SAQA

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SOUTH AFRICAN QUALIFICATIONS AUTHORITY

REGISTERED QUALIFICATION:

Occupational Certificate: Moulder

SAQA QUAL ID	QUALIFICATION TITLE
91785	Occupational Certificate: Moulder
ORIGINATOR
Development Quality Partner - MERSETA
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY			NQF SUB-FRAMEWORK
QCTO - Quality Council for Trades and Occupations			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	364	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
66449	National Certificate: Foundry Operations	Level 3	NQF Level 03	126	Complete
66489	Further Education and Training Certificate: Foundry Operations	Level 4	NQF Level 04	128	Complete
66512	National Certificate: Foundry Operations	Level 2	NQF Level 02	121	Complete

PURPOSE AND RATIONALE OF THE QUALIFICATION

Purpose:
The purpose of this qualification is to prepare a learner to operate as a moulder.

Moulders install, test, repair and operate moulding/core making machines, sand plant, equipment and system components for the purpose of creating a sand-moulded cavity (including cores where required) by hand or machine, into which metal is poured producing quality metal castings in foundries.

A qualified learner will be able to:

Plan and prepare for the operations of a moulding/core making production process at NQF Level 3.

Produce moulds, produce and assemble cores, and close moulds NQF Level 4.

Set up, operate, make adjustments and perform first line maintenance on sand plant and moulding/core making equipment NQF Level 4.

Solve moulding/core making operations and casting defect problems and adjust and maintain moulding/core making process NQF Level 4.

Rationale:
A shortage of Moulding skills and capacity within the industry was identified as one of the major gaps within the Foundry Industry and listed on the critical skills list of the MERSETA.

The range of typical learners that will enter this qualification are people who would like to gain access to employment opportunities in Moulding specifically working within a Foundry environment.

This qualification resides as one of several in the mechanical engineering and manufacturing environments and makes allowance for any feeder occupation within this context to gain access to the Moulder qualification. The Moulder qualification also makes provision for people to progress within this discipline to other aspects such as mould and core production and assembly processes and moulding and core making machine operations and processes.

The main benefits of this qualification are that the learner has an opportunity to be recognised as a qualified artisan with well-structured, relevant and current competencies and have access to skilled employment opportunities within the mechanical engineering and manufacturing environments.

Society will be served by qualified Moulders that not only undertake work with improved skills but are also contributing to the competitiveness of South Africa's manufacturing sector. The overall benefits for the economy would include efficient and effective Moulder competencies available to be utilised for economic growth purposes.

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:
NQF Level 3 qualification equivalent to N2 knowledge areas of Engineering Maths, Science and Engineering Drawing.

RECOGNISE PREVIOUS LEARNING?

QUALIFICATION RULES

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

Knowledge Modules:

Applied Mathematics, Sciences and Drawings, NQF Level 4, 3 Credits.

Metallurgy and Moulding Processes, NQF Level 4, 12 Credits.

Health, Safety, Quality and Legislation, NQF Level 3, 10 Credits.

Environment, Energy Efficiency and Ethics, NQF Level 4, 5 Credits.

Tools, Equipment, Materials and Workplace Practice, NQF Level 4, 12 Credits.

Sand Technology and Sand Casting, NQF Level 4, 25 Credits.

Casting and Die Casting, NQF Level 4, 23 Credits.

Total number of Credits for Knowledge Modules: 90.

Practical Skill Modules:

Plan and prepare for sand analysis, NQF Level 2, 4 Credits.

Plan and prepare moulding/core making equipment and consumables, NQF Level 2, 4 Credits.

Prepare, set up, operate, monitor, maintain and adjust moulding/core making machines, equipment and operations, NQF Level 3, 10 Credits.

Prepare for the operations of a moulding/core making production process, NQF Level 4, 4 Credits.

Produce a mould, NQF Level 3, 6 Credits.

Produce and assemble cores and close mould, NQF Level 4, 25 Credits.

Produce cores manually and or by machine, NQF Level 3, 18 Credits.

Produce a loose pattern mould, NQF Level 3, 15 Credits.

Produce mould by core assembly, NQF Level 3, 10 Credits.

Produce strickle mould, NQF Level 4, 5 Credits.

Develop a metal casting process, NQF Level 4, 4 Credits.

Monitor equipment indicators and inspect product, NQF Level 4, 10 Credits.

Communicate safety, health, environmental and quality issues affecting moulding/core making equipment and operations, NQF Level 2, 2 Credits.

Prepare for and perform changeovers and finishing activities, NQF Level 3, 10 Credits.

Adjust and maintain production process, NQF Level 4, 10 Credits.

Conduct problem solving activities to address product and process tooling problems, NQF Level 4, 4 Credits.

Execute the operations function in a moulding/core making production process, NQF Level 4, 4 Credits.

Conduct first line maintenance activities in a moulding/core making production process, NQF Level 4, Credits.

Total number of credits for Practical Skill Modules: 149.

This qualification also requires the following compulsory Work Experience Modules:

Planning, preparing and team communication processes related to moulding/core making equipment, materials and consumables, NQF Level 4, 10 Credits.

Mould and core production and assembly processes, NQF Level 4, 70 Credits.

Moulding and core making machine operations and processes, NQF Level 4, 35 Credits.

Problem-solving and adjustment and maintenance of Moulding and core making production processes, NQF Level 4, 10 Credits.

Total number of credits for Work Experience Modules: 125.

EXIT LEVEL OUTCOMES

1. The ability to plan and prepare for the operations of a moulding/core making process.
2. The ability to produce moulds, produce and assemble cores, and close moulds.
3. The ability to set-up, operate, maintain and make adjustments to equipment used in a foundry moulding/core making environment.
4. The ability to solve moulding/core making operations and casting defect problems and adjust and maintain a moulding/core making process.

ASSOCIATED ASSESSMENT CRITERIA

The ability to plan and prepare for the operations of a moulding/core making process.

Associated Assessment Criteria for Exit Level Outcome 1:

Moulding sand is sampled and prepared in accordance with specific standard operating procedures as an integral part of sand analysis.

Pre-check activities and /or checklists are completed for the specific moulding equipment, tools, materials and consumables required to perform the job in accordance with standard operating procedures.

The sequencing of the task is determined and meets the requirements of the job instructions and timeframes.

Knowledge and understanding to plan and prepare for the operations of a moulding/coremaking process are demonstrated.

Associated Assessment Criteria for Exit Level Outcome 2:

Production equipment is set and adjustments are made to equipment before proceeding with first production run in accordance with organisational standard operating procedures to meet specifications of customers and equipment.

Moulding machine and support equipment is operated economically, the product and process quality parameters are monitored in line with job and organisation standard operating procedures.

Cores are produced using a range of core manufacturing machines and processes, in sufficient quantities and of acceptable quality to satisfy the job, in accordance with organisation standard operating procedures.

Coremaking pattern equipment, tools, materials and consumables are inspected, prepared and set up for core manufacturing process in line with organisational practice.

Moulds are produced to job and quality requirements in line with best practice and organisation operating procedures.

Mould sections are layered and assembled to job and quality requirements in line with best practice and organisation operating procedures.

Strickle moulding area is prepared and the mould/core layout is marked on the strickle board.

Knowledge and understanding to produce moulds, produce and assemble cores, and close moulds are demonstrated.

Associated Assessment Criteria for Exit Level Outcome 3:

Customer metal casting requirements are analysed in terms of metal specification, shape, size, volumes and are mapped against available production resources, existing production commitments, required delivery dates and profit margins in developing a metal casting process.

Quality inspection and test results are available and communicated to appropriate parties in accordance with organisation standard operating procedures.

A process to systematically gather and record information on the nature and possible causes of equipment and process problems is implemented through visual inspections on the machines, observation during operations and statistical process control.

Knowledge and understanding to set-up, operate, maintain and make adjustments to equipment used in a foundry moulding/core making environment are demonstrated.

Associated Assessment Criteria for Exit Level Outcome 4:

Changeover parts or packaging material are received and maintained in order for the changeover to be done as quickly as possible to keep the changeover timing low.

Start up and shut down of machines is done in accordance with the sequence and timing required to ensure that starts and/or stops does not induce any unnecessary mechanical or thermal damage or cause cyclic conditions on the components of the system which may lead to premature failure or forced outages.

A suitable problem solving methodology is used to identify the symptoms, determine possible causes, minimise number of possible causes through elimination, identify most probable cause, define number of possible solutions, select best solution, implement solution, verify success of solution and establish solution as best practice.

Production information is completed, compiled and reported on through daily production sheets in accordance with standard operating procedures and policies.

All maintenance activities, specifically with regard to moulding/coremaking operations, moulding/core making plant and moulding/core making equipment, as planned and scheduled are communicated to relevant staff to make sure the maintenance is properly carried out.

Knowledge and understanding to solve moulding/core making operations and casting defect problems and adjust and maintain moulding/core making process are demonstrated.

Integrated Assessment:
An external integrated summative assessment, conducted through the relevant 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 model requires that the external assessment will be conducted through a combination of a written assessment and practical task at an accredited trade test centre. The written examination will be concluded at an accredited trade test centre and marked by registered assessors. Practical tasks will also be assessed by registered assessors. The combination of the written and practical assessment will be conducted over a period of two working days.

INTERNATIONAL COMPARABILITY

The South African Institute of Foundrymen (SAIF) and the National Foundry Technology Network (NFTN) in conjunction with the Community of Expert Practitioners (CoP) and other industry stakeholders, including the Aluminium Federation of South Africa and the training institutions, notably the University of Johannesburg, decided to conduct a comparability review of this curriculum with the following three countries considered leaders in the field of metal casting technology and production.

The United States of America (USA), has been one of the leaders in casting technology of both non-ferrous and ferrous metals and their alloys. There are approximately two thousand foundries in the USA and the research institutions are globally recognised for both the quality and quantity of the research projects published.

Germany has a vibrant foundry industry of over 900 individual plants, on which their heavy engineering plant manufacturing sector as well as the highly developed rail, sea and road transportation sector is based. Germany is a leader in wind energy turbine development, and leads the world in the demanding technology required for these applications. Their training and research establishments are world-renowned.

India became in 2010 the second largest casting manufacturer in the world. Its foundry industry has been developed for many years, but recently has been growing at significant levels and produces for all the engineering sectors, including automotive, agricultural implements and tractors, infrastructure projects and manufactured products. The Indian Institute of Foundrymen, is represented at the BRICS Foundry Forum, of which South Africa is also a member.

According to the research conducted by Modern Castings in 2011, the United States of America, Germany and India, are in the four top casting producers in the world. They are also amongst the leading research countries in the field of metal casting and have developed innovative casting technologies in their respective countries. They are considered to be appropriate countries with which to compare our curriculum.

Germany and the USA provide specialisation areas within the curricula.

The analysis of the occupations provided evidence that there is a high level of commonalities between them. All occupations are regarded as trade/occupational qualifications and stipulate a set of national standards in all three countries. In Germany and India a nationally standardised trade test is conducted to award the qualifications. In the USA different standards apply in various states and no standardised approach to national summative assessment is followed.

Due to the fact that the principles of foundry processes and the occupational challenges they face are all very alike, similarity was found across all four countries (including South Africa) in:

Occupational context, technical content and competencies required.

Tasks to perform.

Job titles used.

Materials, equipment and tools.

Life skills.

Emphasis on the practical and on-the-job training.

Conclusion:
The South African qualification is comparable to what is found in the chosen benchmark, in terms of what the qualification covers and the level of skills that have to be developed. It is, however, designed to meet the needs of the South African foundry industry as well as to meet the current transformational challenges in South Africa.

ARTICULATION OPTIONS

Learners entering this qualification will likely feed into the industry with an Occupational Certificate: Engineering Production Systems Worker.

The likely vertical progression for a qualified learner with this qualification is an Occupational Certificate: Manufacturing Technician (Metal Manufacturing Technician).

This Occupational Certificate articulates horizontally with other foundry trades and occupations with cross-cutting credits in the Knowledge Specifications. This includes, Occupational Certificates: Engineering Patternmaker, Melter and Toolmaker.

MODERATION OPTIONS

N/A

CRITERIA FOR THE REGISTRATION OF ASSESSORS

Accreditation of providers will be done against the criteria as reflected in the relevant curriculum on the QCTO website.

REREGISTRATION HISTORY

As per the SAQA Board decision/s at that time, this qualification was Reregistered in 2015.

NOTES

This Qualification replaces the following Qualifications:

66512, "National Certificate: Foundry Operations", Level 2, 121 Credits.

66449, "National Certificate: Foundry Operations", Level 3, 126 Credits.

66489, "Further Education and Training Certificate: Foundry Operations", Level 4, 128 Credits.

This qualification covers the following recorded trades:

ID 61077, Moulder.

ID 61071, Moulder.

ID 61065, Moulder.

ID 61143, Moulder.

ID 61053, Moulder.

ID 61085, Moulding.

Qualifying for External Assessment:
In order to qualify for an external assessment, learners must provide proof of completion of all required modules by means of statements of results and work experience.

Foundational Learning:
Foundational learning competence is a pre-requisite for the awarding of this qualification.

Part Qualifications:
This qualification does not have any associated part qualifications.

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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