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

Prepare, set up and operate process equipment in a production environment 
SAQA US ID UNIT STANDARD TITLE
259697  Prepare, set up and operate process equipment in a production environment 
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 3  NQF Level 03  36 
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 replaces: 
US ID Unit Standard Title Pre-2009 NQF Level NQF Level Credits Replacement Status
116596  Prepare, set up and operate process equipment  Level 3  NQF Level 03  36   

PURPOSE OF THE UNIT STANDARD 
This is the main function of any individual who will prepare and operate the main processing equipment in the metal production environment. There are a number of contexts in which the learner can operate. The time it will take a learner to acquire the competencies to operate the different heavy machines in his/her context within the metal production environment will depend on the type of equipment a learner will need to operate in that context. A learner should also be cognisant of the fact that these are huge pieces of equipment which are extremely expensive and correct operation is very important not only for the longevity of the machine but also for the continuation of the production process.

Learners credited with this standard will be able to:
  • Plan the set-up process production equipment.
  • Prepare and set-up equipment.
  • Operate equipment.
  • Perform post-operation activities. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
  • Communication at NQF Level 2.
  • Mathematical literacy at NQF Level 2. 
    		•

    UNIT STANDARD RANGE 
    This unit standard is designed for learners learning and working in a particular process within a specific metals production environment, for example:
  • For iron and steel, these may include: 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, briquette making, aluminium reheating and hot working, aluminium cold working, and gas, fumes and bath treatment.
  • 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 
    Plan the set-up process production equipment. 
    OUTCOME RANGE 
    Process equipment includes all equipment in the manufacturing process, e.g. furnaces, casting machines, mills, holding vessels, roll stands, tundishes, converters, kilns, degassers, ovens, stokers, stoves, pots, reactors, pot tending machinery, autoclaves, ingot lines, coolers, moulding vibrators/presses, mixers, machining equipment, loading machinery (trolleys, tractors, front end loaders forklifts), crushers, flying saw, horizontal castors, degassing equipment, rolling ingot vertical direct casting, granulator. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Production schedules are interpreted and communicated to ensure that the production team is aware of what needs to be done. 

    ASSESSMENT CRITERION 2 
    Set-up requirements are determined and in accordance with process and manufacturer's specifications. 

    ASSESSMENT CRITERION 3 
    The sequence of activities to set-up the production equipment is determined in terms of standard operating procedures. 

    ASSESSMENT CRITERION 4 
    Production process cycle is planned to comply with customer and company requirements. 

    ASSESSMENT CRITERION 5 
    The consequences of poor planning and practices are discussed in terms of their impact on the production schedule and the cost of production. 

    SPECIFIC OUTCOME 2 
    Prepare and set-up equipment. 
    OUTCOME RANGE 
    Set up includes but is not limited to alignment, calibration, replacement of components and parts, preheating, lubrication, positioning, roll gap setting, verifying checklists. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The production equipment is inspected and functionality is tested. 

    ASSESSMENT CRITERION 2 
    Parameters for equipment are set and necessary adjustments are made according to standard operating procedures at first intent. 

    ASSESSMENT CRITERION 3 
    The auxiliary services are checked to ensure correct operation. 
    ASSESSMENT CRITERION RANGE 
    Auxiliary services include gas, water, hydraulics, pneumatics; iron, refractories and cathode lining materials.
     

    ASSESSMENT CRITERION 4 
    The role and importance of the different systems that enable the equipment to function are described to facilitate a broad and integrated understanding of the way the systems operate. 
    ASSESSMENT CRITERION RANGE 
    Systems include but are not limited to hydraulic, pneumatic, heating, cooling and electrical systems.
     

    SPECIFIC OUTCOME 3 
    Operate equipment. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The equipment is operated as per standard operating procedure and manufacturer's specifications. 

    ASSESSMENT CRITERION 2 
    Equipment indicators are monitored regularly to detect an anomaly, deviation or problem. 

    ASSESSMENT CRITERION 3 
    Problems/deviations that fall within the scope of practice of the operator are identified and resolved or communicated to control personnel and/or maintenance specialists. 

    ASSESSMENT CRITERION 4 
    Adjustments or changes are made using appropriate equipment. 

    ASSESSMENT CRITERION 5 
    Problem solving techniques are applied to ensure that equipment operates optimally. 

    ASSESSMENT CRITERION 6 
    Emergencies that occur during operation of equipment are responded to as per standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
    Emergencies include but are not limited to power failures, fire, temperature, overflows, cobbles, breakouts, under fills, system failures.
     

    ASSESSMENT CRITERION 7 
    Work is performed with due care for the safety of self, fellow workers, equipment, materials and the environment. 

    SPECIFIC OUTCOME 4 
    Perform post operation activities. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    All relevant information pertaining to setting-up and operating equipment is recorded and reported to relevant parties according to standard operating procedure. 
    ASSESSMENT CRITERION RANGE 
  • Information includes but is not limited to problems, anomalies, maintenance aspects, repairs.
  • Relevant parties include control personnel, maintenance specialists, next shift personnel.
     
    		•

    ASSESSMENT CRITERION 2 
    Shift changeover discussions are conducted to convey important information so that the production is uninterrupted. 

    ASSESSMENT CRITERION 3 
    Quality control mechanisms are complied with to ensure customer and downline satisfaction with product. 


    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.
  • Functions of manufacturing units.
  • Hydraulic, pneumatic, heating, cooling, electrical, oxygen and gas systems.
  • Safety equipment.

    Attributes, descriptions, characteristics and properties:
  • Materials to be processed.
  • Materials used for equipment, machines and tooling.
  • Manufacturing process.

    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.
  • Operating and monitoring 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 that could go wrong, for example, accidents, power and service failure, wrong or poorly prepared materials, poor planning procedures, change of plan or schedules.

    Procedures and techniques:
  • Quality.
  • Safety.
  • Worksite and standard operating.
  • Installation and removal.
  • Setting and running.
  • Operating.
  • Shutting down.
  • Measurement.
  • Monitoring.
  • Communication.
  • Recording and report.

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

    Theory: rules, principles, laws:
  • 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 set up, materials, processes and final product. 
    		•

    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:
  • Reporting problems beyond scope of practice to control and/or maintenance personnel.
  • Monitoring equipment and making relevant adjustments. 
    		•

    UNIT STANDARD CCFO WORKING 
    Work effectively with others as a member of a team, group, organisation, community to:
  • Ensure that production process equipment runs smoothly and efficiently.
  • 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.
  • Planning the set-up equipment.
  • Setting-up and operating the equipment. 
    		•

    UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information to:
  • Solve problems by making adjustments.
  • Deal with changes 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 production process equipment. 
    		•

    UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically, showing responsibility towards the environment and the health of others by:
  • Using 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 
    This unit standard replaces unit standard 116596, "Prepare, set up and operate process equipment", Level 3, 36 credits. 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  64190   National Certificate: Metals Production  Level 3  NQF Level 03  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  As per Learning Programmes recorded against this Qual 
    Elective  58785   National Certificate: Production Technology  Level 3  NQF Level 03  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  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.
     
    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.