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SOUTH AFRICAN QUALIFICATIONS AUTHORITY

REGISTERED UNIT STANDARD THAT HAS PASSED THE END DATE:

Control a manufacturing process

SAQA US ID	UNIT STANDARD TITLE
116600	Control a manufacturing process
ORIGINATOR
SGB Manufacturing and Assembly Processes
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-
FIELD			SUBFIELD
Field 06 - Manufacturing, Engineering and Technology			Manufacturing and Assembly
ABET BAND	UNIT STANDARD TYPE	PRE-2009 NQF LEVEL	NQF LEVEL	CREDITS
Undefined	Regular	Level 4	NQF Level 04	60
REGISTRATION STATUS		REGISTRATION START DATE	REGISTRATION END DATE	SAQA DECISION NUMBER
Passed the End Date - Status was "Registered"		2004-04-07	2007-04-07	SAQA 0553/04
LAST DATE FOR ENROLMENT		LAST DATE FOR ACHIEVEMENT
2008-04-07		2011-04-07

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 unit standard replaces:

US ID	Unit Standard Title	Pre-2009 NQF Level	NQF Level	Credits	Replacement Status
9903	Control a manufacturing process	Level 4	NQF Level 04	60

PURPOSE OF THE UNIT STANDARD

Controlling a manufacturing process.

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING

This unit standard has been designed as part of a progression. It is one of a series of unit standards for activities below, at and above this level. The credits assigned to it are based on the assumption that I am learning what is needed for this unit standard as part of my learning for a range of related unit standards at this level or below it.

If I have experience in these related activities but do not have credits for them, I can obtain credits by being assessed through a process that recognises prior learning.

If I do not have such experience of related activities, then my learning time will be increased. I can choose to be assessed and obtain credits against those other unit standards as I make progress towards the outcomes of this unit standard.

UNIT STANDARD RANGE

A general guide to the scope, context conditions, and level at which I am expected to perform.

See range statements under specific outcome: 'Plan manufacturing process'.

Specific Outcomes and Assessment Criteria:

SPECIFIC OUTCOME 1

Plan manufacturing process.

OUTCOME NOTES

Plan the process against production schedule requirements

Check availability of material, tools and equipment necessary for process

Allocate materials, tools, equipment and tasks

Communicate requirements to appropriate personnel

OUTCOME RANGE

Process refers to a particular process within a metals production environment, for example:

For iron and steel: iron making, the direct reduction process, coke making, steel making and refining, liquid metal casting, steel reheating and hot working, steel cold working, steel cold processing and product coating.

For aluminium, these may include the direct reduction process, liquid metal casting, anode making, anode baking, anode rodding, sodarberg briquette making, aluminium reheating and hot working, aluminium cold working, and gas, fumes and bath treatment, rod rolling process, furnace batching.

For copper, these may include the electrolysis, direct reduction process, copper refining, liquid metal casting, copper hot working, copper cold working.

For graphite, these may include mill mixing and forming, baking, pitch impregnation, graphitising, machining.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

How will I be able to judge if I am capable? How will I be assessed? Evidence which will show that I have mastered the skill:

Results achieved:
1. Production goals are met
2. Product complies with customer specifications
3. Process set up meets specifications
4. Manufacturing process cycle time meets customer and company requirements

Indicators:
1. Adjustments to process are made to apply with company and customer requirements
2. Process tools, consumable, material is available and utilized according to operational requirements.
3. Process is set up and controlled to ensure continuous production flow.
4. Product inspection procedures are adhere to.
5. Process variations are identified and corrected.
6. Procedures for setting up controlling, inspecting product, change over, working safely, communication, recording and quality.
6. Documentation up-to-date and systematically completed.

Understanding confirmed:
1. Explain, show and discuss consequences of inadequate planning, poor practices, incorrect settings, changes in production schedule, process problems
2. Explain, show and discuss the manufacturing process and the different stages
3. Explain and discuss how to go about monitoring the process in order to optimise the process.

SPECIFIC OUTCOME 2

Set up process.

OUTCOME NOTES

Determine material requirements and specifications

Check and set process parameters

Start up process

OUTCOME RANGE

Process parameters include temperature, flow (air, water, gas, metal), pressure, emissions, cycle times, tonnage, consumption of auxiliary services, quality specifications, casting speed, chemical compositions.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

SPECIFIC OUTCOME 3

Control the process.

OUTCOME NOTES

Monitor and control process variables and deviations

Compare process performance to optimise equipment operation

Monitor and adjust process flow

Shut down process

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

SPECIFIC OUTCOME 4

Inspect product-in-process against quality specifications.

OUTCOME NOTES

Interpret sample analysis.

OUTCOME RANGE

Inspection activities include visual checking and measurement of product dimensions, mass, density and shape, requirements for specific materials, product properties, tensile, hardness, conductivity, elongation, dust fineness, granulometry.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

SPECIFIC OUTCOME 5

Recognise and respond to process problems.

OUTCOME NOTES

Identify root cause of quality problems

Make adjustments to bring process back into line

Test corrective action to determine if problem is solved

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

SPECIFIC OUTCOME 6

Complete changeover process.

OUTCOME NOTES

Instruct and discuss forward actions with workgroup members who will take over the running of the process.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

SPECIFIC OUTCOME 7

Work safely with due care for self, fellow workers, equipment, materials and the environment.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

SPECIFIC OUTCOME 8

Record all activities and results.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

SPECIFIC OUTCOME 9

Discuss and explain information related to planning the process, setting up and controlling the process and the products produced.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS

My assessment will be governed by the policies and guidelines of the MERSETA Education and Training Quality Assurer who has jurisdiction over this field of learning. My assessor will (at the very least) be accredited and have a technical qualification in this learning area.

I can be assessed in the language of my choice although if I have to report incidents or conditions to someone else, I will be assessed on my ability to report in the language commonly used in my working environment.

I will be assessed in the workplace but I can submit documents, projects, test results and assignments that were not produced in the workplace.

I can be assessed against this unit standard to obtain credits or as part of an integrated assessment for a qualification.

UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE

Things I know and can explain:

1. Names & functions of:

Consumables

Materials

Components, controls, instruments and equipment

Hydraulic, pneumatic, heating, cooling, electrical, oxygen and gas systems

Product

2. Attributes, descriptions, characteristics & properties:

Materials to be processed

Equipment, machines and tooling

Manufacturing process

Machinery specifications and capacity

Preventive maintenance

Common causes of equipment failure

Common areas of wear and tear on equipment

Process control software

3. Sensory cues:

Cues for different defects (visual, noise, smell, vibration) related to the setting up of manufacturing equipment

4. Purpose of:

Monitoring equipment indicators

Product changeovers

Set up procedures

Quality procedures

Health and safety procedures

5. Processes, events, causes and effects, implications:

Temperature and state changes

Pressure changes

Oil temperature changes

Calibration process

Impact of settings on product cost

Things going wrong, e.g. accidents, power and service failure, wrong or poorly prepared materials, poor planning procedures, change of plan or schedules

Impact of early diagnosis of equipment malfunctioning

6. Procedures and techniques:

Process controlling

Manufacturing practices

Quality

Safety

Worksite/standard operating procedures

Diagnostic

Testing

Analysing test results

Installation and removal

Setting and running

Shutting down

Measurement

Monitoring

Communication

Recording and report

Procedures for reporting major problems with machinery and equipment

7. Regulations, legislation, agreements, policies, standards:

Regulations related to safety and health

Regulations appropriate to the product

Provisions of applicable acts

8. Theory: rules, principles, laws:

Metallurgical principles related to the product and the process, e.g. quality, grades, chemical composition of materials

Process principles, e.g. cooling, oxidation, desulphurisation, slag practices, lubrication

Temperature, changes of state, melting properties

Torque, viscosity, fluid dynamics

Electricity, current, power, resistance, circuits, components

Behaviour of gases, fluids and solids

Pressure, vacuum

Units of measure

9. Relationships, systems:

Relationship between materials, process and environment

Auxiliary services influences on quality

Relationships between process set up and control and final product

Impact of troubleshooting and diagnosing malfunctions on equipment on production efficiencies

UNIT STANDARD DEVELOPMENTAL OUTCOME

N/A

UNIT STANDARD LINKAGES

N/A

Critical Cross-field Outcomes (CCFO):

UNIT STANDARD CCFO IDENTIFYING

Identify and solve problems:

Identify faults related to the process and undertake appropriate actions

Identify and correct conditions or practices which will damage or reduce the life of the machinery and equipment

Identify conditions or practices that will impact on the properties of the material to be processed or the end product performance and correct

UNIT STANDARD CCFO WORKING

Work effectively with others:

Interact with workgroup members to effect efficient and problem free manufacturing, changeovers and set ups

Interact with maintenance specialists to troubleshoot and determine most effective ways of repairing problems/optimising manufacturing process

Organise work teams

UNIT STANDARD CCFO ORGANISING

Organise and manage myself and my activities:

Prepare, plan and sequence events and procedures

UNIT STANDARD CCFO COLLECTING

Collect, analyse, organise and critically evaluate information:

Record, categorise and explain problems, faults and down times related to process

Collect and record changes to settings for repeatability

UNIT STANDARD CCFO COMMUNICATING

Communicate effectively:

Request or instruct workgroup members and associated people to co-ordinate and effect process activities

UNIT STANDARD CCFO SCIENCE

Use science and technology effectively and critically:

Explain metallurgical principles as they apply to the manufacturing process

Use a methodical approach to analysing test results

UNIT STANDARD CCFO DEMONSTRATING

Demonstrate an understanding of the world as a set of related systems:

Solutions to problems reflect an awareness that process control forms the key to quality, output and cost effectiveness

UNIT STANDARD ASSESSOR CRITERIA

N/A

UNIT STANDARD NOTES

This unit standard replaces unit standard 9903, "Control a manufacturing process", Level 4, 60 credits.

QUALIFICATIONS UTILISING THIS UNIT STANDARD:

	ID	QUALIFICATION TITLE	PRE-2009 NQF LEVEL	NQF LEVEL	STATUS	END DATE	PRIMARY OR DELEGATED QA FUNCTIONARY
Core	49020	Further Education and Training Certificate: Metals Production	Level 4	NQF Level 04	Passed the End Date - Status was "Registered"	2007-04-07

PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD:

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.

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