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 THAT HAS PASSED THE END DATE: 

Control a production process 
SAQA US ID UNIT STANDARD TITLE
259694  Control a production 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  25 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Passed the End Date -
Status was "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 accredited with this standard will be able to perform this most essential task in the metal production environment, that is, to control the production process itself. This standard constitutes is a very extensive set of competencies because a production process is a relatively large-scale operation. It entails having knowledge of and coordinating/managing all the processes, equipment and systems related to a production process. In the iron and steel industry, for example, this entails managing all the activities around a blast furnace.

Generally the process controller's work begins from the time the materials are brought into the production process, sent through the conversion process itself, to the time a quality product is produced. It also involves problem solving techniques in the event of something going wrong, which in these industries could be extremely costly. This in essence means taking responsibility for the activities of the individuals who provide the support function and those who operate the main production process equipment. It also entails responsibility for the materials and consumables that are all part of the production process.

Learners credited with this standard will be able to:
  • Start-up/initiate the production process.
  • Control the process for a particular production schedule.
  • Inspect the product-in-process.
  • Identify and respond to problems that compromised the quality of a product.
  • Complete shift changeover process.
  • Shut down the production process. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    Plan and set-up a metal production process at NQF Level 4 (New Standard). 

    UNIT STANDARD 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.
  • For platinum, chrome and manganese, these may include tapping, metal casting, electrode joining, slag tapping, paste handling and baking. 
    		•

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Start-up/initiate the production process. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Input material and resources are prepared to ensure efficient production process. 

    ASSESSMENT CRITERION 2 
    Support and related activities are checked to ensure that all systems are in place for the production process. 

    ASSESSMENT CRITERION 3 
    Problems and delays are resolved as per standard operating procedure. 

    SPECIFIC OUTCOME 2 
    Control the process for a particular production schedule. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Information related to controlling the process is discussed in terms of the requirements of the production schedule. 

    ASSESSMENT CRITERION 2 
    Process variables and deviations are monitored, interpreted and controlled so that the production parameters are maintained. 

    ASSESSMENT CRITERION 3 
    The process is maintained to ensure continuous production flow. 

    ASSESSMENT CRITERION 4 
    The production flow is monitored and adjusted to comply with the quality and quantity as per the production schedule. 

    ASSESSMENT CRITERION 5 
    Work is performed with due regard to the safety of self, others, equipment, materials and the environment. 

    ASSESSMENT CRITERION 6 
    Production process delays are managed to limit loss of production and time wastage. 

    SPECIFIC OUTCOME 3 
    Inspect the product-in-process. 
    OUTCOME RANGE 
    Inspection activities include but are not limited to 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 
    The importance of maintaining quality product is explained in terms of company reputation. 

    ASSESSMENT CRITERION 2 
    Product inspection procedures are complied with to ensure continuous quality. 

    ASSESSMENT CRITERION 3 
    Analyses are interpreted and appropriate actions taken to ensure that the problem is resolved efficiently. 

    SPECIFIC OUTCOME 4 
    Identify and respond to problems that occur during the production operation. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The root causes of problems are identified so that correct solution is found. 

    ASSESSMENT CRITERION 2 
    Adjustments are made to bring process back into line. 

    ASSESSMENT CRITERION 3 
    Corrective action is tested to determine if problem is solved correctly. 

    SPECIFIC OUTCOME 5 
    Complete shift changeover process. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The changeover is managed as per standard operating procedure. 

    ASSESSMENT CRITERION 2 
    Actions to be taken forward are discussed to ensure smooth running of the process. 

    ASSESSMENT CRITERION 3 
    Documentation recording all the activities, problems and results is prepared. 

    SPECIFIC OUTCOME 6 
    Shutdown the production process. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Personal protective and safety equipment is used in accordance with prescribed practices. 

    ASSESSMENT CRITERION 2 
    The shutdown process is conducted in accordance with plant/company standard operating procedures. 

    ASSESSMENT CRITERION 3 
    The shutdown process is monitored and controlled in accordance with plant/company standard operating procedures. 

    ASSESSMENT CRITERION 4 
    Tools and equipment are used in the shut down process in accordance with prescribed practices. 

    ASSESSMENT CRITERION 5 
    Hazards and risks associated with the shut down process are explained and eliminated/minimised in accordance with recommendations set out in the applicable risk assessment. 

    ASSESSMENT CRITERION 6 
    Operational problems encountered during the shut down process are explained and resolved in accordance with specified requirements. 

    ASSESSMENT CRITERION 7 
    The shutdown process is conducted consistently with environmental policy and other legislation. 


    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 ETQA.
  • Any institution offering learning that will enable the achievement of this unit standard 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 policies and guidelines for assessment and moderation.
  • Moderation must include both internal and external moderation of assessments at exit points of the qualification, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described both in individual unit standards as well as the integrated competence described in the qualification. 
    		•

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

    Attributes, descriptions, characteristics and 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.

    Sensory cues:
  • Cues for different defects (visual, noise, smell, vibration) related to the setting up of manufacturing equipment.

    Purpose of:
  • Monitoring equipment indicators.
  • Product changeovers.
  • Set up procedures.
  • Quality procedures.
  • Health and safety procedures.

    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.

    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.

    Regulations, legislation, agreements, policies, standards:
  • Regulations related to safety and health.
  • Regulations appropriate to the product.
  • Provisions of applicable acts.

    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.

    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 in which responses display that responsible decisions using critical and creative thinking have been made when:
  • Monitoring the production process and making relevant adjustments to deal with variations and deviations.
  • Resolving problems that impact on the production process.
  • Identifying risks and hazards and dealing with them. 
    		•

    UNIT STANDARD CCFO WORKING 
    Work effectively with others as a member of a team, group, organisation, community to:
  • Ensure that production process runs efficiently.
  • Deal with problems.
  • Ensure that the safety of all personnel and equipment is maintained. 
    		•

    UNIT STANDARD CCFO ORGANISING 
    Organise and manage oneself and one's activities responsively and effectively when:
  • Interpreting production schedules.
  • Controlling the production process.
  • Problem solving. 
    		•

    UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information to:
  • Solve problems by making adjustments to the process.
  • Manage quality problems.
  • Deal with variations and deviations. 
    		•

    UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively using visual, mathematical and/or language skills in the modes of oral and/or written presentation to:
  • Ensure the efficient functioning of the equipment and systems of the production process.
  • Resolve problems as quickly as possible. 
    		•

    UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically, showing responsibility towards the environment and the health of others by:
  • Coordinating the use of the equipment according to manufacturer's instructions and standard operating procedure. 
    		•

    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
    Core  64209   Further Education and Training Certificate: Metals Production  Level 4  NQF Level 04  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  As per Learning Programmes recorded against this Qual 


    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.
     
    NONE 


    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.