SAQA

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SOUTH AFRICAN QUALIFICATIONS AUTHORITY

REGISTERED QUALIFICATION:

Occupational Certificate: Metal Manufacturing, Melting and Refining Process Controller

SAQA QUAL ID	QUALIFICATION TITLE
102159	Occupational Certificate: Metal Manufacturing, Melting and Refining Process Controller
ORIGINATOR
Development Quality Partner - MERSETA
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY			NQF SUB-FRAMEWORK
-			OQSF - Occupational Qualifications Sub-framework
QUALIFICATION TYPE	FIELD		SUBFIELD
Occupational Certificate	Field 06 - Manufacturing, Engineering and Technology		Manufacturing and Assembly
ABET BAND	MINIMUM CREDITS	PRE-2009 NQF LEVEL	NQF LEVEL	QUAL CLASS
Undefined	241	Not Applicable	NQF Level 04	Regular-ELOAC
REGISTRATION STATUS		SAQA DECISION NUMBER	REGISTRATION START DATE	REGISTRATION END DATE
Reregistered		EXCO 0425/24	2018-07-01	2025-12-30
LAST DATE FOR ENROLMENT		LAST DATE FOR ACHIEVEMENT
2026-12-30		2029-12-30

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 qualification replaces:

Qual ID	Qualification Title	Pre-2009 NQF Level	NQF Level	Min Credits	Replacement Status
64209	Further Education and Training Certificate: Metals Production	Level 4	NQF Level 04	140	Complete

PURPOSE AND RATIONALE OF THE QUALIFICATION

Purpose:
The purpose of this qualification is to prepare a learner to operate as a Metal Manufacturing Melting and Refining Process Controller.

A Metal Manufacturing Melting and Refining Process Controller, controls the operational efficiency of the melting and refining process of metals, including operating and monitoring multi-functional machinery and equipment.

A qualified learner will be able to:

Execute activities related to melting and refining processes.

Rationale:
The metal manufacturing melting and refining process is characterised by diverse manufacturing melting and refining processes operating in a competitive and challenging environment. The manufactured products have to meet a wide variety of exacting customer and consumer requirements. The highly developed metal manufacturing sector is well-established. It is in the interest of the country and the sector to ensure that those who operate in the metal manufacturing melting and refining processes environment are trained to improve productivity and efficiency.

This qualification provides critical competencies for learners who want to follow a career in the metal manufacturing melting and refining processes. It reflects the skills, knowledge and understanding required to participate effectively in the metal manufacturing environment either in micro, small, medium or large operations.

This qualification is aimed at learners who will be working in or who wish to enter the metal manufacturing melting and refining processes environment and wish to further their career or involvement within this environment.

The qualification and its related learning components were developed to standardise the accreditation of learning programmes, resulting in improved quality in terms of programme delivery. It will ensure that the quality of education and training in the metal manufacturing melting and refining processes environment is enhanced and of quality standard. The qualification will allow learners to develop their knowledge and skills in the metal manufacturing melting and refining sector against international standards.

The qualification is constructed according to the needs expressed by industry and it will provide mobility and career opportunities for process controllers working in a vast number of strategically important sectors.

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING

Recognition of Prior Learning (RPL):
RPL for access to the external integrated summative assessment: Accredited providers and approved workplaces must apply the internal assessment criteria specified in the related curriculum document to establish and confirm prior learning. Accredited providers and workplaces must confirm prior learning by issuing a statement of result or certifying a work experience record.

RPL for access to the qualification: Accredited providers and approved workplaces may recognise prior learning against the relevant access requirements.

Entry Requirements:

Level 3 with Mathematical Literacy.
Or

A minimum of 4 years working experience within the metal manufacturing environment as a Metal Melting and Refining Process Operator.

RECOGNISE PREVIOUS LEARNING?

QUALIFICATION RULES

This qualification is made up of the following compulsory Knowledge and Practical Skill Modules:

Knowledge Modules:

313501004-KM-01, Occupational Health and Safety and environmental requirements for manufacturing process controller, Level 4, 8 Credits.

313501004-KM-02, Process Plant management for manufacturing process controller, Level 4, 24 Credits.

313501004-KM-03, Quality Management systems for manufacturing process controller, Level 4, 5 Credits.

313501004-KM-04, Materials Feed into furnace (Melting and Refinery), Level 4, 16 Credits.

313501001-KM-05, Materials Handling in the Metal Manufacturing Melting and Refining Process, Level 3, 12 Credits.
Total number of credits for Knowledge Modules: 65.

Practical Skill Modules:

313501004-PM-01, Comply with Health, Safety and environmental requirements, Level 4, 8 Credits.

313501004-PM-02, Comply with plant management requirements, Level 03, 8 Credits.

313501004-PM-03, Comply with quality standards, Level 04, 8 Credits.

313501004-PM-04, Monitor and control material availability/movement), Level 04, 24 Credits.

313501004-PM-05, Start, monitor and stop all material handling equipment, Level 04, 24 Credits.
Total number of credits for Practical Skill Modules: 72.

This qualification also requires the following Work Experience Modules:

313501004-WM-01, Risk Management, Level 4, 8 Credits.

313501004-WM-02, Coordination of Materials and handling processes, Level 4, 32 Credits.

313501004-WM-03, Coordination of the processed product handling processes, Level 3, 8 Credits.

313501004-WM-04, Participate, attend, contribute and conduct workplace safety meeting, Level 04, 8 Credits.

313501004-WM-05, Manage the processes of melting and refining and related activities, Level 04, 48 Credits.
Total number of credits for Work Experience Modules: 104.

EXIT LEVEL OUTCOMES

1. Conduct a risk assessment in the Metal Manufacturing Melting and Refining process operations by identifying appropriate actions that deal with deviations and mitigate the associated risks.
2. Start the melting and refining equipment in sequence.
3. Monitor and control the melting and refining process.
4. Stop the melting and refining equipment sequentially.

ASSOCIATED ASSESSMENT CRITERIA

Associated Assessment Criteria for Exit Level Outcome 1:

Descriptions of typical hazard identification, risk assessment systems and process are valid and indicate how these systems are applied at the candidate worksite.

Various Occupational Health, Safety and Environmental information pertaining to the Melting and Refining processes are identified; described and explanations include what actions must be taken to mitigate the associated risks.

Physical ability to conduct risk assessment in metal manufacturing process environments following all the required procedures and standards is demonstrated.

Associated Assessment Criteria for Exit Level Outcome 2:

Plant specific pre-start checks are performed according to plant specific procedures.

Equipment is started-up in sequence and material is charged were applicable according to plant specific procedures.

The start-up process is monitored to identify and correct deviations according to plant specific procedures.

Associated Assessment Criteria for Exit Level Outcome 3:

Process performance is monitored and controlled according to plant specific procedures.

Process deviations are monitored and controlled according to plant specific procedures.

Potential deviations and their associated corrective actions are explained according to plant specific procedures.

Process performance conditions and/or deviations are communicated and reported to stakeholders.

All sampling points in the specific operations are identified

Relevant samples are taken in accordance with plant specific procedure.

The location of the parameter data is identified and all relevant data pertaining to the melting and refining process is recorded.

Associated Assessment Criteria for Exit Level Outcome 4:

Melting and refining equipment is stopped in sequence according to plant specific procedures.

The various conditions that warrant the stopping process are explained.

Reasons for stoppage are communicated and reported to stakeholders.

Integrated Assessment:
Integrated Formative Assessment:
The skills development provider will use the curriculum to guide them on the stipulated internal assessment criteria and weighting. They will also apply the scope of practical skills and applied knowledge as stipulated by the internal assessment criteria. This formative assessment leads to entrance into the integrated external summative assessment.

Integrated Summative Assessment:
An external integrated summative assessment, conducted through the relevant Quality Council for Trades and Occupations (QCTO) Assessment Quality Partner is required for the issuing of this qualification. The external integrated summative assessment will focus on the Exit Level Outcomes and Associated Assessment Criteria. The external assessment will be conducted through the evaluation of on the job performance and written assessment at approved workplace sites by registered assessors.

INTERNATIONAL COMPARABILITY

The South African Metal Manufacturing Process Control Technician's occupation has six specialised occupational qualifications which include: Material Preparation Process Controller, Rolling Process Controller, Casting Process Controller, Melting and Refining Process Controller, Electrolysis Process Controller and Finishing Process Controller. The international comparability study conducted covers all the six specialised occupational qualifications within one qualification and resulting in an extended learning duration. The decision to cover all the six specialised occupational qualification was influenced by the limited amount of training information provided in countries whose qualifications and courses were used for the comparison.

International comparability was done against International Metals Manufacturing Qualifications in Countries such as United Kingdom, New Zeeland, Australia, India, Japan, China, United State of America and Germany due to the highly-developed metal and engineering manufacturing process industries in the above countries and the significance of the metal production qualifications in their respective economies and the advanced technologies used in those countries.

United Kingdom (UK):
Research has indicated that although training in metal manufacturing related courses is offered by some colleges in the UK, information related to the contents of the courses was limited. This made this comparison difficult.

Motherwell College has been found to offer a qualification that resonates to the South African Qualifications in metal manufacturing process controlling processes.

The college offers Engineering SVQ Level 3 over a period of two years.

This course provides the knowledge and skills required by engineering personnel in their relevant industrial fields. Successful completion provides the incumbent with a certification of competence. The course includes:

Complying with Statutory Regulations and Organisational Safety Requirements.

Using and interpreting engineering data and documentation.

Working efficiently and effectively within the Engineering field.

New Zealand:
National Certificate in Manufacturing (Metal and Related Products) (Level 4) has resonance with the competencies to be demonstrated by a qualified learner who has undergone training on the South African occupational qualification for Metal Manufacturing Process Control Technician.

The qualification is designed for people who work as or are training towards team leaders or supervisors that are employed in the manufacturing of metals and related products. The qualification combines specialised manufacturing processes, with technical skills and management skills expected of team leaders or supervisors.

Entry into the qualification was found to be open with some organisations hiring learners from high schools who are taught the skills through assisting experienced workers. At least three years of relevant experience may substitute for the formal qualifications listed above. In some instances relevant experience and/or on-the-job training may be required in addition to the formal qualification.

Tasks listed below are covered in the qualification:

Selecting metal stock for job requirements.

Heating metal in forges and furnaces and hammering, punching and cutting metal using hand tools and machine presses.

Tempering and hardening finished articles by quenching in oil or water baths or by cooling gradually in air.

Preparing electrolytic and silver solutions for electroforming, and applying solution to the objects to be coated.

Setting and adjusting controls to regulate electric current and depositing of coating on objects.

Preparing horses' hooves for shoeing, nailing horseshoes to hooves, and trimming hooves.

Cutting, trimming, shaping and smoothing stock to form mould patterns.

Filling boxes with sand and setting patterns in place, and pouring molten metal into moulds.

Applying refractory paint and positioning cores in moulds.

Finishing metal and articles by polishing and buffing and applying shellac, lacquer, paint and other finishes.

Similarities:
With limitations regarding the contents of training offered in countries visited, research has indicated that the competencies required for Metals Manufacturing Process Controllers are very similar to the limited information found. The proposed occupational qualifications that have been developed for the South African context cover all of the required components and can therefore be considered as equivalent or more advanced than found in other countries.

Similarities have been found in areas such as: controlling process operations; technical support; teamwork; work handover; preparing, controlling, maintaining, restoring and completing processing operations; quality management; cleaning and preparing equipment; Safety, Health, Environment and Quality (SHEQ) requirements; problem solving; risk assessment and quality control.

Conclusion:
The competencies covered in the Metal Manufacturing Melting and Refining Process Controller qualification are similar to the qualifications and courses that are offered in countries compared with.

ARTICULATION OPTIONS

Horizontal Articulation
This qualification articulates horizontally with following qualifications:

Occupational Certificate: Melter, Level 4, SAQA ID 91877.

Vertical Articulation:
This qualification articulates vertically with the following qualification:

National Certificate: Manufacturing Management, Level 5, SAQA ID 49743.

MODERATION OPTIONS

N/A

CRITERIA FOR THE REGISTRATION OF ASSESSORS

N/A

NOTES

Qualifying for external assessment:
In order to qualify for an external assessment, learners must provide proof of completion of all required standards by means of statements of results and work experience including the Foundational Learning Competence.

Additional legal or physical entry requirements:
None.

Criteria for the accreditation of providers:
Accreditation of providers will be done against the criteria as reflected in the relevant curriculum on the Quality Council for Trades and Occupations (QCTO) website.

The curriculum title and code is: Metal Manufacturing Melting and Refining Process Controller: 313501004.

This qualification encompasses the following trades as recorded on the NLRD:

This is not a trade qualification.

Part Qualifications
None.

LEARNING PROGRAMMES RECORDED AGAINST THIS QUALIFICATION:

When qualifications are replaced, some (but not all) of their learning programmes are moved to the replacement qualifications. If a learning programme appears to be missing from here, please check the replaced qualification.

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PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS QUALIFICATION:

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.

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