. 7 Describe the make-ready and operating procedures for web fed lithography. 8 Identify the procedures for controlling quality in machine printing including sampling and inspection regimes. No of Questions No of Marks %

24 Printing and Graphic Communications Level 3 Title: Unit 308 Machine Printing (Flexography) Assignment type - Written (short answer) Test duration 1 hour 45 minutes Total number of questions: 20 Outcome Identify the printing products associated with 1 the various printing processes and reasons for selecting one over another. Describe the types and characteristics of 2 paper, board filmic and other plastic materials. Identify the procedures for controlling the 3 inking, coatings drying systems commonly used in machine printing. Describe the properties, structures and 4 manufacture of the materials commonly used in machine printing. Identify the principle types of proof used and 5 their role in the printing process. Identify and explain the use of 6 microprocessors and computers commonly found in machine printing. 7 Describe the make-ready and operating procedures for flexography. 8 Identify the procedures for controlling quality in machine printing including sampling and inspection regimes. No of Questions No of Marks %

25 Printing and Graphic Communications Level 3 Title: Unit 309 Machine Printing (Gravure) Assignment type - Written (short answer) Test duration 1 hour 45 minutes Total number of questions: 20 Outcome Identify the printed products associated with 1 the various printing processes and reasons for selecting one over another. Describe the types and characteristics of 2 paper and board. Identify the procedures for controlling the 3 inking, coatings drying systems commonly used in machine printing. Describe the properties, structures and 4 manufacture of the materials commonly used in machine printing. Identify the principle types of proof used and 5 their role in the printing process. Identify and explain the use of 6 microprocessors and computers commonly found in machine printing. 7 Describe the make-ready and operating procedures for gravure. 8 Identify the procedures for controlling quality in machine printing including sampling and inspection regimes. No of Questions No of Marks %

26 Printing and Graphic Communications Level 3 Title: Unit 310 Machine Printing (Screen). Assignment type - Written (short answer) Test duration 1 hour 45 minutes. Total number of questions: 20 Outcome Identify the printed products associated with 1 the various printing processes and reasons for selecting one over another. Describe and evaluate the types and 2 characteristics of substrates used in screen printing. Identify the key parameters of the screen 3 printing process including inks, coatings and drying systems. Explain physical, chemical and behavioural 4 properties of materials and the theory of colour. Identify the principal types of proof used and 5 their role in the printing process. Identify and explain the use of 6 microprocessors and computers commonly found in machine printing. 7 Describe and evaluate the make-ready and operating procedures for screen printing. 8 Identify the procedures for controlling quality in machine printing, including sampling and inspection regimes. No of Questions No of Marks %

27 Printing and Graphic Communications Level 3 Title: Unit 311 Mechanised Print Finishing and Binding. Assignment type - Written (short answer) Test duration 1 hour 45 minutes. Total number of questions: Outcome Describe and identify the terminology for imposition and folding schemes used in print finishing, converting and bookbinding. Describe and evaluate the types and characteristics of paper and board. Identify the properties and characteristics of materials used in finishing and binding operations. Describe and evaluate the make-ready and operating procedures for a range of print finishing equipment. Explain the purpose and procedures for quality control in mechanised print finishing and binding. Describe the procedures to control damage to materials during finishing and binding operations. No of Questions No of Marks %

28 Printing and Graphic Communications Level 3 Title: Unit 312 Carton Manufacturing Processes. Assignment type - Written (short answer) Test duration 1 hour 45 minutes. Total number of questions: 20 Outcome Identify the materials and equipment used in 1 carton manufacturing processes. Identify the principles, methods and 2 techniques of carton design and manufacturing processes. Describe the technological changes in design 3 and manufacture of cartons as a form of packaging. Describe the make-ready and operational 4 procedures for cutting and creasing machinery, multi-folding and gluing machinery, and enhancing machinery. Describe the manufacturing procedures of die 5 making and cutting, and creasing forms. Describe the purpose and principles of 6 machine stripping. 7 Describe the purpose of and procedures for quality control in carton manufacturing processes. No of Questions No of Marks %

29 Printing and Graphic Communications Level 3 Title: Unit 313 ICT for Print Administration. Assignment type - Written (short answer) Test duration 1 hour 15 minutes. Total number of questions: Outcome No of No of % Questions Marks Describe the principles of ICT Describe the use of spreadsheets in print administration. Describe the use of databases in print administration. Describe the use of reports and presenting information. Describe the use of electronic communications in print administration

30 Printing and Graphic Communications Level 3 Title: Unit 314 Estimating and Costing. Assignment type - Written (short answer) Test duration 1 hour 15 minutes. Total number of questions: Outcome Explain how estimates are made u, how direct and indirect costs are provided for within the estimate, and how a selling price is determined. Explain why different methods of producing a job will affect the cost of production and how estimating software contributes to the process of accurate estimating and process optimisation. Describe estimated and actual costs of production. State the procedures for producing invoices and dealing with queries. No of Questions No of Marks %

31 Printing and Graphic Communications Level 3 Title: Unit 315 Production Planning and Control Assignment type - Written (short answer) Test duration 1 hour 15 minutes. Total number of questions: 15 1 Outcome No of No of % Questions Marks Identify the requirements for production Identify the procedures for preparing production schedules. Identify the procedures for organising and monitoring production

32 Printing and Graphic Communications Level 3 Title: Unit 316 Service Customer Accounts. Assignment type - Written (short answer) Test duration 1 hour 15 minutes. Total number of questions: Outcome Identify the methods of promoting company products and services. Identify the methods of contacting customers and handling their different needs. Describe the procedures for handling customer complaints and ways of improving customer service. No of Questions No of Marks %

33 Relationship to NVQ units Level 3 Printing and Graphic Communications Industry Unit Outcome This award contributes towards the knowledge and understanding of the following elements of the NVQ in Printing (5157) 301 Working in the Printing and Graphic Communications Industry 1. describe the responsibility of an employee for health and safety under the Health and Safety at Work Act describe the health and safety risks associated with equipment and processes in the workplace 3. describe the use of safety clothing, footwear and equipment in the workplace 4. describe how to create and maintain effective working relationships 5. identify the principles of personal development planning and training 6. describe the principles and techniques of communicating with others 7. identify the printing processes and their common applications Level / / / / describe the stages in the printing process from pre-press to finished printed product 9. identify types of representative organisations and other associations 10. describe the key job functions within the printing and graphic communications industry and their main purposes No specific reference identify legal issues concerning employment and working in the printing and graphic communications industry. 31

34 302 Productivity and Quality Assurance in Desktop Publishing (DTP) and Pre-Press 1. identify the issues which affect profitable production and productivity, and the reasons why these are important in the printing and graphic communications industry 2. identify the main features of quality assurance and quality control systems 3. identify the activities and processes within DTP and pre-press areas and plan the workflow B1.1 / B1.2 / / IT1 / 305 IT3 / / / / / / / / / / / / / identify the administrative control procedures in DTP and pre-press areas / / / 34D.1 5. describe the different methods of producing proofs and the strengths and weaknesses of each 6. to describe the methods used archive DTP and pre-press work. 312 IT.2 / 312 IT.3 / / / / IT.1 / 212 IT.3 / 305 IT.4 / 312 IT.3 / / Productivity and Quality Assurance in Desktop Publishing (DTP) and Pre-Press 1. identify the issues which affect profitable production and productivity, and the reasons why these are important in the printing and graphic communications industry 2. identify the main features of quality assurance and quality control systems 3. identify the systems and documentation usually used in the printing and graphic communications industry to organise and control production 4. explain the roles and responsibilities for cleaning, lubrication and preventative maintenance and for reporting and recording machine faults 5. explain the principal activities involved with machine cleaning, lubricating and component replacement as part of a preventative maintenance programme 6. identify machine faults and how they can be rectified 7. identify procedures for the safe use of chemicals and the disposal of waste 32 B1.1 / B1.2 / / B1.2 / / / / 316 / 317 / 318 / 319 / 320 / 321 / 322 / 323 / 324 / 325 / 326 / 327 / / B1.1 / B1.2 / / / /

35 304 Digital Pre- Press Processes 1. describe the operation of hardware and software systems typically used in pre-press 2. explain the systems and processes for converting originals into digital files 3. explain the principles of layout and imposition including the use and placement of marks and control guides 4. describe the principles for the production of the image carriers 5. describe the principles for the production of digital proofs 6. identify the procedures for pre-flighting and ripping files in digital pre-press / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / Desktop Publishing (DTP) 1. explain the principles involved in planning and designing DTP documents to meet customer requirements 2. describe the operation of hardware and software systems typically used in DTP 3. describe digital fonts, their attributes and application in DTP 4. explain the systems and processes for the creation, editing and use of digital images in DTP documents 5. explain the principle issues involved in defining, viewing and outputting colour in DTP documents 6. identify the principles of setting up and laying out documents in DTP 7. describe the use of proofs during the design and production of DTP documents, and the pre-flighting and handover of approved documents for print or publishing. 305 IT.1 / 305 IT.2 / / / / / / IT.2 / / / 312 IT.1 / 312 IT.2 / 312 IT.3 / / / / / / IT.3 / 305 IT.4 / / IT.1 / 312 IT.1 / D.2 / 312 IT.2 / 312 IT.3 / /

36 306 Machine Printing (Sheet Fed Lithography) 1. identify the printed products associated with the various printing processes and reasons for selecting one over another 2. describe the types and characteristics of paper and board 3. identify the procedures for controlling the inking, coatings drying systems commonly used in machine printing 4. describe the properties, structures and manufacture of the materials commonly used in machine printing 5. identify the principal types of proof used and their role in the printing process 6. identify and explain the use of microprocessors and computers commonly found in machine printing 7. describe the make-ready and operating procedures for sheet fed lithography 8. identify the procedures for controlling quality in machine printing including sampling and inspection regimes / / / / / / / / / / / no specific reference / / / / / / / /

37 307 Machine Printing (Web Fed Lithography) 1. identify the printed products associated with the various printing processes and reasons for selecting one over another 2. describe the types and characteristics of paper and board 3. identify the procedures for controlling the inking, coatings drying systems commonly used in machine printing 4. describe the properties, structures and manufacture of the materials commonly used in machine printing 5. identify the principal types of proof used and their role in the printing process 6. identify and explain the use of microprocessors and computers commonly found in machine printing 7. describe the make-ready and operating procedures for web fed lithography 8. identify the procedures for controlling quality in machine printing including sampling and inspection regimes No specific reference / / / / / no specific reference / / / / / / / / / / / 234.1/ / / / / / / / /

38 308 Machine Printing (Flexography) 1. identify the printed products associated with the various printing processes and reasons for selecting one over another 2. describe the types and characteristics of paper and board 3. identify the procedures for controlling the inking, coatings drying systems commonly used in machine printing 4. describe the properties, structures and manufacture of the materials commonly used in machine printing 5. identify the principal types of proof used and their role in the printing process 6. identify and explain the use of microprocessors and computers commonly found in machine printing 7. describe the make-ready and operating procedures for flexography 8. identify the procedures for controlling quality in machine printing including sampling and inspection regimes / / / / / / / / / / / / / / /

39 309 Machine Printing (Gravure) 1. identify the printed products associated with the various printing processes and reasons for selecting one over another 2. describe the types and characteristics of paper and board 3. identify the procedures for controlling the inking, coatings drying systems commonly used in machine printing 4. describe the properties, structures and manufacture of the materials commonly used in machine printing 5. identify the principal types of proof used and their role in the printing process 6. identify and explain the use of microprocessors and computers commonly found in machine printing 7. describe the make-ready and operating procedures for gravure 8. identify the procedures for controlling quality in machine printing including sampling and inspection regimes / / / / / / no specific reference / / / / / / / /

40 310 Machine Printing (Screen) 1. identify the printed products associated with the various printing processes and reasons for selecting one over another 2. understand and evaluate the types and characteristics of substrates used screen printing 3. identify the key parameters of the screen printing process including inks, coatings and drying systems 4. understand physical, chemical and behavioural properties of materials; and the theory of colour. 5. identify the principle types of proofs used and their role in the printing process 6. identify and understand the use of microprocessors and computers commonly found in machine printing 7. understand and evaluate the make-ready and operating procedures for screen printing 8. identify the procedures for controlling quality in machine printing including sampling and inspection regimes / / / / 231.1/ / / / / / / / / / / / / /

41 311 Mechanised Print Finishing and Binding 1. describe and understand identify the terminology, imposition and folding schemes used in print finishing, converting and bookbinding 2. understand and evaluate the types and characteristics of paper and board 3. identify the properties and characteristics of materials used in finishing and binding operations / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / understand and evaluate the make-ready and operating procedures for a range of print finishing equipment 5. define the purpose and procedures for quality control in mechanised print finishing and binding 6. understand the procedures to control damage to materials during finishing and binding operations / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / no specific reference 39

42 312 Carton Manufacturing Processes 1. identify the materials and equipment used in carton manufacturing processes 2. identify the principles, methods and techniques of carton design and manufacturing processes 3. describe the technological changes in design and manufacture of cartons as a form of packaging 4. describe the make ready and operational procedures for cutting and creasing machinery, multi-folding and gluing machinery, and enhancing machinery 5. describe the manufacturing procedures of die making and cutting and creasing formes 6. describe the purpose and principles of machine stripping 7. describe the purpose and procedures for quality control in carton manufacturing processes / / / / / / / / / / / / / / no specific reference / no specific reference no specific reference / / / / / / / ICT for Print Administration 1. describe the principles of ICT 2. use spreadsheets in print administration 3. use databases in print administration 4. produce reports and present information / / / / / / / / / / / / / / / / use electronic communications in print administration / / / / / / / / / / / / / / / /

43 314 Estimating and Costing 1. explain how estimates are made up, how direct and indirect costs are provided for within the estimate, and how a selling price is determined 2. explain why different methods of producing a job will affect the cost of production and how estimating software contributes to the process of accurate estimating and process optimisation 3. describe estimated and actual costs of production 4. state the procedures for producing invoices and dealing with queries / / / B1.1 / B1.2 / / / / Production Planning and Control 316 Service Customer Accounts 1. identify the requirements for production 2. identify the procedures for preparing production schedules 3. identify the procedures for organising and monitoring production 1. identify the methods of promoting company products and services 2. identify the methods of contacting customers and handling their different needs 3. describe the procedures for handling customer complaints and ways of improving customer service / / / B1.1 / / / / / / / / / / / / / / / / / / /

44 Key Skills Signposting Level 3 Unit No and Title Communication Application Of Number Information Technology Working With others Improving own learning and performance Problem solving ,1.3, 2.2, , 1.2, 1.3, , 1.3, , 1.2, 1.3, , 1.2, , , 1.2, , , 1.2, 1.3, ,1.3, 2.2, , 1.2, , 2.1, , 01.2, , , 1.2, , , 1.2, 1.3, , , , , , , , , , , , 1.2, 1.3, 2.1, , 1.2, 1.3, 2.1, 2.2, , 01.2, , 1.2, , , , 1.2, , , , 1.3, 2.1b 1.1, 1.2, 1.3, 1.1, , 1.2, , ,

45 Health and safety, spiritual etc, environmental and European issues Level 3 The level 3 units provide opportunities to address the following issues as indicated: Units Spiritual, Moral Ethical, Social and Cultural Environmental Health and Safety European Development 301 YES YES YES YES 302 YES YES 303 YES YES YES 304 YES 305 YES 306 YES YES YES 307 YES YES YES 308 YES YES YES 309 YES YES YES 310 YES YES YES 311 YES YES YES 312 YES YES YES 313 YES 314 YES

46 Unit 301 Working in the printing and graphic communications industry Rationale This unit is concerned with developing an understanding of working in the printing and graphic communications industry, including health and safety, personal development, working relationships, an industry overview and the rights and responsibilities of employers and employees. Outcomes There are eleven outcomes to this unit. The candidate will be able to 1. describe the responsibility of an employee for health and safety under the Health and Safety at Work Act describe the health and safety risks associated with equipment and processes in the workplace 3. describe the use of safety clothing, footwear and equipment in the workplace 4. describe how to create and maintain effective working relationships 5. identify the principles of personal development planning and training 6. describe the principles and techniques of communicating with others 7. identify the printing processes and their common applications 8. describe the stages in the printing process from pre-press to finished printed product 9. identify types of representative organisations and other associations 10. describe the key job functions within the printing and graphic communications industry and their main purposes 11. identify legal issues concerning employment and working in the printing and graphic communications industry. Connection with other awards This unit contributes towards the knowledge and understanding required for units 001 and 002 of the Level 3 NVQ in Printing. Assessment This unit will be assessed by means of a short written answer test covering the eleven outcomes. 44

47 Outcome 1: Describe the responsibility of an employee for health and safety under the Health and Safety at Work Act 1974 Underpinning knowledge The candidate will be able to 1. state that the Health and Safety at Work Act 1974 was introduced to prevent injuries and accidents in the workplace 2. state that employees have legal duties that include: a) taking reasonable care for their own health and safety and that of others who may be affected by what they do or do not do b) co-operating with their employer on health and safety c) correctly using work items provided by their employer, including Personal Protective Equipment (PPE), in accordance with training or instructions d) not interfering with or misusing anything provided for health and safety 3. state that, in general, employer s duties include: a) making the workplace safe and without risks to health b) ensuring that plant and machinery are safe and that safe systems of work are set and followed c) ensuring articles and substances are moved, stored and used safely d) providing adequate welfare facilities e) giving employees the information, instruction, training and supervision necessary for their health and safety 4. describe the following regulations, and how they might apply to employees, appropriate to the printing and graphic communications industry: a) Control of Substances Hazardous to Health Regulations (COSHH) 1999 b) Health and Safety (Display Screen Equipment) Regulations 1992 c) Electricity at Work Regulations 1989 d) Fire Precautions (Workplace) 1999 e) Health and Safety (First-Aid) Regulations 1981 f) Workplace (Health, Safety and Welfare) Regulations 1992 g) Management of Health and Safety at Work Regulations 1999 h) Manual Handling Operations Regulations 1992 i) Noise at Work Regulation 1989 j) Personal Protective Equipment Regulations 1994 k) Provision and Use of Work Equipment Regulations 1998 l) Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR) 1995 m) Health and Safety (Safety Signs and Signals) Regulations 1996 n) Special Waste Regulations state that the under the Management of Health and Safety at Work Regulations 1999 a competent person in every company should have responsibility for health and safety (a competent person is regarded as a person who has sufficient training, experience or knowledge and other qualities to enable them to properly assist in undertaking these measures) 45

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