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: 

Prepare, set up and operate process equipment 
SAQA US ID UNIT STANDARD TITLE
116596  Prepare, set up and operate process equipment 
ORIGINATOR
SGB Manufacturing and Assembly Processes 
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 3  NQF Level 03  36 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Passed the End Date -
Status was "Registered" 		 2004-04-07  2007-04-07  SAQA 0553/04 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2008-04-07   2011-04-07  

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 replaces: 
US ID Unit Standard Title Pre-2009 NQF Level NQF Level Credits Replacement Status
9901  Prepare and set up process equipment  Level 3  NQF Level 03  36   

This unit standard is replaced by: 
US ID Unit Standard Title Pre-2009 NQF Level NQF Level Credits Replacement Status
259697  Prepare, set up and operate process equipment in a production environment  Level 3  NQF Level 03  36   

PURPOSE OF THE UNIT STANDARD 
Preparing, setting up and operating process equipment for a manufacturing process. 

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
This unit standard has been designed as part of a progression. It is one of a series of unit standards for activities below, at and above this level. The credits assigned to it are based on the assumption that I am learning what is needed for this unit standard as part of my learning for a range of related unit standards at this level or below it.

If I have experience in these related activities but do not have credits for them, I can obtain credits by being assessed through a process that recognises prior learning.

If I do not have such experience of related activities, then my learning time will be increased. I can choose to be assessed and obtain credits against those other unit standards as I make progress towards the outcomes of this unit standard. 

UNIT STANDARD RANGE 
A general guide to the scope, context conditions, and level at which I am expected to perform.

1. In this unit standard, the learner is required to prepare, set up and operate process equipment for the manufacturing process.

2. This unit standard is designed for learners learning and working in a particular process within a specific metals production environment, for example:
  • For iron and steel, these may include: iron making, the direct reduction process, coke making, steel making and refining, liquid metal casting, steel reheating and hot working, steel cold working, steel cold processing and product coating.
  • For aluminium, these may include the direct reduction process, liquid metal casting, anode making, anode baking, anode rodding, briquette making, aluminium reheating and hot working, aluminium cold working, and gas, fumes and bath treatment.
  • For copper, these may include the electrolysis, direct reduction process, copper refining, liquid metal casting, copper hot working, copper cold working.
  • For graphite, these may include mill mixing and forming, baking, pitch impregnation, graphitising, machining. 
    		•

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Plan set up process. 
    OUTCOME NOTES 
  • Read interpret and communicate production schedule
  • Determine set up requirements
  • Determine sequence of activities to set up manufacturing equipment 
    		•
    OUTCOME RANGE 
    Process equipment includes all equipment in the manufacturing process, e.g. furnaces, casting machines, mills, holding vessels, roll stands, tundishes, converters, kilns, degassers, ovens, stokers, stoves, pots, reactors, pot tending machinery, autoclaves, ingot lines, coolers, moulding vibrators/presses, mixers, machining equipment, loading machinery (trolleys, tractors, front end loaders forklifts), crushers, flying saw, horizontal castors, degassing equipment, rolling ingot vdc, rod mills. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    How will I be able to judge if I am capable? How will I be assessed? Evidence which will show that I have mastered the skill:

    1. Set up meets equipment and process specifications
    2. First production run meets specifications
    3. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Equipment was set up to manufacturer and customer specifications
    2. Procedures for setting up, operating, monitoring, recording, working safely communicating and quality are adhered to
    3. Problems and corrections are recorded and communicated
    4. A clean and safe work environment is maintained

    Understanding confirmed:
    1. Explain, show and discuss consequences of poor planning, poor practices, incorrect settings, changes in production schedule
    2. Explain, show and discuss the set up process / procedures and the different systems that enable the machinery to function, e.g. hydraulic, pneumatic, heating, cooling and electrical systems
    3. Explain, show and discuss the operating and monitoring activities
    4. Describe how to respond to emergencies, e.g. power failures, fire, temperature, overflows, cobbles, breakouts, under fills, system failures 

    SPECIFIC OUTCOME 2 
    Prepare and set up equipment for use. 
    OUTCOME NOTES 
  • Inspect manufacturing equipment
  • Test functionality of equipment
  • Set parameters for equipment
  • Make necessary adjustments to equipment
  • Check auxiliary services are available 
    		•
    OUTCOME RANGE 
  • Set up includes alignment, calibration, replacement of components and parts, preheating, lubrication, positioning, roll gap setting, verifying checklists.
  • Auxiliary services include gas, water, hydraulics, pneumatics; iron, refractories and cathode lining materials. 
    		•

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    How will I be able to judge if I am capable? How will I be assessed? Evidence which will show that I have mastered the skill:

    1. Set up meets equipment and process specifications
    2. First production run meets specifications
    3. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Equipment was set up to manufacturer and customer specifications
    2. Procedures for setting up, operating, monitoring, recording, working safely communicating and quality are adhered to
    3. Problems and corrections are recorded and communicated
    4. A clean and safe work environment is maintained

    Understanding confirmed:
    1. Explain, show and discuss consequences of poor planning, poor practices, incorrect settings, changes in production schedule
    2. Explain, show and discuss the set up process / procedures and the different systems that enable the machinery to function, e.g. hydraulic, pneumatic, heating, cooling and electrical systems
    3. Explain, show and discuss the operating and monitoring activities
    4. Describe how to respond to emergencies, e.g. power failures, fire, temperature, overflows, cobbles, breakouts, under fills, system failures 

    SPECIFIC OUTCOME 3 
    Operate equipment and monitor equipment indicators. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    How will I be able to judge if I am capable? How will I be assessed? Evidence which will show that I have mastered the skill:

    1. Set up meets equipment and process specifications
    2. First production run meets specifications
    3. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Equipment was set up to manufacturer and customer specifications
    2. Procedures for setting up, operating, monitoring, recording, working safely communicating and quality are adhered to
    3. Problems and corrections are recorded and communicated
    4. A clean and safe work environment is maintained

    Understanding confirmed:
    1. Explain, show and discuss consequences of poor planning, poor practices, incorrect settings, changes in production schedule
    2. Explain, show and discuss the set up process / procedures and the different systems that enable the machinery to function, e.g. hydraulic, pneumatic, heating, cooling and electrical systems
    3. Explain, show and discuss the operating and monitoring activities
    4. Describe how to respond to emergencies, e.g. power failures, fire, temperature, overflows, cobbles, breakouts, under fills, system failures 

    SPECIFIC OUTCOME 4 
    Liaise with process control personnel and maintenance specialists. 
    OUTCOME NOTES 
    Recognise and report problems, repair needs and preventative maintenance needs. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    How will I be able to judge if I am capable? How will I be assessed? Evidence which will show that I have mastered the skill:

    1. Set up meets equipment and process specifications
    2. First production run meets specifications
    3. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Equipment was set up to manufacturer and customer specifications
    2. Procedures for setting up, operating, monitoring, recording, working safely communicating and quality are adhered to
    3. Problems and corrections are recorded and communicated
    4. A clean and safe work environment is maintained

    Understanding confirmed:
    1. Explain, show and discuss consequences of poor planning, poor practices, incorrect settings, changes in production schedule
    2. Explain, show and discuss the set up process / procedures and the different systems that enable the machinery to function, e.g. hydraulic, pneumatic, heating, cooling and electrical systems
    3. Explain, show and discuss the operating and monitoring activities
    4. Describe how to respond to emergencies, e.g. power failures, fire, temperature, overflows, cobbles, breakouts, under fills, system failures 

    SPECIFIC OUTCOME 5 
    Work safely with due care for self, fellow workers, equipment, materials and the environment. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    How will I be able to judge if I am capable? How will I be assessed? Evidence which will show that I have mastered the skill:

    1. Set up meets equipment and process specifications
    2. First production run meets specifications
    3. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Equipment was set up to manufacturer and customer specifications
    2. Procedures for setting up, operating, monitoring, recording, working safely communicating and quality are adhered to
    3. Problems and corrections are recorded and communicated
    4. A clean and safe work environment is maintained

    Understanding confirmed:
    1. Explain, show and discuss consequences of poor planning, poor practices, incorrect settings, changes in production schedule
    2. Explain, show and discuss the set up process / procedures and the different systems that enable the machinery to function, e.g. hydraulic, pneumatic, heating, cooling and electrical systems
    3. Explain, show and discuss the operating and monitoring activities
    4. Describe how to respond to emergencies, e.g. power failures, fire, temperature, overflows, cobbles, breakouts, under fills, system failures 

    SPECIFIC OUTCOME 6 
    Record all activities and results. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    How will I be able to judge if I am capable? How will I be assessed? Evidence which will show that I have mastered the skill:

    1. Set up meets equipment and process specifications
    2. First production run meets specifications
    3. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Equipment was set up to manufacturer and customer specifications
    2. Procedures for setting up, operating, monitoring, recording, working safely communicating and quality are adhered to
    3. Problems and corrections are recorded and communicated
    4. A clean and safe work environment is maintained

    Understanding confirmed:
    1. Explain, show and discuss consequences of poor planning, poor practices, incorrect settings, changes in production schedule
    2. Explain, show and discuss the set up process / procedures and the different systems that enable the machinery to function, e.g. hydraulic, pneumatic, heating, cooling and electrical systems
    3. Explain, show and discuss the operating and monitoring activities
    4. Describe how to respond to emergencies, e.g. power failures, fire, temperature, overflows, cobbles, breakouts, under fills, system failures 

    SPECIFIC OUTCOME 7 
    Discuss and explain information related to preparing and setting up of manufacturing equipment and the shift changeover procedure. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    How will I be able to judge if I am capable? How will I be assessed? Evidence which will show that I have mastered the skill:

    1. Set up meets equipment and process specifications
    2. First production run meets specifications
    3. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Equipment was set up to manufacturer and customer specifications
    2. Procedures for setting up, operating, monitoring, recording, working safely communicating and quality are adhered to
    3. Problems and corrections are recorded and communicated
    4. A clean and safe work environment is maintained

    Understanding confirmed:
    1. Explain, show and discuss consequences of poor planning, poor practices, incorrect settings, changes in production schedule
    2. Explain, show and discuss the set up process / procedures and the different systems that enable the machinery to function, e.g. hydraulic, pneumatic, heating, cooling and electrical systems
    3. Explain, show and discuss the operating and monitoring activities
    4. Describe how to respond to emergencies, e.g. power failures, fire, temperature, overflows, cobbles, breakouts, under fills, system failures 


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
    My assessment will be governed by the policies and guidelines of the MERSETA Education and Training Quality Assurance body who has jurisdiction over this field of learning. My assessor will be accredited and have a technical qualification in this learning area.

    I can be assessed in the language of my choice although if I have to report incidents or conditions to someone else, I will be assessed on my ability to report in the language commonly used in my working environment.

    I will be assessed in the workplace but I can submit documents, projects, test results and assignments that were not produced in the workplace.

    I 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 
    Things I know and can explain:

    1. Names & functions of:
  • Consumables
  • Materials
  • Components, controls, instruments and equipment
  • Functions of manufacturing units
  • Hydraulic, pneumatic, heating, cooling, electrical, oxygen and gas systems
  • Safety equipment

    2. Attributes, descriptions, characteristics & properties:
  • Materials to be processed
  • Materials used for equipment, machines and tooling
  • Manufacturing process

    3. Sensory cues:
  • Cues for different defects (visual, noise, smell, vibration) related to the setting up of manufacturing equipment

    4. Purpose of:
  • Monitoring equipment indicators
  • Product changeovers
  • Set up procedures
  • Operating and monitoring procedures
  • Quality procedures
  • Health and safety procedures

    5. Processes, events, causes and effects, implications:
  • Temperature and state changes
  • Pressure changes
  • Oil temperature changes
  • Calibration process
  • Impact of settings on product cost
  • Things going wrong, e.g. accidents, power and service failure, wrong or poorly prepared materials, poor planning procedures, change of plan or schedules

    6. Procedures and techniques:
  • Quality
  • Safety
  • Worksite and standard operating
  • Installation and removal
  • Setting and running
  • Operating
  • Shutting down
  • Measurement
  • Monitoring
  • Communication
  • Recording and report

    7. Regulations, legislation, agreements, policies, standards:
  • Regulations related to safety and health
  • Regulations appropriate to the product
  • Provisions of applicable acts

    8. Theory: rules, principles, laws:
  • Temperature, changes of state, melting properties
  • Torque, viscosity, fluid dynamics
  • Electricity, current, power, resistance, circuits, components
  • Behaviour of gases, fluids and solids
  • Pressure, vacuum
  • Units of measure

    9. Relationships, systems:
  • Relationship between materials, process and environment
  • Auxiliary services influences on quality
  • Relationships between set up, materials, processes and final product 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems:
  • Identify process faults related to setting and undertake appropriate actions
  • Identify and correct conditions or practices which will damage or reduce the life of the machinery and equipment
  • Identify conditions or practices that will impact on the properties of the material to be processed or the end product performance and correct 
    		•

    UNIT STANDARD CCFO WORKING 
    Work effectively with others:
  • Interact with workgroup members 
    		•

    UNIT STANDARD CCFO ORGANISING 
    Organise and manage myself and my activities:
  • Prepare, plan and sequence events and procedures 
    		•

    UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information:
  • Record, categorise and explain problems, faults and down times related to settings and changeovers
  • Collect and record changes to settings for repeatability 
    		•

    UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively:
  • Request or instruct workgroup members and associated people to co-ordinate and effect settings or changeovers
  • Report on impact of settings on the performance of the process equipment and the properties of the material and end product 
    		•

    UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically:
  • Explain physics principles as they apply to set up of manufacturing equipment (gas flow of burners, water pressure of water panels etc.) 
    		•

    UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems:
  • Solutions to problems reflect an awareness that setting forms the key to quality, output and cost effectiveness
  • The relationship of time taken for changeovers or setting and production cost factors 
    		•

    UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    UNIT STANDARD NOTES 
    This unit standard has been replaced by unit standard 259697, which is "Prepare, set up and operate process equipment in a production environment", Level 3, 36 credits.

    This unit standard replaces unit standard 9901, "Prepare and set up process equipment", Level 3, 36 credits. 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  49019   National Certificate: Metals Production  Level 3  NQF Level 03  Passed the End Date -
    Status was "Registered"     		 2007-04-07   


    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.