SAQA

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.

SOUTH AFRICAN QUALIFICATIONS AUTHORITY

REGISTERED QUALIFICATION THAT HAS PASSED THE END DATE:

National Certificate: Maintenance of High-speed Production Processes (Fast-moving Consumer Goods)

SAQA QUAL ID	QUALIFICATION TITLE
48730	National Certificate: Maintenance of High-speed Production Processes (Fast-moving Consumer Goods)
ORIGINATOR
SGB Food
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY			NQF SUB-FRAMEWORK
FOODBEV - Food and Beverages Manufacturing Industry Sector 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	160	Level 5	Level TBA: Pre-2009 was L5	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	2015-06-30
LAST DATE FOR ENROLMENT		LAST DATE FOR ACHIEVEMENT
2016-06-30		2019-06-30

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 does not replace any other qualification and is not replaced by any other qualification.

PURPOSE AND RATIONALE OF THE QUALIFICATION

Qualified maintenance personnel (artisans) in the past had few options in pursuing formal qualifications in their field. They had a choice between becoming technicians or following a general management route.
The purpose of this qualification is to describe the skills and knowledge required in what is becoming a new discipline: the science and technology of maintenance in the context of sophisticated, high-speed production lines.

The increased sophistication is reflected in:

greater automation

integrated lines that combine a range of processing, product handling and packaging operations

combinations of mechanical, electrical and electronic components

integration of measurement, control and communication devices

an in-depth understanding of the production or manufacturing processes and their impact on the maintenance processes.
A failure in any part of the system can have severe implications in terms of reduced output, damage to product, wastage and possible injury. Consequences of such failure can include negative impacts on the health of workers and consumers and on the profitability and reputation of the company.

The process of managing failure has implications for the maintenance of equipment and requires new sets of skills and knowledge, representing a shift away from hand skills to the skills required to analyse data in records and make recommendations, plan and implement specific maintenance programmes and install new or updated equipment.

This and related qualifications will act as a framework for providers, assessors and learners to plan, implement and measure the outcomes of suitable learning programmes, or the recognition of prior learning, in this new discipline.

The specific purpose of the qualification represents the skills, knowledge and understanding required by competent practitioners to:
1. Initiate, implement and oversee engineering and maintenance practices and improvements that:

ensure high-speed production lines operate continuously at optimum efficiency

introduce new technology, equipment and product lines

co-ordinate activities of maintenance staff and contractors

2. Solve problems and provide technical support to the maintenance personnel.
This qualification can be obtained in the context of a variety of manufacturing and packaging operations for fast-moving consumer goods.

This qualification is conceptualised as forming an integrated part of the National Diploma in Maintenance of High-speed Production Processes (Fast-moving Consumer Goods): NQF Level 5.
However, it is also complete in itself and fulfils all the requirements for a National Certificate.

Rationale for the qualification:

There is an increased sophistication in the machinery and equipment used for high-speed production processes. The management of failure in such an environment presents opportunities for qualified artisans to pursue a career in maintenance beyond NQF level 4 or artisan level.
This qualification represents the beginning of a career in the science and technology of maintenance as a discipline. It is a qualification in its own right but it is also designed so that the credits and the exit level outcomes form a part of the National Diploma in Maintenance of High-speed Production Processes (Fast-moving Consumer Goods): NQF Level 5.

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING

The credits and the related unit standards assume that the learner is either formally qualified or has extensive experience in the installation, repair and maintenance of electrical, mechanical and electronic components and control systems and some experience with instrumentation. If a learner does not have such experience or qualifications, the learning time will be increased.

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

RECOGNISE PREVIOUS LEARNING?

QUALIFICATION RULES

N/A

EXIT LEVEL OUTCOMES

1. Implement new maintenance programmes.

2. Monitor, manage and maintain machinery and equipment.

3. Plan, implement and monitor a project.

A continuous improvement project

New product

New sizes of product

4. Co-ordinate the activities of maintenance staff and contractors.

5. Solve equipment and machinery realted problems and provide technical support to maintenance personnel.
Range:

Equipment and machinery related problems would include all parts of the production line, mechanical, electric, electronic, instrumentation, communication and control; repair maintenance, programming, diagnostics.

ASSOCIATED ASSESSMENT CRITERIA

The new maintenance intervention is operational

The intervention is implemented in time and within budget

Feedback on the effectiveness of the intervention is provided

Understanding of various maintenance programmes and the implementation steps required is demonstrated.

2.

Machinery and equipment availability is optimised

Operations are within budget

Equipment and machinery safety devices are operational and in use

Production and maintenance records are analysed and evaluated and recommendations are made

Issues related to cost impacts, maintenance, spares and downtime and maintenance options are explained and discussed.

3.

The intervention is implemented on time and within budget and the intervention works as planned

All aspects of the project are co-ordinated effectively

Progress against set milestones is achieved

Issues related to project management in the maintenance environment are explained and discussed

4.

Work is scheduled and allocated

Documents for the process are prepared and provided

Progress and quality, including safety, health and environmental issues, are evaluated and verified

Stoppages are communicated, documents collated and progress reported

The ability to prioritise and allocate resources for maintenance is demonstrated

An understanding of the machinery, the control systems and the process is demonstrated

5.

An in-depth knowledge and understanding of the machinery, equipment and systems is demonstrated

Records show that the problem has been eliminated or controlled or the frequency of failure has been consistently reduced

Records show that downtime has been reduced, efficiencies have improved and waste has been reduced

Complex failures or problems have been documented and show the impact of changes

Maintenance personnel have been trained and coached and task teams have been provided with leadership and guidance.

Integrated Assessment.
The integrated assessment must be based on a summative assessment guide. The guide must spell out how the assessor will assess different aspects of the performance and will include:

Observing (and listening to) the learner at work, both in primary activities as well as in other interactions, or in relevant simulations

Asking questions and initiating short discussions to test understanding

Looking at records and reports and evaluating projects included in a portfolio of evidence.

The learner may choose in which language s/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 presented if pertinent to any of the exit level outcomes.

The assessment process should cover the explicit tasks required for the qualification as well as the understanding of the concepts and principles that underpin the activities required for installation, repair and maintenance of high-speed and integrated production equipment. The assessment process should also establish how the learning process has advanced the critical outcomes.

Assessors should also evaluate evidence that the learner has been performing consistently over a period of time.

INTERNATIONAL COMPARABILITY

A search for similar qualifications elsewhere was made. This was done in three phases:
1. Reviewing qualifications on the New Zealand Qualifications Framework
2. Conducting a search on the world-wide web
3. Liaising with respondents in the international partner sites of local companies

No comparable qualifications were found. This is not surprising since it is a relatively new and emerging discipline. Some overseas respondents expressed an interest in such a qualification for their own use.

ARTICULATION OPTIONS

This qualification has been designed and structured so that qualifying learners can move from one context to another. Employers or institutions should be able to evaluate the outcomes of this qualification against the needs of their context and structure top-up learning appropriately. Equally, holders of other qualifications may be evaluated against this qualification for the purpose of RPL.

MODERATION OPTIONS

Moderators for the qualification should be qualified and accredited with an appropriate ETQA.
To assure the quality of the assessment process, the moderation should cover the following:

Assessor credentials

The assessment instrument

The assessment process

CRITERIA FOR THE REGISTRATION OF ASSESSORS

The following criteria should be applied by the relevant ETQA:
1. Appropriate qualification in the field of maintenance science, with a minimum of 2 years' experience in a high-speed manufacturing environment. The subject matter expertise of the assessor can be established by recognition of prior learning.
2. Appropriate experience and understanding of assessment theory, processes and practices.
3. Good interpersonal skills and ability to balance the conflicting requirements of:

Maintaining national standards

The interests of the learner

The need for transformation and redressing the legacies of the past

The cultural background and language of the learner.
4. Registration as an assessor with a relevant ETQA.
5. Any other criteria required by a relevant ETQA.

Notes: Since this a new feld, it may be some time before there are sufficient qualified assessors. The relevant ETQAs should allow interim arrangements to be made.

REREGISTRATION HISTORY

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

NOTES

N/A

UNIT STANDARDS:

	ID	UNIT STANDARD TITLE	PRE-2009 NQF LEVEL	NQF LEVEL	CREDITS
Core	13224	Monitor the application of safety, health and environmental protection procedures	Level 4	NQF Level 04	4
Core	9895	Coordinate predictive and preventive maintenance	Level 5	Level TBA: Pre-2009 was L5	12
Core	9904	Coordinate work group to produce product	Level 5	Level TBA: Pre-2009 was L5	8
Core	114718	Implement a new maintenance programme	Level 5	Level TBA: Pre-2009 was L5	34
Core	114721	Install and commission a high-speed production line	Level 5	Level TBA: Pre-2009 was L5	32
Core	114717	Optimise maintenance activities and practices for high-speed production lines	Level 5	Level TBA: Pre-2009 was L5	18
Fundamental	8647	Apply workplace communication skills	Level 5	Level TBA: Pre-2009 was L5	10
Fundamental	12669	Implement new projects in a rubber manufacturing and assembly process	Level 5	Level TBA: Pre-2009 was L5	30
Elective	13835	Contribute to project initiation, scope definition and scope change control	Level 4	NQF Level 04	9
Elective	10144	Identify, suggest and implement corrective actions to improve quality	Level 4	NQF Level 04	6
Elective	10134	Participate in the estimation and preparation of cost budgets for an element of work and monitor and control actual cost against budget	Level 4	NQF Level 04	6
Elective	13114	Install, test and maintain a complex computer integrated manufacturing system	Level 5	Level TBA: Pre-2009 was L5	20

LEARNING PROGRAMMES RECORDED AGAINST THIS QUALIFICATION:

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.

NONE