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 QUALIFICATION:

Occupational Certificate: Metal Manufacturing Casting Process Controller

SAQA QUAL ID	QUALIFICATION TITLE
102160	Occupational Certificate: Metal Manufacturing Casting 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	205	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 does not replace any other qualification and is not replaced by any other qualification.

PURPOSE AND RATIONALE OF THE QUALIFICATION

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

A Metal Manufacturing Casting Process Controller controls the operational efficiency of the casting process of metal including operating and monitoring multi-functional machinery and equipment.

A qualified learner will be able to:

Execute activities related to casting processes.

Rationale:
The metal manufacturing casting process is characterised by diverse manufacturing casting 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 casting 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 casting 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 casting 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 casting processes environment is enhanced and of a high standard. The qualification will allow learners to develop their knowledge and skills in the metal manufacturing casting 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 casting operator.

RECOGNISE PREVIOUS LEARNING?

QUALIFICATION RULES

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

Knowledge Modules:

313501003-KM-01, Occupational Health and Safety and environmental requirements for manufacturing process controller, Level 4, 8 Credits.

313501003-KM-02, Process Plant management for manufacturing process controller, Level 4, 24 Credits.

313501003-KM-03, Quality Management systems for a manufacturing process controller, Level 4, 5 Credits.

313501003-KM-04, Monitoring and controlling requirements for the casting process, Level 4, 12 Credits.

313501001-KM-05, Casting Materials Handling, Level 3, 12 Credits.
Total number of credits for Knowledge Modules: 61.

Practical Skill Modules:

313501003-PM-01, Comply with Health, Safety and environmental requirements, Level 4, 8 Credits.

313501003-PM-02, Comply with plant management requirements, Level 3, 8 Credits.

313501003-PM-03, Comply with quality standards, Level 4, 8 Credits.

313501003-PM-4, Start, monitor and control material availability/movement and relevant equipment during the casting processes, Level 4, 24 Credits.
Total number of credits for Practical Skill Modules: 48.

This qualification also requires the following Work Experience Modules:

313501003-WM-01, Risk Management, Level 4, 8 Credits.

313501003-WM-02, Materials and handling processes, Level 4, 32 Credits.

313501003-WM-03, Administration and coordination of processed product handling processes, Level 3, 8 Credits.

313501003-WM-04, Casting process activities, Level 4, 48 Credits.
Total number of credits for Work Experience Modules: 96.

EXIT LEVEL OUTCOMES

1. Conduct a risk assessment in the metal casting process operations by identifying appropriate actions that deal with deviations and mitigate the associated risks.
2. Prepare and start the metal casting process equipment in sequence.
3. Monitor and control molten material at the casting process.
4. Stop the metal casting process equipment sequentially.

ASSOCIATED ASSESSMENT CRITERIA

Associated Assessment Criteria for Exit Level Outcome 1:

Describe and identify the typical hazard, risk assessment systems and process are valid and indicate how these systems are applied at the worksite.

Identify, describe and explain occupational health, safety and environmental information pertaining to the casting processes and identify; and include what actions must be taken to mitigate the associated risks.

Demonstrate the ability to conduct candidates' physical risk assessment in metal manufacturing process environments following all the required procedures and standards.

Associated Assessment Criteria for Exit Level Outcome 2:

Perform the plant specific pre-start checks according to plant specific procedures.

Prepare the casting equipment/area in accordance with plant specific procedures.

Start-up the equipment sequence in accordance with plant specific procedures.

Monitor and identify the start-up process molten material and correct deviations according to plant specific procedures.

Associated Assessment Criteria for Exit Level Outcome 3:

Select the correct parameters and casting medium as per requirements.

Cast the molten material from the furnace/pot as per plant specific procedures.

Communicate the process performance monitored and controlled according to plant specific procedures.

Communicate the process deviations monitored and controlled according to plant specific procedures.

Explain the potential deviations and their associated corrective actions according to plant specific procedures.

Identify all sampling points in the specific operations.

Take the relevant samples in accordance with plant specific procedure.

Record the location of the parameter data and all relevant data pertaining to the casting process.

Associated Assessment Criteria for Exit Level Outcome 4:

Stop the casting equipment in sequence according to plant specific procedures.

Explain the various conditions that warrant the stopping processes.

Explain the various unsafe conditions that emanate from an uncontrolled stoppage.

Communicate and report the reasons for stoppage 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.

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 Zealand, 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:
Research has indicated that although training in metal manufacturing related courses is offered by some colleges in the United Kingdom (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 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 whom 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 similar with ors more advanced than those 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 Casting Process Controller qualification are similar to the qualifications and courses that are offered in the countries compared with.

ARTICULATION OPTIONS

Horizontal Articulation:
This qualification articulates horizontally with following qualifications:

Occupational Certificate: Melter, Level 4.

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

National Certificate: Manufacturing Management, Level 5.

MODERATION OPTIONS

N/A

CRITERIA FOR THE REGISTRATION OF ASSESSORS

N/A

NOTES

N/A

LEARNING PROGRAMMES RECORDED AGAINST THIS QUALIFICATION:

NONE

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.

NONE