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SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD: 

Maintain manufacturing efficiencies 
SAQA US ID UNIT STANDARD TITLE
119159  Maintain manufacturing efficiencies 
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 5  Level TBA: Pre-2009 was L5  12 
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
9893  Maintain production efficiencies  Level 5  Level TBA: Pre-2009 was L5  12  Complete 

PURPOSE OF THE UNIT STANDARD 
In order for me to perform effectively in the field of plastics manufacturing, I will be able to:
  • Maintain production efficiencies in a volume plastics manufacturing process.
  • Apply methods and techniques to ensure that efficiency is measured, analysed and calculated.
  • Respond to deviations, problems and incidents which affect efficiency.

    I will also know and understand:
  • Factors that impact on efficiency.
  • Techniques for measuring, analysing and calculating efficiency.
  • Techniques and principles for involving all the actors and role-players in the process.

    I can be assessed against this unit standard in the context of any volume plastics manufacturing process, e.g.
  • 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, the knowledge and the values reflected in this unit standard form part of the exit level outcomes required for the National Certificate in Plastics Manufacturing NQF Level 5. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    The credits for this unit standard assume that I have a National Certificate in Plastics Manufacturing NQF Level 4 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 4 qualification.
  • Experience in a relevant field, especially experience in a particular manufacturing process.

    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.

    This unit standard focuses on the technical aspects of the production process. It is not meant to be a replacement for management or supervisory standards. Issues of work organisation, discipline, grievances or relationships between management and workers are not assessed as part of this standard.

    This unit standard deals with the change from working with physical processes to working with information.

    It would apply to a technological expert who would link with others, taking a lead role in an activity while still being very much part of the team in the sense of feeding others with information needed to do their jobs (e.g. standing next to a person and helping to solve problems).

    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 
    Collect and analyse process-related information, maintain records, summarise information and generate reports. 
    OUTCOME RANGE 
    Process-related information includes information related to:
  • Materials.
  • Process equipment.
  • Processing conditions.
  • Tooling.
  • Product changeovers.
  • The work group.
  • Administration and reporting.
  • Tests and testing.
  • Customer requests, reports and complaints.

    Analyse includes performing calculations of measures such as overall equipment efficiency (OEE); developing or reading graphs and charts.

    Information includes losses, rejects and rework, start up losses, breakdown, setup and adjustment, minor stoppages, reduced speed. 

  • ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the last outcome. 
    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 
    Set and agree targets and levels of efficiency. 
    OUTCOME RANGE 
    Targets are any measures which relate to efficiency including output rates, scrap rates, down- or up-time, costs, quality standards.

    Set and agree involves providing information and discussing options with decision makers (or in micro and small companies making decisions) and including a degree of involvement from the manufacturing team in the process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the last outcome. 
    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 
    Identify and respond to deviations, problems and incidents which impact on production efficiencies. 
    OUTCOME RANGE 
    Deviations, problems and incidents refer primarily to internal issues within the control of the production team. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the last outcome. 
    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 and evaluate activities, safety, product quality and housekeeping. 
    OUTCOME RANGE 
    Activities include all those activities directly related to the production process and include material storage, preparation and transport; and tooling storage, transport, maintenance and installation. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the last outcome. 
    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 
    Share and discuss information with relevant people and resolve external issues which impact on quality and output. 
    OUTCOME RANGE 
    External issues refer primarily to those issues over which the production team does not have direct control. These include delivery, maintenance and quality of materials and tooling.

    Share and discuss includes an element of training, and coaching. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Production and support processes function effectively to an agreed standard of efficiency over a period of time. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved. 
    ASSESSMENT CRITERION RANGE 
    Period of time: Records and reports should cover a period of at least four weeks. The assessor should also evaluate whether the agreed standard of efficiency is appropriate to the level of technology and the type of manufacturing operation, and reflects industry or sub-industry norms.
     

    ASSESSMENT CRITERION 2 
    Production targets are met while also achieving agreed levels of quality. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved. 

    ASSESSMENT CRITERION 3 
    Practices which waste time or other resources are minimised. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 4 
    Records and reports are accurate, up-to-date and reflect a consistent effort to maintain efficiency. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 5 
    Deviations, problems and incidents are recognised and responded to quickly and effectively. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 
    ASSESSMENT CRITERION RANGE 
    Quickly - the assessor should evaluate whether the speed of the response is appropriate to the level of technology and the type of manufacturing operation.

    Effectively - the assessor should evaluate whether the chosen option is appropriate.
     

    ASSESSMENT CRITERION 6 
    Safety, health and environmental standards are maintained. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 7 
    The personnel receive adequate information and support. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 8 
    Discussions of issues demonstrate that I have an understanding of the key concepts and principles related to optimising production processes and an understanding of how these relate to application in practice. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Understanding confirmed. 
    ASSESSMENT CRITERION RANGE 
    Discussion includes: explanation, motivation and justification.

    Issues, key concepts and principles include:
  • Internal and external issues impacting on quality and output.
  • Impact of materials, equipment and tooling on efficiency.
  • Types and measure of efficiency.
  • Other factors impacting on efficiency.
  • Techniques for establishing causes of inefficiency.
     


  • 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 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 embedded 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 the 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 standards that underpin 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 the 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 & functions of:
  • Sources and types of information.
  • Measures of efficiency.
  • Losses.
  • Factors relating to efficiency.
  • Factors relating to productivity.
  • Concepts related to statistical process control.

    2. Purpose of:
  • Information gathering and analysis.
  • Efficiency measures.
  • Purpose of statistical process control.

    3. Attributes, descriptions, characteristics & properties:
  • Types of efficiency measures.
  • Types of losses.
  • Factors in measuring efficiency.
  • Properties of materials and equipment which impact on efficiencies.
  • Types of statistical process control charts.

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

    5. Causes and effects, 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. corrosion, degradation, abrasion, wear.

    6. Procedures and techniques:
  • Methods of collecting, analysing, organising, summarising and presenting data.
  • Methods of determining and calculating efficiencies.
  • Statistical methods of determining variances.
  • Fault finding and correction techniques.
  • Quality related procedures.

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

    8. Regulations, legislation, agreements, policies, standards:
  • Safety, health and environmental legislation and regulations.
  • Quality policies, standards and agreements.

    9. Theory: rules, principles, laws:
  • Interrelationship of physical and chemical properties and factors which impact on them.
  • Key concepts related to manufacturing efficiencies, e.g. lean production, just-in-time, overall equipment efficiency, optimising material flows, cleaner production, eco-efficiency, supply chain management, maintenance strategies.
  • Key concepts related to statistical process control.

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

    11. Relationships, systems:
  • 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 
  • In complex environments and systems.
  • Based on analysing data sets. 

  • UNIT STANDARD CCFO WORKING 
  • Maintain focus on achieving production efficiencies.
  • Coach people to improve their understanding and performance.
  • Build relationships to maintain efficiencies. 

  • UNIT STANDARD CCFO ORGANISING 
    Maintain a consistent and regular approach to achieve efficient production, e.g. patrols, regular checks, reporting procedures. 

    UNIT STANDARD CCFO COLLECTING 
    Collect and analyse process-related information, maintain records, summarise information and generate reports related to efficiency. 

    UNIT STANDARD CCFO COMMUNICATING 
  • Communicate information and feedback appropriate to level of person.
  • Provide relevant information and feedback to help people make decisions or implement actions. 

  • UNIT STANDARD CCFO SCIENCE 
    Use a methodical, scientific approach to monitoring information and identifying problems and solutions. 

    UNIT STANDARD CCFO DEMONSTRATING 
  • Develop solutions which will not impact negatively on other aspects of the process, costs or end-user needs.
  • Demonstrate an awareness of the interrelationship of factors within complex manufacturing systems. 

  • UNIT STANDARD ASSESSOR CRITERIA 
    My assessor will be registered and have a plastics manufacturing qualification at NQF 6 or higher. In the absence of assessors with such qualifications, the ETQA can make interim arrangements. 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 9893, "Maintain production efficiencies", Level 5, 12 credits. 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  21007   National Certificate: Automotive component manufacturing and assembly  Level 5  Level TBA: Pre-2009 was L5  Passed the End Date -
    Status was "Reregistered" 
    2008-11-01  Was MERSETA until Last Date for Achievement 
    Core  71969   National Certificate: Automotive Components: Manufacturing and Assembly  Level 5  Level TBA: Pre-2009 was L5  Passed the End Date -
    Status was "Reregistered" 
    2015-06-30  MERSETA 
    Core  78843   National Certificate: Diamond Processing  Level 5  Level TBA: Pre-2009 was L5  Reregistered  2023-06-30  MQA 
    Core  49448   National Certificate: Plastics Manufacturing  Level 5  Level TBA: Pre-2009 was L5  Reregistered  2023-06-30  MERSETA 
    Core  57122   National Certificate: Printing and Manufacture of Packaging  Level 5  Level TBA: Pre-2009 was L5  Passed the End Date -
    Status was "Reregistered" 
    2015-06-30  FPMSETA 
    Elective  21013   National Certificate: Power and Telecommunication Cable Manufacturing  Level 4  NQF Level 04  Reregistered  2023-06-30  MERSETA 
    Elective  59201   National Certificate: Generic Management  Level 5  Level TBA: Pre-2009 was L5  Reregistered  2023-06-30  As per Learning Programmes recorded against this Qual 
    Elective  49743   National Certificate: Manufacturing Management  Level 5  Level TBA: Pre-2009 was L5  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.
     
    1. Alvern Cables (Pty) Ltd (GERMISTON) (TP) 
    2. Career Pathing Solutions (Pty) Ltd (KRUGERSDORP) (TP) 
    3. College of Production Technology 
    4. CREATIVE FOUNDATION TRAINING 
    5. DMP Training (PINETOWN) (TP) 
    6. DYNA TRAINING (PTY) LTD (Cape Town) 
    7. Plastics Federation of South Africa (MAITLAND) (TP) 
    8. Plastics Federation of South Africa (MIDRAND) (TP) 
    9. Plastics Federation of South Africa (WESTMEAD) (TP) 
    10. QTE Training & Consulting cc T/A QTE (GERMISTON) (TP) 
    11. Ronald Sewell & Associates SA (Pty) Ltd T/A Sewells (BRYANSTON) (TP) 
    12. Russ Projects T/A Academy Workplace Development (AWD) (HARRIETDALE) (T 
    13. SANDVIK MINING & CONSTRUCTION RSA (PTY) LTD 
    14. Scaw Metals Group (Pty) Ltd T/A Scaw Metals (DINWIDDIE) (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.