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SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED QUALIFICATION THAT HAS PASSED THE END DATE: 

National Certificate: Foundry Operations 
SAQA QUAL ID QUALIFICATION TITLE
66449  National Certificate: Foundry Operations 
ORIGINATOR
SGB Manufacturing and Assembly Processes 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY NQF SUB-FRAMEWORK
MERSETA - Manufacturing, Engineering and Related Services Education and Training Authority  OQSF - Occupational Qualifications Sub-framework 
QUALIFICATION TYPE FIELD SUBFIELD
National Certificate  Field 06 - Manufacturing, Engineering and Technology  Manufacturing and Assembly 
ABET BAND MINIMUM CREDITS PRE-2009 NQF LEVEL NQF LEVEL QUAL CLASS
Undefined  126  Level 3  NQF Level 03  Regular-Unit Stds Based 
REGISTRATION STATUS SAQA DECISION NUMBER REGISTRATION START DATE REGISTRATION END DATE
Passed the End Date -
Status was "Reregistered" 
SAQA 0695/12  2012-07-01  2013-11-07 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2014-11-07   2017-11-07  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This qualification is replaced by: 
Qual ID Qualification Title Pre-2009 NQF Level NQF Level Min Credits Replacement Status
91785  Occupational Certificate: Moulder  Not Applicable  NQF Level 04  364  Complete 
91877  Occupational Certificate: Melter  Not Applicable  NQF Level 04  361  Complete 

PURPOSE AND RATIONALE OF THE QUALIFICATION 
Purpose:

This qualification is designed to enhance the skills of learners operating within Foundry Operations, manufacturing either quality pattern equipment (wooden patternmaking and metal tooling), or sand composite moulds and cores by hand (floor moulding) or machine (machine moulding and coremaking) for consumption within a metal casting process, or producing the liquid metal (foundry melting) consumed by such metal casting processes.

This qualification gives recognition for the skills, knowledge and values acquired by learners involved with:
  • The inspection, repairs to and manufacture of three-dimensional wooden and metal pattern equipment required for the sand moulding process or;
  • The manufacture of sand composite moulds and cores or;
  • The preparation, use and operation of Foundry Melting equipment.

    The main skills learnt in this qualification are the ability to:
  • Manufacture and maintain three-dimensional regular shaped wooden and metal pattern equipment and recognise and respond to equipment defects. This capability requires an understanding of pattern equipment materials, associated engineering hand and power tools, quality requirements and the ability to draw and interpret detailed engineering drawings or;
  • Manufacture moulds and cores. This capability requires an elevated understanding of the associated pattern equipment, engineering hand and measuring tools, quality requirements and the ability to draw and interpret simple engineering drawings or;
  • Prepare, use and operate Foundry Melting equipment. This capability requires a foundational understanding of metallurgy associated with the foundry melting process.

    Practical skills play a large role in this qualification:

    On completion, the learner will receive recognition for the ability to:
  • Manufacture a product (pattern equipment or sand moulds and cores) or produce liquid metal that is consumed in downstream processes.
  • Check product against customer requirements, engineering drawings or quality standards.
  • Report on the quality of the manufactured product.
  • Take corrective action where required.
  • Solve associated problems.
  • Function in workplaces that utilise such Foundry Operations.

    Qualified learners will also understand:
  • Their role in the business, i.e. in production and related activities and how their actions affects the business.
  • How they are affected by legislation, regulations, agreements and policies related to their particular working environment.
  • How they should function and participate within the legislative, safety, health, environmental, quality and risk management systems that govern their workplace.
  • How to apply the various organisational policies and procedures.

    Qualifying in the exit level outcomes will enable learners to effectively perform a range of workplace activities. What learners achieve in this qualification will also serve as a basis for further learning within Foundry Patternmaking, Foundry Moulding or Foundry Melting processes. Learners will also have foundational competence in mathematics, science, reading, writing and speaking relevant to Foundry Operations.

    Rationale:

    The Foundry industry is a complex and specialised sector supplying a vast range of quality metal products to downstream customers. The emergence of South Africa as a cost-effective supplier to international markets has created a demand for people with the skills to manufacture the final products as well as function within the support processes to the manufacturing process. These processes include Foundry Patternmaking, Foundry Moulding and Foundry Melting.

    This is the second in a series of qualifications in Foundry Operations starting at NQF Level 2 and progressing to NQF Level 4. This series of qualifications will enable learners to:
  • Develop their existing skill level and progress vertically in a selected career path within the Foundry industry.
  • Receive recognition for experience gained in the workplace through an RPL process.
  • Obtain skills and knowledge portable within similar metal product manufacturing industries.
  • Gain access to higher levels of learning and learning provision.
  • Access opportunities to progress in their personal life and career, and add value to the operations in which they function.
  • Contribute to the growth of the South African economy and the development of society. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    It is assumed that learners have already completed the National Certificate: Foundry Operations, at NQF Level 2.

    If the learner does not already have such a qualification, learning in preparation for this qualification would also have to included:
  • Communication and Mathematical Literacy at NQF Level 2.
  • Basic concepts of science and technology related to material, machinery and equipment in use in foundry operation processes at NQF Level 2.
  • Basic concepts regarding organising factors in labour, business and the economy.
  • Purpose of procedures related to the workplace, governing:
    > Relationships.
    > Roles.
    > Responsibilities.

    Recognition of Prior Learning:

    This qualification may be obtained through a process of RPL. The learner should be thoroughly briefed prior to the assessment and support provided and guidance should be provided to assist in the process of developing a portfolio. While this is primarily a workplace-based qualification, evidence from other areas of endeavour may be introduced if pertinent to any of the exit-level outcomes.

    Care should be taken that the process used provides the learner with an opportunity to demonstrate competence and is not too demanding as to prevent learners from taking up the RPL option towards gaining a qualification.

    Access to the Qualification:

    Access is open bearing in mind learning assumed to be in place.

    Access for learners with physical disabilities is dependent:
  • On the type and severity of disability.
  • On the nature of the Foundry Operations environment and the inherent requirements of equipment operation. 

  • RECOGNISE PREVIOUS LEARNING? 

    QUALIFICATION RULES 
    This is a 126 credits certificate:
  • All listed unit standards in the Fundamental category of the qualification totalling 36 credits.
  • All listed unit standards in the Core category of the qualification totalling 17 credits.
  • A selection of specialisation unit standards in the Elective category of the qualification totalling 73 credits.

    Depending on their area of specialisation (Foundry Patternmaking, Foundry Moulding or Foundry Melting), learners may choose from the categories:

    Specialization Area 1: Wooden Patternmaking:
  • Unit standard ID 264076: Manufacture three dimensional regular shaped wooden pattern equipment; 40 credits; Level 3.
  • Unit standard ID 9914: Handle and care for materials; 12 credits; Level 3.
  • Unit standard ID 13297: Grind tools and drill bits; 4 credits; Level 3.
  • Unit standard ID 13298: Produce detailed engineering drawings; 6 credits; Level 3.
  • Plus a choice of unit standards from the Elective category of learning to the value of at least 11 credits.

    Specialization Area 2: Metal Tooling:
  • Unit standard ID 264154: Manufacture three dimensional regular shaped metal tooling; 40 credits; Level 3.
  • Unit standard ID 9914: Handle and care for materials; 12 credits; Level 3.
  • Unit standard ID 13297: Grind tools and drill bits; 4 credits; Level 3.
  • Unit standard ID 13298: Produce detailed engineering drawings; 6 credits; Level 3.
  • Plus a choice of unit standards from the Elective category of learning to the value of at least 11 credits.

    Specialization Area 3: Floor Moulding:
  • Unit standard ID 264096: Produce cores by hand; 16 credits; Level 3.
  • Unit standard ID 264016: Produce a mould using a loose pattern; 16 credits; Level 3.
  • Unit standard ID 9914: Handle and care for materials; 12 credits; Level 3.
  • Unit standard ID 12238: Draw and interpret simple engineering drawings; 10 credits; Level 2.
  • Plus a choice of unit standards from the Elective category of learning to the value of at least 19 credits.

    Specialization Area 4: Machine Moulding:
  • Unit standard ID 244338: Operate a production process; 15 credits; Level 2.
  • Unit standard ID 9914: Handle and care for materials; 12 credits; Level 3.
  • Unit standard ID 12238: Draw and interpret simple engineering drawings; 10 credits; Level 2.
  • Plus a choice of unit standards from the Elective category of learning to the value of at least; 36 credits.

    Specialization Area 5: Foundry Melting:
  • Unit standard ID 264038: Demonstrate understanding of chemical reactions in, and the solidification of, liquid metals; 6 credits; Level 3.
  • Unit standard ID 244338: Operate a production process; 15 credits; Level 2.
  • Unit standard ID 12768: Demonstrate knowledge of fundamental chemical and physical reactions; 8 credits; Level 3.
  • Unit standard ID 13974: Demonstrate an understanding of the refractory materials, products and processes; 5 credits; Level 6.
  • Plus a choice of unit standards from the Elective category of learning to the value of at least 39 credits. 

  • EXIT LEVEL OUTCOMES 
    1. Solve familiar problems related to foundry operations.

    2. Communicate with team members, internal customers and members of supervisory/management levels.

    A choice of the following Exit Level Outcomes depending on the chosen specialisation area:

    3. Interpret and produce detailed technical drawings or;

    4. Prepare and set up the Foundry Operations process or;

    5. Manufacture a range of complex pattern equipment or;

    6. Produce a range of complex moulds and cores or;

    7. Monitor and control the Foundry Melting process. 

    ASSOCIATED ASSESSMENT CRITERIA 
    Associated Assessment Criteria for Exit Level Outcome 1:

    1.1 Output and quality requirements are explained and applied in foundry operations.
    1.2 Solve problems in an efficient and effective manner according to procedures.
    1.3 Unfamiliar problems are accurately reported to appropriate personnel according to procedure.

    Associated Assessment Criteria for Exit Level Outcome 2:

    2.1 Relevant information is gathered from a range of sources and accurately summarised and reported in an appropriate and timely manner to relevant parties.
    2.2 Foundry Operation issues are discussed and resolved in work area on a regular basis with other team members, internal customers and supervisors/management.
    2.3 Relationships with peers and supervisory/management levels are established and maintained in accordance with organizational requirements.

    Associated Assessment Criteria for Exit Level Outcome 3:

    3.1 Required calculations are made and detailed drawings are produced to scale.
    3.2 Freehand sketches and pattern layouts are made from detailed engineering drawings.
    3.3 Components and assemblies to be manufactured are identified and their requirements are interpreted from detailed technical drawings.

    Associated Assessment Criteria for Exit Level Outcome 4:

    4.1 Appropriate materials or consumables, tools and instruments are used to make adjustments or changes to process equipment set up and tooling.
    4.2 Equipment specifications and manufacturing requirements are complied with set standards.
    4.3 Process equipment availability and readiness for manufacturing processes is maintained during operations.
    4.4 A clean and safe work area is maintained according to procedures.

    Associated Assessment Criteria for Exit Level Outcome 5:

    5.1 Acceptable materials, consumables, tools and equipment are used to achieve the expressed customer and quality requirements.
    5.2 Pattern equipment is manufactured according to equipment specifications and manufacturing requirements.
    5.3 Foundry Operations process and product is monitored according to product and customer requirements are met.
    5.4 Process is brought back into specification and indicators are responded to when deviations occur according to standard operating procedures.
    5.5 A clean and safe work area is maintained according to housekeeping procedures.

    Associated Assessment Criteria for Exit Level Outcome 6:

    6.1 Technical drawings are read, interpreted and drawn in accordance with the code of practice.
    6.2 Acceptable materials, consumables, tools and equipment are used to achieve the expressed customer and quality requirements.
    6.3 Moulds and cores produced according to equipment specifications and manufacturing requirements.
    6.4 Foundry Operations process and product is monitored in accordance with requirements.
    6.5 Product and customer requirements are met in accordance with organizational standards.
    6.6 Process is brought back into specification and indicators responded to when deviations occur.

    Associated Assessment Criteria for Exit Level Outcome 7:

    7.1 Acceptable materials, consumables, tools and equipment are used to achieve the expressed customer and quality requirements.
    7.2 Equipment specifications and manufacturing requirements are complied with at all times.
    7.3 Foundry Operations process and product is monitored according to standard operating procedures.
    7.4 Process is brought back into specification and indicators responded to when deviations occur according to procedures.
    7.5 A clean and safe work area is maintained at all times according to procedures.

    Integrated Assessment:

    Integrated assessment at the level of the qualification provides an opportunity for learners to show they are able to integrate concepts, actions and ideas achieved across a range of unit standards and contexts.

    Integrated assessment must evaluate the quality of observable performance as well as the thinking behind the performance, and must be based on a summative assessment guide. The guide will spell out how the assessor will assess different aspects of the performance and will include:
  • Observing the learner at work (both in the primary activity as well as other interactions).
  • Asking questions and initiating short discussions to test understanding.
  • Looking at records and reports in the portfolio and reviewing previous assessments.

    In some cases, inference will be necessary to determine competence depending on the nature and context within which performance takes place.

    Since this is a foundational qualification, it is necessary to ensure that the fundamental part of the qualification is also targeted to ensure that while the competence may have been achieved in a particular context, learners are able to apply it in a range of other contexts and for further learning. The assessment should also ensure that all the critical cross-field outcomes have been achieved.

    The learner may choose in which language she/he wants to be assessed. This should be established as part of a process of preparing the learner for assessment and familiarising the learner with the approach being taken.

    While this is primarily a workplace-based qualification, evidence from other areas of endeavour may be introduced if pertinent to any of the exit-level outcomes. The assessment process should cover both the explicit tasks required for the qualification as well as the understanding of the concepts and principles that underpin the activities associated with Foundry Operations. 

  • INTERNATIONAL COMPARABILITY 
    An extensive international search was conducted for evidence of comparable education and training systems. Countries included in the search were Australia, New Zealand, Britain, Scotland, Canada, North and South America, Sweden, Finland, Germany and SADC countries.

    Despite the fact that Foundry Operations are evident and well developed world-wide, relatively little sources of outcomes-based, standards-based and/or learning material could be found during the research. Indications are that operatives are trained on the job by skilled co-workers, supported by equipment and input material suppliers.

    Additional to this, subject matter experts party to the standards generation process contacted their international counterparts to establish what learning processes they have available. There is evidence of training material, although not aligned to any formal qualification framework.

    The only detailed information found, related to the New Zealand Qualifications Authority, where reference was found within the National Certificate Metal Casting (Technology) (Level 4), reference #0129. This qualification embraces both Engineering as well as Foundry (Patternmaking and Moulding) disciplines.

    Further to this, the New Zealand qualification does not specify the level of complexity that has to be achieved. The applied competence in the South African qualification focuses on achieving a specific level of competence required by a person working in a real-world Foundry Operations context in which a degree of specialisation, experience and problem-solving ability is required.

    Further comparison elements are highlighted below:

    Comparison Element, New Zealand Metal Casting qualifications & This Foundry Operations qualification suite:
  • Scope: Nominal competence in a wide range of mechanical engineering skills, Mastery of specific foundry moulding skills in context.
  • Approach: Task based, Skills development-based.
  • Level(s): Level 1, 2, 3 and 4, Level 2, 3 and 4.
  • Context: Partly contextualised, Contextual.
  • Assessment: Institution or work-based, Work-based and portfolio-based.
  • Essential embedded knowledge: Not clear, Specified.
  • Credits: 20, 124, 88 and 75 respectively, 120, 126 and 140 respectively.
  • Fundamental learning: Not formally specified, Specified.
  • Business relations: Not formally specified, Specified.
  • Working with and developing others: Not formally specified, Specified.
  • Life skills: Not formally specified, Specified.

    There are considerable similarities in the competencies required but the approach of the South African qualification looks at whole-person development in not only technological, but also in team and business-related skills and makes explicit assumptions related to level of schooling and life skills.

    It is evident that the technical content of this qualification for Foundry Operations places emphasis on safety, quality and best practice but is of better quality and greater value to learners when compared with that found during the research. 

  • ARTICULATION OPTIONS 
    This qualification allows for vertical articulation with:
  • ID 66489: FETC Foundry Operations (In process of registration), Level 4.

    And horizontal articulation with:
  • ID 22670: National Certificate: Construction Carpentry, Level 3.
  • ID 23280: National Certificate: Mechanical Engineering, Tooling Manufacture, Level 3.
  • ID 36155: National Certificate: Polymer Composite Fabrication, Level 3.
  • ID 58719: National Certificate: Metals Processing, Level 3.
  • ID 21009: National Certificate: Iron and Steel Manufacturing, Level 3.
  • ID 64190: National Certificate: Metals Production, Level 3. 

  • MODERATION OPTIONS 
  • Anyone assessing a learner or moderating the assessment of a learner against this Qualification must be registered as an assessor with the relevant ETQA.
  • Any institution offering learning that will enable the achievement of this Qualification must be accredited as a provider with the relevant ETQA.
  • Assessment and moderation of assessment will be overseen by the relevant ETQA according to the ETQA`s policies and guidelines.
  • A learner wishing to be assessed for this Qualification can only be assessed through an accredited assessment provider/centre. 

  • CRITERIA FOR THE REGISTRATION OF ASSESSORS 
    The following criteria should be applied by the relevant ETQA:
  • At least the NQF Level 4 Foundry Operations qualification with relevant workplace experience of at least 12 months in the field of Foundry Operations or equivalent. The subject matter experience of the assessor can be established by recognition of prior learning.
  • Registration as an assessor with the relevant ETQA.
  • Any other criteria required by the relevant ETQA. 

  • REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this qualification was Reregistered in 2012. 

    NOTES 
    This Qualification has been replaced by the following Qualifications:
  • ID 91877, "Occupational Certificate: Melter", Level 4, 361 Credits.
  • ID 91785, "Occupational Certificate: Moulder", Level 4, 364 Credits.

    .
    N/A 

  • UNIT STANDARDS: 
      ID UNIT STANDARD TITLE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
    Core  13234  Apply quality procedures  Level 3  NQF Level 03 
    Core  13223  Apply safety, health and environmental protection procedures  Level 3  NQF Level 03 
    Core  14048  Apply Self Management Concepts  Level 4  NQF Level 04 
    Fundamental  119472  Accommodate audience and context needs in oral/signed communication  Level 3  NQF Level 03 
    Fundamental  9010  Demonstrate an understanding of the use of different number bases and measurement units and an awareness of error in the context of relevant calculations  Level 3  NQF Level 03 
    Fundamental  9013  Describe, apply, analyse and calculate shape and motion in 2-and 3-dimensional space in different contexts  Level 3  NQF Level 03 
    Fundamental  119457  Interpret and use information from texts  Level 3  NQF Level 03 
    Fundamental  9012  Investigate life and work related problems using data and probabilities  Level 3  NQF Level 03 
    Fundamental  119467  Use language and communication in occupational learning programmes  Level 3  NQF Level 03 
    Fundamental  7456  Use mathematics to investigate and monitor the financial aspects of personal, business and national issues  Level 3  NQF Level 03 
    Fundamental  119465  Write/present/sign texts for a range of communicative contexts  Level 3  NQF Level 03 
    Elective  258939  Carry out basic electric arc welding in an electrical environment  Level 2  NQF Level 02 
    Elective  12238  Draw and interpret simple engineering drawings  Level 2  NQF Level 02  10 
    Elective  264135  Manufacture a resin pattern  Level 2  NQF Level 02  16 
    Elective  244338  Operate a production process  Level 2  NQF Level 02  15 
    Elective  258679  Operate and monitor a lathe  Level 2  NQF Level 02  12 
    Elective  258678  Operate and monitor a milling machine  Level 2  NQF Level 02  12 
    Elective  243014  Operate and monitor computerised numerically controlled (CNC) machining equipment  Level 2  NQF Level 02  16 
    Elective  242976  Operate overhead/gantry cranes  Level 2  NQF Level 02 
    Elective  264014  Set up a production machine  Level 2  NQF Level 02  16 
    Elective  117924  Use a Graphical User Interface (GUI)-based word processor to format documents  Level 2  NQF Level 02 
    Elective  243063  Weld carbon steel work-pieces using the shielded metal arc welding process in the down-hand position.  Level 2  NQF Level 02  15 
    Elective  264038  Demonstrate an understanding of chemical reactions in, and the solidification of, liquid metals  Level 3  NQF Level 03 
    Elective  13974  Demonstrate an understanding of the refractory materials, products and processes  Level 3  NQF Level 03 
    Elective  13915  Demonstrate knowledge and understanding of HIV/AIDS in a workplace, and its effects on a business sub-sector, own organisation and a specific workplace  Level 3  NQF Level 03 
    Elective  12768  Demonstrate knowledge of fundamental chemical and physical reactions  Level 3  NQF Level 03 
    Elective  12429  Develop a personal financial plan  Level 3  NQF Level 03 
    Elective  12457  Develop learning strategies and techniques  Level 3  NQF Level 03 
    Elective  12456  Explain and use organisational procedures  Level 3  NQF Level 03 
    Elective  13297  Grind tools and drill bits  Level 3  NQF Level 03 
    Elective  9914  Handle and care for materials  Level 3  NQF Level 03  12 
    Elective  242812  Induct a member into a team  Level 3  NQF Level 03 
    Elective  13975  Install and maintain castable/mouldable refractory materials  Level 3  NQF Level 03 
    Elective  13976  Install and maintain refractory brickwork/blockwork  Level 3  NQF Level 03  12 
    Elective  13977  Install gunite materials for refractory linings  Level 3  NQF Level 03  10 
    Elective  242820  Maintain records for a team  Level 3  NQF Level 03 
    Elective  264154  Manufacture three dimensional regular shaped metal tooling  Level 3  NQF Level 03  40 
    Elective  264076  Manufacture three dimensional regular shaped wooden pattern equipment  Level 3  NQF Level 03  40 
    Elective  12319  Perform change overs in a production or packaging environment  Level 3  NQF Level 03 
    Elective  12455  Perform the role of a safety, health and environmental protection representative  Level 3  NQF Level 03 
    Elective  264016  Produce a mould using a loose pattern  Level 3  NQF Level 03  16 
    Elective  258715  Produce components by spark eroding machining operations  Level 3  NQF Level 03 
    Elective  264096  Produce cores by hand  Level 3  NQF Level 03  16 
    Elective  13298  Produce detailed engineering drawings  Level 3  NQF Level 03 
    Elective  264059  Produce pressure die castings  Level 3  NQF Level 03  12 
    Elective  116930  Use a Graphical User Interface (GUI)-based presentation application to enhance presentation appearance  Level 3  NQF Level 03 
    Elective  116940  Use a Graphical User Interface (GUI)-based spreadsheet application to solve a given problem  Level 3  NQF Level 03 
    Elective  243068  Weld carbon steel workpieces using the gas tungsten arc welding process in the downhand position  Level 3  NQF Level 03  15 
    Elective  242816  Conduct a structured meeting  Level 4  NQF Level 04 


    LEARNING PROGRAMMES RECORDED AGAINST THIS QUALIFICATION: 
    When qualifications are replaced, some of their learning programmes are moved to being recorded against the replacement qualifications. If a learning programme appears to be missing from here, please check the replacement.
     
    NONE 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS QUALIFICATION: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    1. QTE Training & Consulting cc T/A QTE (GERMISTON) (TP) 
    2. Scaw Metals Group (Pty) Ltd T/A Scaw Metals (DINWIDDIE) (TP) 



    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.