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 THAT HAS PASSED THE END DATE: 

Optimise maintenance activities and practices for high-speed production lines 
SAQA US ID UNIT STANDARD TITLE
114717  Optimise maintenance activities and practices for high-speed production lines 
ORIGINATOR
SGB Food 
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 5  Level TBA: Pre-2009 was L5  18 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Passed the End Date -
Status was "Reregistered" 		 2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

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 does not replace any other unit standard and is not replaced by any other unit standard. 

PURPOSE OF THE UNIT STANDARD 
High-speed production lines consist of equipment which integrates a variety of functions, processes and complex control systems. They require constant and on-going maintenance and repair. The maintenance and repair activities and practices require constant review which results in continuous improvement.
This unit standard reflects the skills, values and knowledge required to analyse these maintenance and repair activities and practices, test and implement solutions and evaluate the impact of the changes. Learners will also have to demonstrate a good understanding of repair and maintenance to all aspects of the integrated manufacturing system, including:
  • Mechanical components
  • Services
  • Electrical component and equipment
  • Electronic components
  • Instrumentation
  • Communication and control systems.
    The learning outcomes in this unit standard also contribute to the exit level outcomes required for the National Certificate in Maintenance of High-speed Production Processes (Fast-moving Consumer Goods): NQF Level 5 and related qualifications. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    This unit standard has been designed to fit into a qualification and as part of a progression. It is one of a series of unit standards for repair and maintenance of high-speed integrated manufacturing processes.
    If learners have experience in these related activities but do not have credits for them, they can obtain credits by being assessed through a process that recognises prior learning. If they do not have such experience of related activities, then their learning time will be increased. Learners can choose to be assessed and obtain credits against those other unit standards as they make progress towards the outcomes of this unit standard.

    The credits allocated to this unit standard assume that learners:
  • Have a qualification at Level 4 in one or more of the maintenance disciplines
  • Have experience of maintenance in the context of high-speed integrated manufacturing machinery and equipment
  • Are familiar with some of the other disciplines related to such integrated equipment. 
    		•

    UNIT STANDARD RANGE 
    The ranges as indicated under the specific outcomes determine the scope and level of this unit standard.
    Where maintenance is mentioned, repair is included. 

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Analyse maintenance records, observe maintenance activities, record data and identify opportunities. 
    OUTCOME NOTES 
    Analyse maintenance records, observe maintenance activities, record data and identify opportunities for improvement.
  • Consult maintenance and production personnel. 
    		•
    OUTCOME RANGE 
    Maintenance includes repair. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Results achieved
    1. Implemented changes yield quantifiable and observable improvements
    2. Optimisation projects are performed in varying situations

    Indicators
    1. All repair and maintenance activities meet quality standards
    2. Improvements reduce cost, increase machine reliability, operability and availability
    3. Maintenance and production personnel adopt and maintain the new practices
    4. All relevant procedures are applied
    5. All resources are used effectively and efficiently, wastage and damage is minimised

    Understanding confirmed
    1. Respond to questions and enter into discussions with respect to:
  • Repair and maintenance issues related to all aspects of the integrated manufacturing system
  • Underlying principles used in planning the optimisation process
  • Difficulties, problems, incidents that can be anticipated or were experienced during the implementation process
  • Key quality factors 
    		•

    SPECIFIC OUTCOME 2 
    Generate, test and evaluate options to achieve improvement. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Results achieved
    1. Implemented changes yield quantifiable and observable improvements
    2. Optimisation projects are performed in varying situations

    Indicators
    1. All repair and maintenance activities meet quality standards
    2. Improvements reduce cost, increase machine reliability, operability and availability
    3. Maintenance and production personnel adopt and maintain the new practices
    4. All relevant procedures are applied
    5. All resources are used effectively and efficiently, wastage and damage is minimised

    Understanding confirmed
    1. Respond to questions and enter into discussions with respect to:
  • Repair and maintenance issues related to all aspects of the integrated manufacturing system
  • Underlying principles used in planning the optimisation process
  • Difficulties, problems, incidents that can be anticipated or were experienced during the implementation process
  • Key quality factors. 
    		•

    SPECIFIC OUTCOME 3 
    Develop optimisation plan, brief maintenance and production personnel and implement plan. 
    OUTCOME NOTES 
  • Clarify the objectives of the plan with all personnel
  • Evaluate feedback and adjust plan where warranted. 
    		•

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Results achieved
    1. Implemented changes yield quantifiable and observable improvements
    2. Optimisation projects are performed in varying situations

    Indicators
    1. All repair and maintenance activities meet quality standards
    2. Improvements reduce cost, increase machine reliability, operability and availability
    3. Maintenance and production personnel adopt and maintain the new practices
    4. All relevant procedures are applied
    5. All resources are used effectively and efficiently, wastage and damage is minimised

    Understanding confirmed
    1. Respond to questions and enter into discussions with respect to:
  • Repair and maintenance issues related to all aspects of the integrated manufacturing system
  • Underlying principles used in planning the optimisation process
  • Difficulties, problems, incidents that can be anticipated or were experienced during the implementation process
  • Key quality factors. 
    		•

    SPECIFIC OUTCOME 4 
    Collect and evaluate results; review and adjust the optimisation process until. 
    OUTCOME NOTES 
    Collect and evaluate results; review and adjust the optimisation process until objectives have been achieved.
  • Monitor the optimised process to ensure that new practices are applied consistently. 
    		•

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Results achieved
    1. Implemented changes yield quantifiable and observable improvements
    2. Optimisation projects are performed in varying situations

    Indicators
    1. All repair and maintenance activities meet quality standards
    2. Improvements reduce cost, increase machine reliability, operability and availability
    3. Maintenance and production personnel adopt and maintain the new practices
    4. All relevant procedures are applied
    5. All resources are used effectively and efficiently, wastage and damage is minimised

    Understanding confirmed
    1. Respond to questions and enter into discussions with respect to:
  • Repair and maintenance issues related to all aspects of the integrated manufacturing system
  • Underlying principles used in planning the optimisation process
  • Difficulties, problems, incidents that can be anticipated or were experienced during the implementation process
  • Key quality factors. 
    		•

    SPECIFIC OUTCOME 5 
    Compile reports and update maintenance procedures. 
    OUTCOME NOTES 
    Maintenance procedures include any relevant and related documentation. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Results achieved
    1. Implemented changes yield quantifiable and observable improvements
    2. Optimisation projects are performed in varying situations

    Indicators
    1. All repair and maintenance activities meet quality standards
    2. Improvements reduce cost, increase machine reliability, operability and availability
    3. Maintenance and production personnel adopt and maintain the new practices
    4. All relevant procedures are applied
    5. All resources are used effectively and efficiently, wastage and damage is minimised

    Understanding confirmed
    1. Respond to questions and enter into discussions with respect to:
  • Repair and maintenance issues related to all aspects of the integrated manufacturing system
  • Underlying principles used in planning the optimisation process
  • Difficulties, problems, incidents that can be anticipated or were experienced during the implementation process
  • Key quality factors. 
    		•


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
    The assessment will be governed by the policies and guidelines of a relevant ETQA. The assessor will be accredited and have a technical qualification in this learning area.

    The learner can be assessed in the language of his/her choice although if s/he has to report incidents or conditions to someone else, the learner will be assessed on his/her ability to report in the language commonly used in his/her working environment.

    The learner will be assessed in the workplace but s/he can submit documents, projects, test results and assignments that were not produced in the workplace.

    The learner can be assessed against this unit standard to obtain credits or as part of an integrated assessment for a qualification. 

    UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    1. Names & functions of:
  • All equipment, components, tools and documents related to maintenance and repair
  • Maintenance and repair activities, practices and methodologies

    2. Purpose of:
  • All equipment, components, tools and documents related to maintenance and repair
  • Maintenance and repair activities, practices and methodologies

    3. Attributes, descriptions, characteristics & properties:
  • Various approaches to maintenance
  • All relevant equipment, components, tools
  • Maintenance and repair methodologies

    4. Processes and events:
  • Continuous improvement
  • Maintenance

    5. Causes and effects, implications of:
  • Impact and effect of changes on the system as a whole and the manufacturing process and product in particular
  • Poor planning and implementation
  • Lack of buy-in from affected personnel
  • Poor data collection methods and inaccurate records
  • The materials being processed or used for packaging
  • Poor maintenance results

    6. Procedures and techniques:
  • Analysis and research techniques
  • Methods of collecting, analysing, organising, summarising and presenting data
  • Methods of testing solutions
  • Methods for limiting the effects of specific changes

    7. Regulations, legislation, agreements, policies, standards:
  • Company rules and procedures
  • Safety, health and environmental regulations
  • By-laws
  • Machinery and equipment manufacturers' standards

    8. Theory: rules, principles, laws:
  • Principles of reliability-centred maintenance

    9. Relationships, systems:
  • Link between the manufacturing process, the type of materials being processed, the end products and the maintenance activities and practices. 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems
  • Repair and maintenance problems in integrated, high-speed manufacturing equipment and machinery
  • Resistance to change among maintenance and production personnel 
    		•

    UNIT STANDARD CCFO WORKING 
    Work effectively with others
  • Obtain co-operation in the implementation of new activities and practices
  • Encourage the adoption of new practices and procedures 
    		•

    UNIT STANDARD CCFO ORGANISING 
    Organise and manage myself and my activities
  • Work methodically and systematically to achieve a planned result. 
    		•

    UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information
  • Evaluate maintenance records
  • Observe and note practices and procedures 
    		•

    UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively
  • Present new plans
  • Obtain and respond to feedback 
    		•

    UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically
  • Apply scientific method to the optimisation process
  • Work with complex technology in integrated manufacturing lines 
    		•

    UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems
  • Evaluate the effect on the whole system of changes to one point in the system 
    		•

    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 
    Supplementary Information:

    How credits were determined:

    Classroom learning 40 hours
    On-the-job learning 80 hours
    Self directed learning 40 hours, through Assignments, additional reading
    Coaching required 10 hours
    Other 10 hours, through Portfolio development
    Total hours 180 hours 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  48730   National Certificate: Maintenance of High-speed Production Processes (Fast-moving Consumer Goods)  Level 5  Level TBA: Pre-2009 was L5  Passed the End Date -
    Status was "Reregistered"     		 2015-06-30  FOODBEV 


    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.
     
    NONE 


    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.