SAQA

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SOUTH AFRICAN QUALIFICATIONS AUTHORITY

REGISTERED QUALIFICATION:

Occupational Certificate: Melter

SAQA QUAL ID	QUALIFICATION TITLE
91877	Occupational Certificate: Melter
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	361	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
66512	National Certificate: Foundry Operations	Level 2	NQF Level 02	121	Complete
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

PURPOSE AND RATIONALE OF THE QUALIFICATION

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

Melters prepare, operate, test, maintain and repair (including refractory material installations) melting equipment and system components (including water cooling systems, charge materials control and handling) for the purpose of producing quality metal castings in foundries.

A qualified learner will be able to:

Plan and prepare for the operations of a melting process, at NQF Level 3.

Set up, operate, maintain and make adjustments to equipment used in a foundry melting environment, at NQF Level 3.

Manufacture molten metal for the production of metal castings, at NQF Level 4.

Solve melting operations and casting defect problems and adjust and maintain melting processes, NQF Level 4.

Rationale:
A shortage of Melting 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 Melting, 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 Melter qualification. The Melter qualification also makes provision for people to progress within this discipline to other aspects, such as molten metal manufacturing casting, pouring and refractories, and furnace and related melting equipment operations and processes.

The main benefits of this qualification for the learner 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 Melters who not only undertake work with improved skills but who also contribute to the competitiveness of South Africa's manufacturing sector. The overall benefits for the economy would include efficient and effective Melter competencies which could be utilised for economic growth purposes.

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING

Entry Requirements:

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

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 results 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.

RECOGNISE PREVIOUS LEARNING?

QUALIFICATION RULES

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

Knowledge Modules:

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

Refractories, NQF Level 3, 5 Credits.

Applied Mathematics, Sciences and Drawings, NQF Level 4, 8 Credits.

Metallurgy and Melting Processes, NQF Level 4, 28 Credits.

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

Tools, Equipment, Materials and Workplace Practice, NQF Level 4, 15 Credits.

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

Casting and Die Casting, NQF Level 4, 15 Credits.

Total number of Credits for Knowledge Modules: 90 Credits.

Practical Skill Modules:

Conduct metal analysis, NQF Level 2, 4 Credits.

Plan for and prepare melting equipment, materials and consumables, NQF Level 2, 4 Credits.

Work with refractory materials, NQF Level 2, 4 Credits.

Communicate safety, health, environmental and quality issues affecting melting equipment and operations, NQF Level 2, 2 Credits.

Prepare, set up, operate, monitor, maintain and adjust furnaces, related melting equipment and operations, NQF Level 3, 10 Credits.

Handle and process raw materials to produce a charge, NQF Level 3, 6 Credits.

Manage and control tapping, NQF Level 3, 25 Credits.

Pour castings in sand moulds or dies (gravity), NQF Level 3, 15 Credits.

Install and maintain refractory materials, NQF Level 3, 10 Credits.

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

Prepare for the operations of a melting production process, NQF Level 4, 4 Credits.

Manufacture molten metal, NQF Level 4, 30 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 melting production process, NQF Level 4, 4 Credits.

Conduct first line electro-mechanical and refractory maintenance activities in a melting production process, NQF Level 4, 4 Credits.

Total number of credits for Practical Skill Modules: 146 Credits.

This qualification also requires the following compulsory Work Experience Modules:

Planning, preparing and team communication processes related to melting equipment, materials and consumables, NQF Level 4, 10 Credits.

Molten metal manufacturing processes, NQF Level 4, 35 Credits.

Casting and pouring processes, NQF Level 4, 35 Credits.

Refractories and furnace and related melting equipment operations and processes, NQF Level 4, 35 Credits.

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

Total number of credits for Work Experience Modules: 125 Credits.

EXIT LEVEL OUTCOMES

1. The ability to plan and prepare for the operations of a melting process.
2. The ability to manufacture molten metal for the production of metal castings.
3. The ability to set-up, operate, maintain and make adjustments to equipment used in a foundry melting environment.
4. The ability to solve melting operations and casting defect problems and adjust and maintain the melting process.

ASSOCIATED ASSESSMENT CRITERIA

Associated Assessment Criteria for Exit Level Outcome 1:

Metal analysis activities are undertaken following the specific steps in the standard operating procedures.

Melting equipment, materials and consumables are planned for and prepared in accordance with a checklist and the job instructions and schedule.

The type of furnace and related melting equipment required are prepared, set up, operated, monitored, maintained and adjusted, using the appropriate sequence of operations including: Electric induction furnace, Electric resistance furnace, Electric arc furnace, Blast furnace, Gas-fired furnace, Crucible furnace and related melting equipment, and Cupola furnace.

Demonstrate knowledge and understanding of the planning and preparation for the operations of a melting process.

Associated Assessment Criteria for Exit Level Outcome 2:

The correct planning and preparation activities are undertaken to secure the required material, tools and equipment so that the sequencing of operations and activities are not negatively affected.

Raw materials are gathered, assessed and prepared in accordance with weight and composition requirements for the charge.

Molten metal is manufactured by charging the furnace and related melting equipment with raw material in the correct sequence: temperature, sequence, methods and procedures, in accordance with type of furnace and alloy to be melted.

Tapping processes are managed and controlled by pouring and pre-calculating metal treatment and adding inoculation, whilst monitoring the operational control procedures and conditions, in accordance with standard operating practices.

Castings are poured in sand moulds or dies (gravity) by interpreting production plans and casting schedules to produce a sequential plan for sand mould and/or gravity die casting in accordance with the schedule reflecting the sequence of operations, job or tasks.

Demonstrate knowledge and understanding to manufacture molten metal for the production of metal castings.

Associated Assessment Criteria for Exit Level Outcome 3:

Refractory materials are used when refractory linings or repairs have to be installed into furnaces and related melting equipment and crucibles.

Refractories are installed and maintained using construction techniques relevant to the refractory material being installed.

Communication activities are planned and implemented in accordance with type of information, type of audience, media available, formats, timeframes and standard operating procedures.

Demonstrate knowledge and understanding of setting-up, operating, maintaining and making adjustments to equipment used in a foundry melting environment.

Associated Assessment Criteria for Exit Level Outcome 4:

Personal safety requirements are adhered to when preparing for and performing changeovers and finishing activities, by making sure that appropriate Personal Protective Equipment is utilised, and compliance with all safety rules and procedures is maintained.

Calibration of instruments and other data collection equipment are checked for conformance to a specific standard when adjusting and maintaining the production process.

Different problem solving techniques are used to conduct problem solving activities in addressing product and process tooling problems.

Operational functions are executed in a melting production process by undertaking the necessary planning and ensuring that the appropriate controls are in place to encourage problem-free handovers which minimise unnecessary downtime.

All maintenance activities, specifically with regard to melting operations, melting plant and melting equipment, as planned and scheduled, are communicated to relevant staff to ensure that maintenance is properly carried out.

Demonstrate knowledge and understanding to solve melting operations and casting defect problems, and adjust and maintain the melting process.

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 combined written and oral external assessment will be conducted at an accredited trade test centre.

The written examination will be conducted 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) and other industry stakeholders, including the Aluminium Federation of South Africa, and training institutions, such as the University of Johannesburg, conducted a comparability review of this curriculum with the following two countries which are 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 their 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.

The above were found to comprise some of the standards relevant to the South African Melter curriculum but does not cover all equipment and system components of the melting process as comprehensively as does this qualification, which is also due the different occupational profiles and purposes of the qualifications. These findings and the non-existence of a melter curriculum were confirmed by the German 'Institut f�r Gie�ereitechnik'.

This clearly illustrates that the South African Melter qualification is distinct from what was found in Germany and the USA.

Detailed comparison:
The above mentioned results made a direct comparison difficult and the analysis therefore focused on commonalities and dissimilarities in a broader sense. The analysis provided evidence that in the context of the foundry industry, the occupational profile of the South African Melter matches a combination of job profiles in the two countries named, in essence requiring similar competencies. Job profiles that can be associated with a melter in both countries are mainly related to the operation of furnaces. This confirms that the curriculum is introducing a new generation of melters who are far more skilled. They are equipped with competencies to take responsibility for the production of molten metal within a modern foundry sector that competes globally.

Conclusion:
This comparability review reflects the current status of the availability of related curricula in the two countries. According to the findings the South African qualification is not directly comparable to what is found internationally, in terms of what the qualification covers and the level of skills that have to be developed. It is, however, designed to accommodate the changing skills requirements to meet the needs of the South African foundry industry as it is strategically positioned for growth and innovation, 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 in Engineering Production Systems Worker.

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

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

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

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 this qualification.

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

This Qualification replaces the following Qualifications:

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

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

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

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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