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SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD: 

Respond to changes in plastics manufacturing processes 
SAQA US ID UNIT STANDARD TITLE
119156  Respond to changes in plastics manufacturing processes 
ORIGINATOR
SGB Plastics Manufacturing 
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 2  NQF Level 02 
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 replaces: 
US ID Unit Standard Title Pre-2009 NQF Level NQF Level Credits Replacement Status
12656  Respond to changes in volume production processes  Level 2  NQF Level 02  Complete 

PURPOSE OF THE UNIT STANDARD 
In order for me to perform effectively in the field of plastics manufacturing, I will be able to:
  • Quickly recognise and respond to changes in normal running conditions of a plastics manufacturing process which will have an impact on production efficiency, quality, safety, health or the environment
  • Perform activities which will ensure production efficiency is maintained
  • Perform activities which will maintain quality, safety, health or environmental standards

    I will also know and understand:
  • The implications of changes in the manufacturing process
  • The need to respond quickly to changes
  • The techniques used to ensure that no preventable changes take place

    The skills and knowledge reflected in this unit standard relate to changes in the overall manufacturing context. Skills and knowledge related to changes in product quality are assessed in a companion unit standard

    I can be assessed against this unit standard in the context of any volume plastics manufacturing process, eg
  • Injection moulding
  • Blow moulding
  • Various kinds of extrusion
  • Variations of thermoforming
  • Rotational moulding
  • Calendaring
  • Compression and related moulding processes
  • Reaction injection moulding
  • Polymer composites fabrication processes such as pultrusion, filament winding and resin injection.
    The volume production process also includes the regeneration of recycled materials and the manufacture of intermediate products such as sheet, profiles, compounds and master batches.
    The skill, knowledge and values reflected in this unit standard form part of the exit level outcomes required for the National Certificate in Plastics Manufacturing NQF Level 2. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    The credits for this unit standard assume that I have a have a GETC in Manufacturing, Engineering and Related Activities (NQF Level 1) or an equivalent qualification. They also assume that I am working towards my qualification as part of a learning programme which integrates all the required unit standards.
    My learning time will increase if I do not have:
  • A relevant NQF 1 qualification
  • Experience in a relevant field.
    My learning time will be decreased if I have experience in this field because:
  • my learning programme will be adjusted to build on what I already know
  • I can apply to have that prior learning recognised. 

  • UNIT STANDARD RANGE 
    The scope and level of this unit standard is indicated by range statements related to the specific outcomes.
    The work reflected in this unit standard is normally performed under supervision. 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 
    Recognise and report changes which affect the manufacturing process. 
    OUTCOME RANGE 
  • Changes include: faults, deviations, malfunctions, environmental conditions.
  • Affect includes changes that will impact on production efficiency, quality of output, manufacturing conditions, production output, safe working conditions, my health and the health of others, the environment in general. 

  • ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the outcome: "Respond to 'what', 'what if' and 'why' questions relating to activities, changes and incidents in the plastics manufacturing process." 
    ASSESSMENT CRITERION NOTES 
    The assessment criteria for this unit standard have been consolidated to:
  • Facilitate integrated assessment.
  • Ensure that the purpose of the unit standard as a whole is assessed (not just the component parts).

    Use the consolidated assessment criteria that are reflected under the last outcome to develop the assessment guides and assessment tools for this unit standard. 

  • SPECIFIC OUTCOME 2 
    Carry out housekeeping and simple maintenance processes as required by the process. 
    OUTCOME RANGE 
    Housekeeping and simple maintenance includes:
  • Performing routine cleaning.
  • Collecting and disposing of spilled materials, flash, sprues, runners, edge trim, cut-offs and cut outs, dust, moisture.
  • Handling of hazardous materials.
  • Performing lubricating tasks.
  • Replacing simple components such as blades.
  • Performing tasks which do not require specialist personnel. 

  • ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the outcome: "Respond to 'what', 'what if' and 'why' questions relating to activities, changes and incidents in the plastics manufacturing process." 
    ASSESSMENT CRITERION NOTES 
    The assessment criteria for this unit standard have been consolidated to:
  • Facilitate integrated assessment.
  • Ensure that the purpose of the unit standard as a whole is assessed (not just the component parts).

    Use the consolidated assessment criteria that are reflected under the last outcome to develop the assessment guides and assessment tools for this unit standard. 

  • SPECIFIC OUTCOME 3 
    Monitor material flow and respond to shortages. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the outcome: "Respond to 'what', 'what if' and 'why' questions relating to activities, changes and incidents in the plastics manufacturing process." 
    ASSESSMENT CRITERION NOTES 
    The assessment criteria for this unit standard have been consolidated to:
  • Facilitate integrated assessment.
  • Ensure that the purpose of the unit standard as a whole is assessed (not just the component parts).

    Use the consolidated assessment criteria that are reflected under the last outcome to develop the assessment guides and assessment tools for this unit standard. 

  • SPECIFIC OUTCOME 4 
    Monitor the manufacturing equipment and respond to changes. 
    OUTCOME RANGE 
    Respond to changes includes:
  • Clearing blockages, clearing product sticking in chutes or on conveying equipment, responding to changes in tension.
  • Stopping the process in an emergency or where considerable damage can occur.
  • Making minor adjustments to material, material feed, the equipment, the flow of finished or partly finished products.
  • Reporting issues to a person responsible for more complex decisions or actions. 

  • ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the outcome: "Respond to 'what', 'what if' and 'why' questions relating to activities, changes and incidents in the plastics manufacturing process." 
    ASSESSMENT CRITERION NOTES 
    The assessment criteria for this unit standard have been consolidated to:
  • Facilitate integrated assessment.
  • Ensure that the purpose of the unit standard as a whole is assessed (not just the component parts).

    Use the consolidated assessment criteria that are reflected under the last outcome to develop the assessment guides and assessment tools for this unit standard. 

  • SPECIFIC OUTCOME 5 
    Record processing conditions, outputs, stoppages and changes and determine output figures. 
    OUTCOME RANGE 
  • Record would generally be the use of standard forms to record up- and downtime, incidents.
  • Output figures include hourly, daily or per shift output related to my machine, number and percentage of good production, scrap rates. 

  • ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the outcome: "Respond to 'what', 'what if' and 'why' questions relating to activities, changes and incidents in the plastics manufacturing process." 
    ASSESSMENT CRITERION NOTES 
    The assessment criteria for this unit standard have been consolidated to:
  • Facilitate integrated assessment.
  • Ensure that the purpose of the unit standard as a whole is assessed (not just the component parts).

    Use the consolidated assessment criteria that are reflected under the last outcome to develop the assessment guides and assessment tools for this unit standard. 

  • SPECIFIC OUTCOME 6 
    Respond to 'what', 'what if' and 'why' questions relating to activities, changes and incidents in the plastics manufacturing process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Impacts on production efficiency, quality, safety, health or the environment are minimised. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved. 
    ASSESSMENT CRITERION RANGE 
    I should collect and present evidence gathered over a period of two months which indicate what change took place, how I noticed it, what my response was and how long it took me to respond.
     

    ASSESSMENT CRITERION 2 
    Workspace and equipment is kept clean, tidy and in best operating condition. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved. 
    ASSESSMENT CRITERION RANGE 
    Best operating condition is restricted to those elements for which I am responsible.
     

    ASSESSMENT CRITERION 3 
    Records and reports of production performance and all changes and incidents are available and stored appropriately. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved. 

    ASSESSMENT CRITERION 4 
    All changes are responded to quickly. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 
    ASSESSMENT CRITERION RANGE 
    Responded to includes taking action or reporting.
     

    ASSESSMENT CRITERION 5 
    Records are made accurately. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 6 
    The manufacturing process is never affected by lack of materials where it is within my control. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 7 
    My answers to questions show that I know what I should be doing, why I am doing it and why I should be doing it this way. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Understanding confirmed. 
    ASSESSMENT CRITERION RANGE 
    Answers to questions relate to:
  • The process, the faults and the procedures.
  • The manufacturing process and the functioning of the business in general (the functioning of the business in general relates to the relevance of the activities in this unit standard to the sustainability of the business).

    A thorough understanding of the overall purpose of the unit standard as well as the items indicated under Embedded Knowledge.
     


  • UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
    To obtain credits I must be assessed. The assessment will be based on evidence that I produce. My 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 my assessment is moderated
  • How I can appeal against the outcome of the assessment
    Any institution or company which offers learning that will enable me to achieve the purpose of this unit standard must be accredited as a provider through the relevant ETQA.
    My assessment against this standard should meet 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.
    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 on all the specific outcomes, critical cross-field outcomes and essential embedded knowledge. The specific outcomes must be assessed in their own right, through oral and practical evidence. My assessment will not only be based on observation but also on other evidence which I compile into a portfolio of evidence. I 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 I am able to explain the items which fall under the heading of essential embedded knowledge, but am unable to perform the specific outcomes, then I cannot be assessed as 'competent'. Similarly, if I am 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 I cannot be assessed as 'competent'.
    I will also be assessed on my 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 I know and can discuss.
    My 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 my 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
    1. Names and functions of:
  • Components, materials, equipment (in order to understand instructions and report difficulties)
  • Conditions or characteristics related to the materials, process or products
  • Conditions which could impact on production efficiency, quality, safety, health or the environment
  • Hazardous materials

    2. Purpose of:
  • Processes and procedures related to safety, quality and maintenance
  • Reports
  • Housekeeping and maintenance activities

    3. Attributes, descriptions, characteristics and properties:
  • Basic equipment faults or malfunctions, processing conditions, material characteristics, material grades, machine conditions
  • Product specifications, product uses

    4. Processes and events:
  • Housekeeping
  • Equipment monitoring

    5. Causes and effects, implications of:
  • Implications of poor quality
  • Customer expectations and needs
  • Cost of non-conformance, eg scrap, returns, lost customers
  • Safety equipment and procedures
  • Implications and consequences of situations such as:
  • Poor quality, damaged or faulty equipment
  • Allowing faulty processes to continue
  • Delaying reports about changing conditions

    6. Procedures and techniques:
  • Safety, health and the environment
  • Basic operating procedures
  • Quality procedures

    7. Sensory cues:
  • Smell or appearance of degrading or burning materials
  • Sounds made by faulty equipment or changing process conditions
  • Visual cues to identify changing process conditions

    8. Regulations, legislation, agreements, policies, standards:
  • Quality policy
  • Safety regulations
  • Product requirements (specifications)

    9. Theory: rules, principles, laws:
  • Scientific principles related to the process, the materials and the product, eg heat, change of state, mechanical movement, wear, hardness
  • Role of manufacturing enterprises in the economy; value chain, suppliers, customers, consumers

    10. Categories
  • Hazardous materials
  • Incidents and break downs (required for reporting)

    11. Relationships, systems:
  • Relationship between the purpose of the enterprise and the balance between production and cost reduction on one hand, and quality and customer satisfaction on the other 

  • UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems
  • Monitor and observe process and flow, recognise deviations and respond 

  • UNIT STANDARD CCFO WORKING 
    Work effectively with others
  • Interact with others to achieve the outcomes 

  • UNIT STANDARD CCFO ORGANISING 
    Organise and manage myself and my activities
  • Develop procedures and routines for checking and monitoring processes 

  • UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information
  • Monitor the environment for changes using senses and information provided by the instruments on the equipment
  • Monitor the environment for changes using data provided by instruments or inferred from products 

  • UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively
  • Report incidents, changes and problems
  • Respond to questions or requests for more details 

  • UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically
  • Link aspects of the materials, process and products to scientific principles, especially heat, change of state, hardness, behaviour of fluids, pressure
  • Recognise and explain the relationship between the various systems and sub-systems of the manufacturing equipment - electrical, electronic, control, hydraulics, lubrication, heating and any others found in processing equipment 

  • UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems
  • Respond to interrelationship of different aspects of the environment, eg quality, safety, economic, inter-personal 

  • UNIT STANDARD ASSESSOR CRITERIA 
    My assessor will be registered and have a plastics manufacturing qualification at NQF 3 or higher. My assessor should also be active in the industry and be familiar with the materials, machinery, products and level of technology in which I have contextualised my skills and knowledge. 

    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 12656, which is "Respond to changes in volume production processes", level 2, credits 8 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  49450   National Certificate: Plastics Manufacturing  Level 2  NQF Level 02  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.
     
    1. College of Production Technology 
    2. DMP Training (PINETOWN) (TP) 
    3. ITB MANUFACTURING (PTY) LTD LTD (Isithebe) 
    4. Plastics Federation of South Africa (MAITLAND) (TP) 
    5. Plastics Federation of South Africa (MIDRAND) (TP) 
    6. Plastics Federation of South Africa (WESTMEAD) (TP) 
    7. PS Productive Services (WESTVILLE) (TP) 



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