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: 

Manage, control and optimise manufacturing processes 
SAQA US ID UNIT STANDARD TITLE
377582  Manage, control and optimise manufacturing processes 
ORIGINATOR
SGB Food 
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 6  NQF Level 06  24 
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 
In order for a learner to perform effectively in the field of sensitive consumer manufacturing, he or she will be able to:
  • Demonstrate an understanding the principles of Manufacturing Management.
  • Demonstrate an understanding of production planning and scheduling.
  • Identify opportunities for continuous improvement interventions.
  • Optimise all the elements of a sensitive consumer manufacturing process.
  • Apply methods and techniques to develop, implement and evaluate continuous improvement measures.

    He or she will also know and understand:
  • The principles, value and purpose of continuous improvement.
  • Various philosophies and methods related to continuous improvement.
  • The value of a standard approach to continuous improvement.

    He or she can be assessed against this unit standard in the context of any sensitive consumer manufacturing process, including but not limited to the following:
  • Carbonated Soft drink Manufacturing.
  • Baking.
  • Dairy.
  • Meat processing.
  • Pharmaceutical Manufacturing.
  • Canning.
  • Confectionery Manufacturing.
  • Biscuit Manufacturing.
  • Brewing.
  • Dry and Liquid packaging. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    It is assumed that the learner has experience in a relevant field. 

    UNIT STANDARD RANGE 
    The scope and level of this unit standard is indicated by range statements related to the specific outcomes.

    The production process means a series of operations including raw material intake, product manufacture, process technology, packaging technology, quality assurance and consumer safety.

    Optimising means continually improving the efficiency of the manufacturing plant and the process; it also means developing skills, using resources effectively and reducing overall cost. It requires testing the boundaries of the known and finding new ways of creating improvement.

    Typical contexts for the skill are:
  • Improving workflow and logistical arrangements.
  • Improving operating skills and maintenance skills.
  • Improving output.
  • Reducing faults, deviations, downtime, wastage and spillage.
  • Changing materials, grades and additive packages.
  • Improvements to process and packaging technology as well as asset care and facilities management.

    The work reflected in this unit standard is normally performed autonomously. The work will be guided by relevant worksite procedures, manufacturers' specifications and safety, health and environmental legislation. 

  • Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Demonstrate an understanding of the principles of Manufacturing Management. 
    OUTCOME RANGE 
    The principles of Manufacturing Management include but are not limited to Process Capability, Process Control, Labour Management, Yield Management, Throughput Management, Performance Management and Waste Management. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The principles of Manufacturing Management are explained according to recognized theory and practice. 

    ASSESSMENT CRITERION 2 
    At least three production management techniques are utilised to analyse an organisation's production process. 
    ASSESSMENT CRITERION RANGE 
    Techniques include but are not limited to Mass Balancing, Line Balancing, Plant capability analysis and Statistical Process Control.
     

    SPECIFIC OUTCOME 2 
    Demonstrate an understanding of production planning and scheduling. 
    OUTCOME RANGE 
    Production Planning and scheduling includes but is not limited to Understanding supply and demand, Seasonal trends, Dependent and independent demand forecasting, Scheduling, Sequencing, Loading and Capacity Planning. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Production planning is explained according to accepted theory and practice. 
    ASSESSMENT CRITERION RANGE 
    Production Planning concepts include but are not limited to Inventory Planning, Supply Chain Planning and Capacity Planning.
     

    ASSESSMENT CRITERION 2 
    Production scheduling is explained according to accepted theory and practice. 

    ASSESSMENT CRITERION 3 
    The principles of Capacity planning are explained according to recognised theory and practice. 

    ASSESSMENT CRITERION 4 
    The principles of Materials Resource Planning are explained according to recognised theory and practice. 

    SPECIFIC OUTCOME 3 
    Collect and analyse data and identify opportunities for improvement. 
    OUTCOME RANGE 
    Data: Historical, Customer complaints, Machine process data/records, Product data, Product specification, Test results, Workgroup reports, etc.

    Analyse data: Group and summarise data; Use of data analysis techniques to identify trends; Grouping/clustering of results; Graphs; Limits (e.g. highs, lows and averages); visual aids (e.g. charts and scatter grams); Statistical process control techniques.

    Identify opportunities: Strengths, Deviations, Problem areas highlighted; Solutions discussed, Researched (e.g. check if others have tried this), Simulated; Opinions obtained and Trials run. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    A methodology for data collection is identified and data is collected according to methodology. 

    ASSESSMENT CRITERION 2 
    Data is grouped and summarized according to identified data collection methodology. 

    ASSESSMENT CRITERION 3 
    Areas for improvement are identified according to the principles of Manufacturing Management and recognized production management techniques. 

    SPECIFIC OUTCOME 4 
    Identify the root cause of a problem; generate and test options to achieve improvement. 
    OUTCOME RANGE 
    Generate options includes: Develop working hypothesis and identify key areas of improvement.

    Test options includes: Discuss options, Obtain opinions, Research options (check if others have tried this), Simulate, Run trials, Determine the cost implications and Potential savings. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Problem-solving techniques are identified according to accepted theory and practice. 

    ASSESSMENT CRITERION 2 
    The root cause of the problem within the production process is identified by adopting relevant problem-solving techniques. 

    ASSESSMENT CRITERION 3 
    Possible solutions are generated using accepted creative thinking techniques. 

    ASSESSMENT CRITERION 4 
    Relevant stakeholders are involved to generate further solutions and to evaluate possible solutions. 

    ASSESSMENT CRITERION 5 
    A solution is selected using recognized decision-making theories and practice. 

    SPECIFIC OUTCOME 5 
    Set objective(s), develop a plan and implement the improvement(s). 
    OUTCOME RANGE 
    Plan includes: Objectives, Budgets, Resources required, Documentation for any part of the activity, Requisition, Requests, Submissions, Proposals and Anticipated impact.

    Implement includes: Motivating the plan to superiors, Setting up a project team, Briefing the work group, Negotiating and Co-ordinating with other departments. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    An implementation plan is developed according to accepted planning principles and practice. 

    ASSESSMENT CRITERION 2 
    The implementation plan is implemented according to standard operating procedures. 

    SPECIFIC OUTCOME 6 
    Monitor and evaluate the changes; review and adjust the optimisation process until objective(s) have been achieved. 
    OUTCOME RANGE 
    Monitor and evaluate the changes includes: Collecting data, Identifying improvements or knock-on effects, Identifying trends, Ensuring that the safety and health of the work group and the environment is not affected. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The success of the implementation plan is evaluated according to performance measures and standard operating procedures. 

    ASSESSMENT CRITERION 2 
    Corrective actions are implemented if required according to standard operation procedures. 


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
    To obtain credits a learner must be assessed. The assessment will be based on evidence that he or she produce. The assessment will be governed by the policies and guidelines of a relevant Education and Training Quality Assurance body (ETQA), which has jurisdiction over this field of learning. The policies and procedures of the relevant ETQA will also determine:
  • How their assessment is moderated.
  • How they can appeal against the outcome of the assessment.

    Any institution or company which offers learning that will enable the learners to achieve the purpose of this unit standard must be accredited as a provider through the relevant ETQA.

    The learners assessment against this standard should meet the all the requirements of established principles. It should include practical assessment activities which are appropriate to the contents of this unit standard. These activities should include an appropriate combination of self and peer assessment, practical and oral assessments, observations, etc.

    The learners can be assessed in the language of their choice. Should they have to report incidents or conditions to someone else, they will be assessed on ability to report in the language commonly used in the working environment.

    They will be assessed on all the specific outcomes, critical cross-field outcomes and essential embedded knowledge. Each specific outcome must be assessed in its own right, through oral and practical evidence. Their assessment will not only be based on observation but also on other evidence which they will compile into a portfolio of evidence. They cannot be assessed only through a written or oral test.

    The specific outcomes and essential knowledge will be assessed in relation to each other. If they are able to explain the items which fall under the heading of essential embedded knowledge, but am unable to perform the specific outcomes, then they cannot be assessed as 'competent'. Similarly, if I they are able to perform tasks described under the specific outcomes, but cannot explain or justify them in terms of the fundamental concepts, principles and practice relevant to the level of the unit standard that underpins my skill, then they cannot be assessed as 'competent'.

    They will also be assessed on their ability to apply the principles and techniques related to the critical cross-field outcomes, not only in terms of what I can demonstrate, but also in terms of what they know and can discuss.

    Their assessment for this unit standard can be done in conjunction with the assessment of other unit standards related to a qualification, and even in conjunction with their assessment for the qualification as a whole. 

  • UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    The following items reflect the type of knowledge that the assessor will evaluate:

    Names and functions of:
  • Sources and types of information.
  • Measures of efficiency.
  • Losses.
  • Factors relating to continuous improvement.
  • Concepts related to statistical process control.

    Purpose of:
  • Information gathering and analysis.
  • Efficiency measures.
  • Continuous improvement.
  • Statistical process control.

    Attributes, descriptions, characteristics and properties:
  • Types of efficiency measures.
  • Types of losses.
  • Various approaches to maintaining or improving efficiencies, e.g. lean manufacturing, TPM, TQM, 5s, 6Sigma, Kaizan, etc.
  • Properties of materials and equipment which impact on efficiencies.

    Processes and events:
  • Measurement processes.
  • Analysis processes.
  • Problem solving and evaluation processes.

    Causes, effects and implications of:
  • Typical and unusual causes of losses.
  • Implications of inefficiencies, poor working practices, lack of controls, lack of information and skills.
  • Material and equipment-related issues which affect efficiency, e.g.lack of maintenance and poor replacement strategies.
  • Impact of changes.
  • Sequence of actions.

    Procedures and techniques:
  • Analysis and research techniques.
  • Methods of collecting, analysing, organising, summarising and presenting data.
  • Methods of testing solution options.
  • Methods for limiting the effects of specific variables.
  • Methods of collecting, analysing, organising, summarising and presenting data.
  • Methods of determining and calculating efficiencies.
  • Problem identification and solving techniques.
  • Fault finding and correction techniques.
  • Quality related procedures.

    Sensory cues:
  • Related to incipient problems (identified by sight, sound, smell and feel).

    Regulations, legislation, agreements, policies and standards:
  • Reviewing and adjusting standards and operating procedures.
  • Safety, health and environmental legislation and regulations.
  • Quality policies, standards and agreements.

    Theory: rules, principles and laws:
  • Summarising data (sum, average, difference, deviations and trends).
  • Scientific principles and techniques.
  • Statistical process control.
  • Relevant mathematics and statistics.
  • Relevant manufacturing principles and techniques, focused factories lean manufacturing.
  • Utilities management and the relevant applied science according to process technology.
  • Key concepts of programmes to maintain or improve efficiencies, e.g. lean manufacturing, TPM, TQM, 5s, 6 Sigma, Kaizan, etc.
  • Reasons for intervention failure.
  • Problem identification and solving principles.
  • Process mapping.

    Categories:
  • Types of information.
  • Types of problems.
  • Types of losses.

    Relationships and systems:
  • Impact of interventions on costs (i.e. costs/benefit ratios), performance improvements, safety, health and environmental impacts and the interrelationship between these factors.
  • Output, maintenance and properties of finished product related to costs, sustainability and profitability. 

  • UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
  • Identify opportunities for performance improvement in a complex process with several interrelated variables.
  • Apply a range of problem identification and solving principles and a range of techniques to achieve improved performance.
  • Calculate performance and financial impact of changes. 

  • UNIT STANDARD CCFO WORKING 
    Inform others of, and motivate, negotiate and implement changes to procedure and practice (improved performance). 

    UNIT STANDARD CCFO ORGANISING 
  • Conceptualise, develop and implement plans to generate improvements.
  • Work methodically and systematically, recording progress and improvements. 

  • UNIT STANDARD CCFO COLLECTING 
  • Collect and analyse data, and use results to identify deviations.
  • Apply data analysis techniques. 

  • UNIT STANDARD CCFO COMMUNICATING 
  • Explain, discuss and motivate change.
  • Explain and discuss performance.
  • Negotiate for resources and time. 

  • UNIT STANDARD CCFO SCIENCE 
  • Use data representation and manipulation.
  • Use a methodical and scientific approach. 

  • UNIT STANDARD CCFO DEMONSTRATING 
  • Identify and allow for the effects of change on all aspects of the system.
  • Balance improvements across the needs of all stakeholders. 

  • 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  80686   National Diploma: Supply Chain Management: Sensitive Consumer Products  Level 6  NQF Level 06  Reregistered  2023-06-30  FOODBEV 


    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.