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: 

Control a manufacturing process 
SAQA US ID UNIT STANDARD TITLE
116600  Control a manufacturing process 
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 4  NQF Level 04  60 
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
9903  Control a manufacturing process  Level 4  NQF Level 04  60   

PURPOSE OF THE UNIT STANDARD 
Controlling 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.

See range statements under specific outcome: 'Plan manufacturing process'. 

Specific Outcomes and Assessment Criteria: 

SPECIFIC OUTCOME 1 
Plan manufacturing process. 
OUTCOME NOTES 
  • Plan the process against production schedule requirements
  • Check availability of material, tools and equipment necessary for process
  • Allocate materials, tools, equipment and tasks
  • Communicate requirements to appropriate personnel 
  • OUTCOME RANGE 
    Process refers to a particular process within a metals production environment, for example:
  • For iron and steel: 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, sodarberg briquette making, aluminium reheating and hot working, aluminium cold working, and gas, fumes and bath treatment, rod rolling process, furnace batching.
  • 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. 

  • 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:

    Results achieved:
    1. Production goals are met
    2. Product complies with customer specifications
    3. Process set up meets specifications
    4. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Adjustments to process are made to apply with company and customer requirements
    2. Process tools, consumable, material is available and utilized according to operational requirements.
    3. Process is set up and controlled to ensure continuous production flow.
    4. Product inspection procedures are adhere to.
    5. Process variations are identified and corrected.
    6. Procedures for setting up controlling, inspecting product, change over, working safely, communication, recording and quality.
    6. Documentation up-to-date and systematically completed.

    Understanding confirmed:
    1. Explain, show and discuss consequences of inadequate planning, poor practices, incorrect settings, changes in production schedule, process problems
    2. Explain, show and discuss the manufacturing process and the different stages
    3. Explain and discuss how to go about monitoring the process in order to optimise the process. 

    SPECIFIC OUTCOME 2 
    Set up process. 
    OUTCOME NOTES 
  • Determine material requirements and specifications
  • Check and set process parameters
  • Start up process 
  • OUTCOME RANGE 
    Process parameters include temperature, flow (air, water, gas, metal), pressure, emissions, cycle times, tonnage, consumption of auxiliary services, quality specifications, casting speed, chemical compositions. 

    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:

    Results achieved:
    1. Production goals are met
    2. Product complies with customer specifications
    3. Process set up meets specifications
    4. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Adjustments to process are made to apply with company and customer requirements
    2. Process tools, consumable, material is available and utilized according to operational requirements.
    3. Process is set up and controlled to ensure continuous production flow.
    4. Product inspection procedures are adhere to.
    5. Process variations are identified and corrected.
    6. Procedures for setting up controlling, inspecting product, change over, working safely, communication, recording and quality.
    6. Documentation up-to-date and systematically completed.

    Understanding confirmed:
    1. Explain, show and discuss consequences of inadequate planning, poor practices, incorrect settings, changes in production schedule, process problems
    2. Explain, show and discuss the manufacturing process and the different stages
    3. Explain and discuss how to go about monitoring the process in order to optimise the process. 

    SPECIFIC OUTCOME 3 
    Control the process. 
    OUTCOME NOTES 
  • Monitor and control process variables and deviations
  • Compare process performance to optimise equipment operation
  • Monitor and adjust process flow
  • Shut down process 

  • 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:

    Results achieved:
    1. Production goals are met
    2. Product complies with customer specifications
    3. Process set up meets specifications
    4. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Adjustments to process are made to apply with company and customer requirements
    2. Process tools, consumable, material is available and utilized according to operational requirements.
    3. Process is set up and controlled to ensure continuous production flow.
    4. Product inspection procedures are adhere to.
    5. Process variations are identified and corrected.
    6. Procedures for setting up controlling, inspecting product, change over, working safely, communication, recording and quality.
    6. Documentation up-to-date and systematically completed.

    Understanding confirmed:
    1. Explain, show and discuss consequences of inadequate planning, poor practices, incorrect settings, changes in production schedule, process problems
    2. Explain, show and discuss the manufacturing process and the different stages
    3. Explain and discuss how to go about monitoring the process in order to optimise the process. 

    SPECIFIC OUTCOME 4 
    Inspect product-in-process against quality specifications. 
    OUTCOME NOTES 
    Interpret sample analysis. 
    OUTCOME RANGE 
    Inspection activities include visual checking and measurement of product dimensions, mass, density and shape, requirements for specific materials, product properties, tensile, hardness, conductivity, elongation, dust fineness, granulometry. 

    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:

    Results achieved:
    1. Production goals are met
    2. Product complies with customer specifications
    3. Process set up meets specifications
    4. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Adjustments to process are made to apply with company and customer requirements
    2. Process tools, consumable, material is available and utilized according to operational requirements.
    3. Process is set up and controlled to ensure continuous production flow.
    4. Product inspection procedures are adhere to.
    5. Process variations are identified and corrected.
    6. Procedures for setting up controlling, inspecting product, change over, working safely, communication, recording and quality.
    6. Documentation up-to-date and systematically completed.

    Understanding confirmed:
    1. Explain, show and discuss consequences of inadequate planning, poor practices, incorrect settings, changes in production schedule, process problems
    2. Explain, show and discuss the manufacturing process and the different stages
    3. Explain and discuss how to go about monitoring the process in order to optimise the process. 

    SPECIFIC OUTCOME 5 
    Recognise and respond to process problems. 
    OUTCOME NOTES 
  • Identify root cause of quality problems
  • Make adjustments to bring process back into line
  • Test corrective action to determine if problem is solved 

  • 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:

    Results achieved:
    1. Production goals are met
    2. Product complies with customer specifications
    3. Process set up meets specifications
    4. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Adjustments to process are made to apply with company and customer requirements
    2. Process tools, consumable, material is available and utilized according to operational requirements.
    3. Process is set up and controlled to ensure continuous production flow.
    4. Product inspection procedures are adhere to.
    5. Process variations are identified and corrected.
    6. Procedures for setting up controlling, inspecting product, change over, working safely, communication, recording and quality.
    6. Documentation up-to-date and systematically completed.

    Understanding confirmed:
    1. Explain, show and discuss consequences of inadequate planning, poor practices, incorrect settings, changes in production schedule, process problems
    2. Explain, show and discuss the manufacturing process and the different stages
    3. Explain and discuss how to go about monitoring the process in order to optimise the process. 

    SPECIFIC OUTCOME 6 
    Complete changeover process. 
    OUTCOME NOTES 
    Instruct and discuss forward actions with workgroup members who will take over the running of the process. 

    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:

    Results achieved:
    1. Production goals are met
    2. Product complies with customer specifications
    3. Process set up meets specifications
    4. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Adjustments to process are made to apply with company and customer requirements
    2. Process tools, consumable, material is available and utilized according to operational requirements.
    3. Process is set up and controlled to ensure continuous production flow.
    4. Product inspection procedures are adhere to.
    5. Process variations are identified and corrected.
    6. Procedures for setting up controlling, inspecting product, change over, working safely, communication, recording and quality.
    6. Documentation up-to-date and systematically completed.

    Understanding confirmed:
    1. Explain, show and discuss consequences of inadequate planning, poor practices, incorrect settings, changes in production schedule, process problems
    2. Explain, show and discuss the manufacturing process and the different stages
    3. Explain and discuss how to go about monitoring the process in order to optimise the process. 

    SPECIFIC OUTCOME 7 
    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:

    Results achieved:
    1. Production goals are met
    2. Product complies with customer specifications
    3. Process set up meets specifications
    4. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Adjustments to process are made to apply with company and customer requirements
    2. Process tools, consumable, material is available and utilized according to operational requirements.
    3. Process is set up and controlled to ensure continuous production flow.
    4. Product inspection procedures are adhere to.
    5. Process variations are identified and corrected.
    6. Procedures for setting up controlling, inspecting product, change over, working safely, communication, recording and quality.
    6. Documentation up-to-date and systematically completed.

    Understanding confirmed:
    1. Explain, show and discuss consequences of inadequate planning, poor practices, incorrect settings, changes in production schedule, process problems
    2. Explain, show and discuss the manufacturing process and the different stages
    3. Explain and discuss how to go about monitoring the process in order to optimise the process. 

    SPECIFIC OUTCOME 8 
    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:

    Results achieved:
    1. Production goals are met
    2. Product complies with customer specifications
    3. Process set up meets specifications
    4. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Adjustments to process are made to apply with company and customer requirements
    2. Process tools, consumable, material is available and utilized according to operational requirements.
    3. Process is set up and controlled to ensure continuous production flow.
    4. Product inspection procedures are adhere to.
    5. Process variations are identified and corrected.
    6. Procedures for setting up controlling, inspecting product, change over, working safely, communication, recording and quality.
    6. Documentation up-to-date and systematically completed.

    Understanding confirmed:
    1. Explain, show and discuss consequences of inadequate planning, poor practices, incorrect settings, changes in production schedule, process problems
    2. Explain, show and discuss the manufacturing process and the different stages
    3. Explain and discuss how to go about monitoring the process in order to optimise the process. 

    SPECIFIC OUTCOME 9 
    Discuss and explain information related to planning the process, setting up and controlling the process and the products produced. 

    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:

    Results achieved:
    1. Production goals are met
    2. Product complies with customer specifications
    3. Process set up meets specifications
    4. Manufacturing process cycle time meets customer and company requirements

    Indicators:
    1. Adjustments to process are made to apply with company and customer requirements
    2. Process tools, consumable, material is available and utilized according to operational requirements.
    3. Process is set up and controlled to ensure continuous production flow.
    4. Product inspection procedures are adhere to.
    5. Process variations are identified and corrected.
    6. Procedures for setting up controlling, inspecting product, change over, working safely, communication, recording and quality.
    6. Documentation up-to-date and systematically completed.

    Understanding confirmed:
    1. Explain, show and discuss consequences of inadequate planning, poor practices, incorrect settings, changes in production schedule, process problems
    2. Explain, show and discuss the manufacturing process and the different stages
    3. Explain and discuss how to go about monitoring the process in order to optimise the process. 


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
    My assessment will be governed by the policies and guidelines of the MERSETA Education and Training Quality Assurer who has jurisdiction over this field of learning. My assessor will (at the very least) 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
  • Hydraulic, pneumatic, heating, cooling, electrical, oxygen and gas systems
  • Product

    2. Attributes, descriptions, characteristics & properties:
  • Materials to be processed
  • Equipment, machines and tooling
  • Manufacturing process
  • Machinery specifications and capacity
  • Preventive maintenance
  • Common causes of equipment failure
  • Common areas of wear and tear on equipment
  • Process control software

    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
  • 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
  • Impact of early diagnosis of equipment malfunctioning

    6. Procedures and techniques:
  • Process controlling
  • Manufacturing practices
  • Quality
  • Safety
  • Worksite/standard operating procedures
  • Diagnostic
  • Testing
  • Analysing test results
  • Installation and removal
  • Setting and running
  • Shutting down
  • Measurement
  • Monitoring
  • Communication
  • Recording and report
  • Procedures for reporting major problems with machinery and equipment

    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:
  • Metallurgical principles related to the product and the process, e.g. quality, grades, chemical composition of materials
  • Process principles, e.g. cooling, oxidation, desulphurisation, slag practices, lubrication
  • 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 process set up and control and final product
  • Impact of troubleshooting and diagnosing malfunctions on equipment on production efficiencies 

  • 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 faults related to the process 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 to effect efficient and problem free manufacturing, changeovers and set ups
  • Interact with maintenance specialists to troubleshoot and determine most effective ways of repairing problems/optimising manufacturing process
  • Organise work teams 

  • 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 process
  • 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 process activities 

  • UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically:
  • Explain metallurgical principles as they apply to the manufacturing process
  • Use a methodical approach to analysing test results 

  • UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems:
  • Solutions to problems reflect an awareness that process control forms the key to quality, output and cost effectiveness 

  • UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    UNIT STANDARD NOTES 
    This unit standard replaces unit standard 9903, "Control a manufacturing process", Level 4, 60 credits. 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  49020   Further Education and Training Certificate: Metals Production  Level 4  NQF Level 04  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.