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: 

Set-up production machines 
SAQA US ID UNIT STANDARD TITLE
335865  Set-up production machines 
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  16 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Reregistered  2015-07-01  2018-06-30  SAQA 10105/14 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2019-06-30   2022-06-30  

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
9889  Set up production machines  Level 4  NQF Level 04  30  Complete 

PURPOSE OF THE UNIT STANDARD 
This is the second of two most important Unit Standards for this Qualification. It contains a set of competencies that will assist the learner in performing their activities within a production environment. The learner will have knowledge of setting-up production machines, implementing quality procedures, performing line inspections, applying problem solving techniques and maintaining health and safety.

Learners credited with this standard will be able to:
  • Demonstrate knowledge of setting-up production machines.
  • Implement quality control procedures.
  • Perform line inspections.
  • Analyse machine data.
  • Explain safety, health, environment and quality requirements.
  • Record, report and communicate to improve the production process.
  • Discuss the theory regarding first line maintenance within the context of setting-up production machines. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
  • Communication at NQF Level 3.
  • Mathematical Literacy at NQF Level 3.
  • 'Prepare to set-up production machines'. 

  • UNIT STANDARD RANGE 
  • The automotive components environment includes both the manufacturing and assembly departments or sections.
  • This Unit Standard is not restricted to the automotive environment. It can be used in any component assembly or manufacturing context.
  • 'Production process' includes both manufacturing and assembly. 

  • Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Demonstrate knowledge of setting-up production machines. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Start-up and shut-down procedures are performed according to standard operating procedures. 
    ASSESSMENT CRITERION RANGE 
    Shut down procedure also includes lock-out procedures.
     

    ASSESSMENT CRITERION 2 
    Product change-overs are performed according to product specifications and standard operating procedures. 

    ASSESSMENT CRITERION 3 
    The machine is set-up, verified and adjusted according to production schedule and standard operating procedures. 

    ASSESSMENT CRITERION 4 
    Production time is managed to maximise efficiencies in accordance with organisational requirements. 

    ASSESSMENT CRITERION 5 
    Stable production conditions are maintained through planning and management of human and capital resources. 

    ASSESSMENT CRITERION 6 
    Work is performed responsibly taking accountability for one's actions at this level and in cognisance of the boundaries of one's authority. 

    ASSESSMENT CRITERION 7 
    Work is planned and performed independently with due regard to accepted levels of responsibility. 

    SPECIFIC OUTCOME 2 
    Implement quality control procedures. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The calibration status of machines, instruments and equipment is explained in terms of South African National Standards (SANS). 

    ASSESSMENT CRITERION 2 
    Product specifications are discussed to ensure that machines are accurately set-up to prevent the production of reject products and thereby cost to company. 

    ASSESSMENT CRITERION 3 
    Quality control procedures are implemented to ensure that the machine is set-up according to product specifications. 

    ASSESSMENT CRITERION 4 
    The need for calibration and the procedure for verification of the calibration status of the machine are discussed to ensure that production takes place according to product requirements. 

    ASSESSMENT CRITERION 5 
    The importance of assuming responsibility for the quality of the product is described in relation to the quality management system of the company. 

    SPECIFIC OUTCOME 3 
    Perform line inspections. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Inspection procedures are described that will assist in ensuring that the process runs efficiently. 

    ASSESSMENT CRITERION 2 
    The current performance of the machines are checked to determine the production speed. 
    ASSESSMENT CRITERION RANGE 
    Sampling procedures are performed using a formal sampling plan to ensure quality checks and to meet customer requirements.
     

    ASSESSMENT CRITERION 3 
    Measuring equipment is used to ensure that products remain within required specifications. 

    ASSESSMENT CRITERION 4 
    The importance of performing in-line inspections is described in terms of reducing waste materials and cost to company. 

    ASSESSMENT CRITERION 5 
    The concepts pertaining to laboratory testing are discussed in term of their role in maintaining quality. 

    ASSESSMENT CRITERION 6 
    Sub-standard materials or products are identified to prevent injury and danger downstream. 

    ASSESSMENT CRITERION 7 
    Relevant test results are interpreted in order to take corrective action. 
    ASSESSMENT CRITERION RANGE 
    Data is analysed to solve problems, identify trends, improve customer satisfaction and improve process capability.
     

    SPECIFIC OUTCOME 4 
    Analyse machine data. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The consequences of adjustments are described in relation to how a change in one aspect of the production process will affect other aspects down and upstream. 
    ASSESSMENT CRITERION RANGE 
    Adjustments include but are not limited to temperature and speed.
     

    ASSESSMENT CRITERION 2 
    The adjustments required to correct a process are discussed in terms of their impact on the final product. 

    ASSESSMENT CRITERION 3 
    Techniques for analysing data are discussed and used to show trends, patterns and to yield information about the production process. 
    ASSESSMENT CRITERION RANGE 
    Techniques include basic statistical skills and types of graphs.
     

    ASSESSMENT CRITERION 4 
    Equipment indicators are monitored as per standard operating procedures and the information is analysed to see how it can best be used in the production process. 

    SPECIFIC OUTCOME 5 
    Explain safety, health, environment and quality requirements. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Procedures pertaining to power failures and fire are explained and applied to prevent injury to self and others. 

    ASSESSMENT CRITERION 2 
    Safety, health and environment policies, procedures, aspects and standards are applied and monitored to ensure organisational compliance with legislation. 

    ASSESSMENT CRITERION 3 
    International quality standards are discussed and complied with as part of the quality management system. 

    ASSESSMENT CRITERION 4 
    Personal Protective Equipment (PPE) appropriate to the activity being performed is used to prevent injury. 

    ASSESSMENT CRITERION 5 
    Appropriate housekeeping practices are applied to ensure production efficiency and a cleaner environment. 

    SPECIFIC OUTCOME 6 
    Record, report and communicate to improve the production process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The company's recording and reporting system is used to transmit important information to the appropriate personnel. 
    ASSESSMENT CRITERION RANGE 
    The various types of reports could include but are not limited:
  • Verbal reporting, in-putting data into the computer, filling out forms by hand, preparing a document from scratch.

    Information could include but is not limited:
  • Any deviation, incident/accident or unusual occurrence in the production process, or safety, health and environment aspects.
     

  • ASSESSMENT CRITERION 2 
    The importance of detailed and accurate information is described in terms of enabling informed decision-making regarding the production process. 

    ASSESSMENT CRITERION 3 
    Documented policies and procedures of the company are used in the respective contexts to ensure that any matter of significance to the production process is reported. 

    ASSESSMENT CRITERION 4 
    The communication channels of the company are discussed and used according to company procedure to ensure that any communication is directed at the appropriate person or department and is understood fully. 

    ASSESSMENT CRITERION 5 
    The different modes of communication are discussed in terms of their advantages and disadvantages. 
    ASSESSMENT CRITERION NOTES 
  • Modes include exercising judgement in the planning, selection and presentation of essential information.
  • Essential information will be defined by company policy and procedures. 

  • ASSESSMENT CRITERION 6 
    The importance of reporting problems timeously is discussed to emphasise the possible injury, damages to equipment and costs to company. 
    ASSESSMENT CRITERION RANGE 
    This includes reporting to next shift, other departments in the company (across functional boundaries).
     

    ASSESSMENT CRITERION 7 
    The importance of feedback on critical issues is discussed in relation to improving the production process and
    the product. 
    ASSESSMENT CRITERION RANGE 
    Feedback includes but is not limited to planning feedback, set-up feedback, product feedback.
     

    SPECIFIC OUTCOME 7 
    Discuss the theory regarding maintenance within the context of setting-up production machines. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Complex first line maintenance issues are discussed to show impact of downtime on the company. 
    ASSESSMENT CRITERION RANGE 
    Factors contributing to downtime costs include but are not limited to time, scrap, tooling and equipment fatigue.
     

    ASSESSMENT CRITERION 2 
    The need for performing first line maintenance is discussed in terms of its value-add for the production process. 


    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:
  • Materials.
  • Parts, controls, instruments and equipment.
  • Hydraulic, pneumatic, heating (including steam), cooling, mechanical and electrical systems.
  • Products.

    Attributes, descriptions, characteristics and properties:
  • Materials to be processed.
  • Materials used for equipment, machines and tooling.
  • Production schedule.
  • Production process.
  • Properties and characteristics of tools, equipment and services (pneumatics, hydraulics, mechanical, water, electricity).

    Sensory cues:
  • Noise, smells, vibration related to correct and incorrect settings and visual observations.

    Purpose of:
  • Product changeovers.
  • Set-up and operating procedures.
  • Quality procedures with regards to materials and products.
  • Health and safety procedures.

    Processes, events, causes and effects and 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.

    Procedures and techniques:
  • Quality.
  • Safety.
  • Planning.
  • Installation and removal of tooling.
  • Setting and running.
  • Setting-up.
  • Internal ordering.

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

    Theory: rules, principles and laws:
  • Temperature, changes of state and melting properties.
  • Electricity, current, power, resistance, circuits and components.
  • Behaviour of gases, fluids and solids.
  • Pressure and vacuum.
  • Pressure, torque, viscosity and fluid dynamics.
  • Electricity, current, power, resistance, circuits and components.

    Relationships and systems:
  • Pre-and post-processes related to the material properties.
  • Relationship between materials, process and environment.
  • Environmental 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:
  • Engaging with problems related to setting-up the machine or range of machines. 

  • UNIT STANDARD CCFO WORKING 
    Work effectively with others as a member of a team, group, organisation, community to:
  • Ensure the efficient operation of the production process. 

  • UNIT STANDARD CCFO ORGANISING 
    Organise and manage oneself and one's activities responsively and effectively when:
  • Setting-up production machines.
  • Performing line inspections.
  • Analysing machine data. 

  • UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information to:
  • Perform line inspections. 

  • UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively using visual, mathematical and/or language skills in the modes of oral and/or written presentation to:
  • Record and report to improve the production process. 

  • 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. 

  • UNIT STANDARD CCFO DEMONSTRATING 
  • Demonstrate an understanding of the world as a set of related systems by recognising that the problem-solving contexts do not exist in isolation when engaging with problems during setting-up the production process. 

  • 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 9889 , "Set up production machines", Level 4, 30 credits. 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  71949   Further Education and Training Certificate: Automotive Components: Manufacturing and Assembly  Level 4  NQF Level 04  Reregistered  2018-06-30  MERSETA 
    Core  79687   Further Education and Training Certificate: Metal and Engineering Manufacturing Processes  Level 4  NQF Level 04  Reregistered  2018-06-30  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. Bell Equipment Company SA (Pty) Ltd (ALTON) (TP) 
    2. College of Production Technology 
    3. Columbus Stainless (Pty) Ltd (MIDDELBURG) (TP) 
    4. CREATIVE FOUNDATION TRAINING 
    5. HV Consultants (Pty) Ltd (PORT ELIZABETH) (TP) 
    6. Izizwe Training Centre (Pty) Ltd T/A Simtech Training (NORTHDENE) (TP) 
    7. Keewave Trading 403 (Pty) Ltd T/A VH Consulting (DURBAN) (TP) 
    8. Mercedes Benz South Africa (Pty) Ltd (CENTURION) (TP) 
    9. Mercedes Benz South Africa (Pty) Ltd (EAST LONDON) (TP) 
    10. MZANSI SKILLS BASE CC (Selby)(TP) 
    11. Nissan SA (Pty) Ltd (ROSSLYN) (TP) 
    12. Planet Waves 237 (Pty) Ltd T/A Occupational Learning Centre (OLC) (PRE 
    13. Russ Projects T/A Academy Workplace Development (AWD) (HARRIETDALE) (T 
    14. SMITHS MANUFACTURING (PTY) LTD (New Germany)(TP) 
    15. SSS Sheet Metal Work cc T/A Sheetech SA (DURBAN) (TP) 
    16. Wilbat Projects 148 (Pty) Ltd (ISIPINGO) (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.