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 UNIT STANDARD: 

Prepare material chemically for input 
SAQA US ID UNIT STANDARD TITLE
119051  Prepare material chemically for input 
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  10 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Reregistered  2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

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 unit standard does not replace any other unit standard and is not replaced by any other unit standard. 

PURPOSE OF THE UNIT STANDARD 
Learners who are involved in preparing input material chemically for cold-formed steel tube and pipe manufacturing processes require the skills, values and knowledge reflected in this unit standard.

Qualifying learners can prepare for and chemically prepare input materials for the cold-formed production process. They will understand how chemicals are used to achieve this, the associated dangers and the use of chemicals on the environment. This will include monitoring the chemical treatment process, identifying non-conformances and taking corrective action.

The learning outcomes in this unit standard also contribute to the exit level outcomes required for the National Certificate in Steel Tube and Pipe Manufacturing (Seamless Hot-Finished, Welded or Cold-Formed) (NQF level 4) and related qualifications. 

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
It is assumed that learners are competent in:
  • Communication and mathematical literacy at NQF Level 3 or equivalent
  • The unit standard "Set up process for tube and pipe production" 

  • UNIT STANDARD RANGE 
  • The learner should be able to work autonomously with minimal supervision and according to worksite and manufacturer specifications and occupational safety, health and environmental legislation.
  • Work is generally, but not exclusively, carried out in a team environment
  • The chemical preparation process includes degreasing, acid washing, rinsing, phosphating and soaping
  • Production quantity goals are met
  • Product coating complies with production and customer specifications
  • Material preparation cycle time meets production process requirements.
  • Process, equipment and consumables are utilised according to operational requirements
  • Accurate production data is recorded, process documentation is timeously processed and affected parties liased with
  • Continuous quality product flow is maintained
  • Non-conformances in process and defects in equipment is timeously identified, actioned and continuously monitored to minimise health, environment and quality effects
  • Applicable procedures are followed and understood
  • Strategies, options and choices are described an discussed 

  • Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Plan the process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Interpret job instructions and determine a sequence of operation 

    ASSESSMENT CRITERION 2 
    Acquire associated documentation 

    ASSESSMENT CRITERION 3 
    Plan process against production schedule requirements 

    ASSESSMENT CRITERION 4 
    Communicate product quantity and quality requirements with appropriate personnel 
    ASSESSMENT CRITERION RANGE 
  • Process plan includes planning for product and shift changeover situations
  • Materials include hydrochloric acid, phosphates and soap
  • Documentation includes worksite procedures, production reports, material schedules and non-conformance records
     

  • SPECIFIC OUTCOME 2 
    Select and check availability of consumables, materials, tools and equipment necessary for process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Check availability of consumables, materials and equipment 

    ASSESSMENT CRITERION 2 
    Select appropriate consumables, materials and equipment 
    ASSESSMENT CRITERION RANGE 
    Consumables include degreaser acids, phosphates, soaps and rinsing agents
     

    SPECIFIC OUTCOME 3 
    Prepare and chemically treat input material. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Pre-check, start up and shut down material preparation equipment 

    ASSESSMENT CRITERION 2 
    Chemically treat material 

    ASSESSMENT CRITERION 3 
    Manage waste 

    ASSESSMENT CRITERION 4 
    Control costs to within budget 

    ASSESSMENT CRITERION 5 
    Record activities and process results 
    ASSESSMENT CRITERION RANGE 
  • Material treatment processes include acid wash and descaling, phosphating, soaping and rinsing
  • Results include settings and adjustments made to ensure repeatability
     

  • SPECIFIC OUTCOME 4 
    Analyse process chemicals, determine and affect required adjustments. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Analyse chemical solutions 

    ASSESSMENT CRITERION 2 
    Determine additions to the solution 

    ASSESSMENT CRITERION 3 
    Make required solution concentration changes 
    ASSESSMENT CRITERION RANGE 
    Chemical checks include percentage free acid, refractometer readings on concentrations and Ph levels in rinse water
     

    SPECIFIC OUTCOME 5 
    Identify defects, non-conformances and hazardous conditions and take corrective action. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Defects, non-conformances and hazardous conditions are identified 

    ASSESSMENT CRITERION 2 
    Corrective action and preventative methods for the non-conformances are applied and taken. 

    SPECIFIC OUTCOME 6 
    Work safely with due care for self, fellow workers, equipment, materials and the environment. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Apply safety, health, environmental and quality procedures 

    ASSESSMENT CRITERION 2 
    Appropriate safety equipment and clothing are utilised 
    ASSESSMENT CRITERION RANGE 
    Environmental aspects include the effect of discharge and spillage of consumables
     


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • Anyone assessing a learner or moderating the assessment of a learner against this unit standard must be registered as an assessor with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Any institution offering learning that will enable the achievement of this unit standard must be accredited as a provider with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Assessment and moderation of assessment will be overseen by the relevant Education, Training, Quality, Assurance (ETQA) Body, or by an ETQA that has a Memorandum of Understanding with the relevant ETQA, according to the ETQA's policies and guidelines for assessment and moderation.
  • Moderation must include both internal and external moderation of assessments, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described in the Unit Standard.

    Anyone wishing to be assessed against this unit standard may apply to be assessed by any assessment agency, assessor or provider institution that is accredited by the relevant ETQA. 

  • UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    1. Names and functions of:
  • Consumables
  • Components, controls, instruments and equipment
  • Hydraulic, pneumatic, heating, cooling, electrical, oxygen and gas systems
  • Process

    2. Attributes, descriptions, characteristics & properties:
  • Typical process non-conformances
  • Chemicals used in process
  • Equipment
  • Chemical treatment process
  • Process capacity
  • Chemical surface treatment
  • Preventive maintenance
  • Common causes of equipment failure
  • Common areas of wear and tear on equipment

    3. Purpose of:
  • Chemically preparing input material
  • Monitoring equipment indicators
  • P re-operational checks
  • Quality procedures
  • Health, safety and environmental procedures
  • Analysing chemical solutions

    4. Sensory cues
  • Cues for different defects (visual, noise, smell, vibration) related to the chemical preparation of material

    5. Processes, events, causes and effects, implications:
  • Temperature and state changes
  • Things going wrong, e.g. accidents, power and service failure, wrong or poorly prepared materials, change of plan or schedules
  • Impact of early diagnosis on fluctuating chemical levels
  • Shift changeover
  • Causes and effects / implications and costs of not managing constraints

    6. Procedures and techniques:
  • Business procedures and policies
  • Emergency
  • Company (worksite)
  • Safety, health and environmental
  • Document processes
  • Process controlling
  • Material chemical treatment practices
  • Quality
  • Problem solving and continuous improvement
  • Chemical checking
  • Analysing test results
  • Pre-check, start up and shut down preparation process
  • Measurement
  • Monitoring
  • Communication
  • Team work
  • Recording and reporting
  • Shift changeover

    7. Regulations, legislation, agreements, policies, standards:
  • Regulations related to safety, health and environment
  • Provisions of applicable acts

    8. Theory: rules, principles, laws:
  • Chemical principles related to the process, e.g. chemical concentration
  • Process principles, e.g. heating, cooling and oxidation
  • Units of measure e.g. parts per million

    9. Relationships, systems:
  • Relationship between consumables, process and environment
  • Auxiliary services influences on quality
  • Relationships between process, control and final product
  • Impact of troubleshooting and diagnosing malfunctions on equipment on production efficiencies
  • Preventative / predictive maintenance system
  • Quality, safety and environmental systems 

  • 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 process deviations and take appropriate corrective action
  • 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 prepared and correct 

  • UNIT STANDARD CCFO WORKING 
    Work effectively with others
  • Interact with workgroup members to effect efficient and problem free material preparation and changeovers
  • Interact with maintenance specialists to troubleshoot and determine most effective ways of repairing problems / optimising material preparation process 

  • UNIT STANDARD CCFO ORGANISING 
    Organise and manage myself and my activities
  • Acquire and follow appropriate production schedule
  • Prepare, plan and sequence material preparation events 

  • UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information
  • Compare identified input material with work order requirements
  • Collect data, analyse it for trends and identify opportunities for continuous improvement, then record changes to operational settings for repeatability 

  • UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively
  • Communicate with team members to ensure continuous material preparation 

  • UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically
  • Safe use of material preparation equipment and chemicals 

  • UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems
  • Understanding of the impact of own actions on the total production process 

  • UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    N/A 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Elective  49403   Further Education and Training Certificate: Steel Tube and Pipe Manufacturing (Seamless Hot-Finished OR Welded OR Cold-Formed)  Level 4  NQF Level 04  Passed the End Date -
    Status was "Reregistered" 
    2012-06-30  MERSETA 


    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.
     
    1. ArcelorMittal South Africa Ltd (VANDERBIJLPARK) (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.