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SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD THAT HAS PASSED THE END DATE: 

Changeover and set up tooling for plastics manufacturing processes 
SAQA US ID UNIT STANDARD TITLE
119140  Changeover and set up tooling for plastics manufacturing processes 
ORIGINATOR
SGB Plastics Manufacturing 
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  10 
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 replaces: 
US ID Unit Standard Title Pre-2009 NQF Level NQF Level Credits Replacement Status
13170  Change and set tooling  Level 3  NQF Level 03  16   

PURPOSE OF THE UNIT STANDARD 
In order for me to perform effectively in the field of plastics manufacturing, I will be able to:
  • Changeover and set up tooling such as moulds, dies or forming devices to make quality product.
  • Identify and respond to problems and faults.

    I will also know and understand:
  • Tooling design and construction principles and design.
  • Critical quality and safety issues related to tooling.
  • Typical issues that arise during production and storage.

    In this unit standard I will not be assessed for:
  • Machine setting after a tooling change.
  • Installing and setting up ancillary equipment.

    These skills are assessed in companion unit standards.

    I can be assessed against this unit standard in the context of any volume plastics manufacturing process, e.g.
  • Injection moulding.
  • Blow moulding.
  • Various kinds of extrusion.
  • Variations of thermoforming.
  • Rotational moulding.
  • Calendaring.
  • Compression and related moulding processes.
  • Reaction injection moulding.
  • Polymer composites fabrication processes such as pultrusion, filament winding and resin injection.

    The volume production process also includes the regeneration of recycled materials and the manufacture of intermediate products such as sheet, profiles, compounds and master batches.

    The skill, the knowledge and the values reflected in this unit standard form part of the exit level outcomes required for the National Certificate in Plastics Manufacturing NQF Level 4. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    The credits for this unit standard assume that I have a National Certificate in Plastics Manufacturing NQF Level 3 or an equivalent qualification. They also assume that I am working towards my qualification as part of a learning programme which integrates all the required unit standards.

    My learning time will increase if I do not have:
  • A relevant NQF 3 qualification.
  • Experience in a relevant field.

    My learning time will be decreased if I have experience in this field because:
  • My learning programme will be adjusted to build on what I already know.
  • I can apply to have that prior learning recognised. 
    		•

    UNIT STANDARD RANGE 
    The scope and level of this unit standard is indicated by range statements related to the specific outcomes.

    Tooling includes:
  • Moulds for all variants of injection, blow, injection stretch, rotational and compression moulding; thermo and vacuum forming; polymer composite fabrication processes.
  • Dies for extrusion processes.
  • Forming devices such as:
    > Masks.
    > Calibration bars.
    > Chill rolls.
    > Cooling jigs.
    > Die face cutters and pelletisers.
    > Equipment for stretching.
    > Any equipment that shapes the final form of the manufactured product (where product is understood to be finished products as well as intermediate products which are designed for further conversion or assembly).

    For summative assessment I should prepare a portfolio which reflects that I have performed such changeovers and setting up on a variety of tooling of varying complexity. Where the complexity of the work is reduced by automation, e.g. quick mould changing devices, I should also ensure that I have evidence which includes other types of tooling changeovers which require a greater degree of skill and knowledge on my part.

    The work reflected in this unit standard is normally performed autonomously with minimal supervision. The work will be guided by relevant worksite procedures, manufacturers' specifications and safety, health and environmental legislation. 
    		•

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Determine product and process requirements and plan the tooling changeover process. 
    OUTCOME RANGE 
    Tooling: See unit standard range.

    Product and process requirements include all specifications, installation, removal, transport and any other procedures, work instructions, production planning documentation, reading drawings and sketches.

    Plan includes performing any calculations, preparing documentation such as requisitions, organising and arranging with other persons such as assistants and operational staff. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the last outcome. 
    ASSESSMENT CRITERION NOTES 
    The assessment criteria for this unit standard have been consolidated to:
  • Facilitate integrated assessment.
  • Ensure that the purpose of the unit standard as a whole is assessed (not just the component parts).

    Use the consolidated assessment criteria that are reflected under the last outcome to develop the assessment guides and assessment tools for this unit standard. 
    		•

    SPECIFIC OUTCOME 2 
    Inspect and prepare tooling. 
    OUTCOME RANGE 
    Prepare tooling includes both preparing for the manufacturing process and preparing for storage. Specific activities could include:
  • Reporting maintenance or repair requirements.
  • Cleaning and applying lubrication or corrosion protection.
  • Emptying or evacuating channels and chambers.
  • Removing or replacing heaters, attachments such as hoses or any other ancillary devices.
  • Attaching slings, eye bolts, bars, adaptor plates and rings.
  • Calibrating.
  • Setting die gaps. 
    		•

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the last outcome. 
    ASSESSMENT CRITERION NOTES 
    The assessment criteria for this unit standard have been consolidated to:
  • Facilitate integrated assessment.
  • Ensure that the purpose of the unit standard as a whole is assessed (not just the component parts).

    Use the consolidated assessment criteria that are reflected under the last outcome to develop the assessment guides and assessment tools for this unit standard. 
    		•

    SPECIFIC OUTCOME 3 
    Co-ordinate the storing, transporting, lifting and lowering of tooling. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the last outcome. 
    ASSESSMENT CRITERION NOTES 
    The assessment criteria for this unit standard have been consolidated to:
  • Facilitate integrated assessment.
  • Ensure that the purpose of the unit standard as a whole is assessed (not just the component parts).

    Use the consolidated assessment criteria that are reflected under the last outcome to develop the assessment guides and assessment tools for this unit standard. 
    		•

    SPECIFIC OUTCOME 4 
    Remove existing tooling; install and set up the replacement tooling and related services. 
    OUTCOME RANGE 
    Remove and install includes detaching and attaching directly or indirectly though clamps and spacers of various design.

    Set up includes attaching and detaching electrical, pneumatic or hydraulic devices, sensors and instruments; transporting related attachments and aids; making mechanical adjustments; using any built-in machine functions; heat soaks; setting safety devices, movement controls or inhibitors; attaching and setting up downstream equipment - slitting devices, cut-off saws, belling equipment, vacuum baths, in-line (small scale) printing devices, corona discharge equipment. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the last outcome. 
    ASSESSMENT CRITERION NOTES 
    The assessment criteria for this unit standard have been consolidated to:
  • Facilitate integrated assessment.
  • Ensure that the purpose of the unit standard as a whole is assessed (not just the component parts).

    Use the consolidated assessment criteria that are reflected under the last outcome to develop the assessment guides and assessment tools for this unit standard. 
    		•

    SPECIFIC OUTCOME 5 
    Recognise and respond to problems related to tooling. 
    OUTCOME RANGE 
    Problems include damage, breakages, blockages, wear, abrasion, stuck products or material residues, decrease in the quality of the product.

    Respond to includes making the necessary adjustments and repairs, requesting assistance from responsible party, reporting, requesting advice. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the last outcome. 
    ASSESSMENT CRITERION NOTES 
    The assessment criteria for this unit standard have been consolidated to:
  • Facilitate integrated assessment.
  • Ensure that the purpose of the unit standard as a whole is assessed (not just the component parts).

    Use the consolidated assessment criteria that are reflected under the last outcome to develop the assessment guides and assessment tools for this unit standard. 
    		•

    SPECIFIC OUTCOME 6 
    Engage in discussions with other parties on issues related to the set up process and product requirements. 
    OUTCOME RANGE 
    Discussions includes the oral and written evidence; generation of sketches to describe particular features and reports relating to specific incidents, problems or tooling.

    Issues includes: tooling design and construction principles; shrinkage, orientation, degradation, flow paths, entrapment of volatiles, venting, heating cooling, quality of tooling materials; particular issues and problems related to individual tooling items, or tooling in general; safety, health and environmental issues. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The correct tooling is installed, conforms to specifications and is ready for production. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved. 
    ASSESSMENT CRITERION RANGE 
    The tooling is ready for production in terms of conditions such as:
  • Alignment.
  • Mechanical movements (speeds, pressures).
  • Temperature.
  • Services are connected and functioning.
  • Safety devices are operating.

    For summative assessment I should prepare a portfolio which reflects that I am capable of performing such changeovers and set ups with a variety of tooling of varying complexity.

    If my workplace does not offer sufficient variety I may have to perform such changeovers and set-ups in another plant.
     
    		•

    ASSESSMENT CRITERION 2 
    Records and reports are available, accurate and up-to-date. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 
    ASSESSMENT CRITERION RANGE 
    Records include both written and electronically stored information.

    Reports could be oral or written, and would include the completion of any related documentation.
     

    ASSESSMENT CRITERION 3 
    Where faults have occurred with the tooling, appropriate action has been taken to resume quality production within a reasonable period of time. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved. 
    ASSESSMENT CRITERION RANGE 
    Appropriate action includes removal of tooling and request for repair, resetting or adjustments.

    Reasonable period of time lies within the discretion of my assessor to determine and depends on the context and the nature of the problems experienced. I should provide evidence of problems I have resolved over a period of time prior to the summative assessment.
     

    ASSESSMENT CRITERION 4 
    Tooling is ready for production within the standard time for that specific tooling. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 5 
    The changeover and set up process is completed while observing all safety, health and environmental rules and regulations, and with due care for the tooling and manufacturing equipment. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 6 
    All work is carried out according to relevant worksite procedures. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 7 
    Work is carefully planned, and is carried out systematically and consistently. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 
    ASSESSMENT CRITERION RANGE 
    Work includes:
  • Preparation phase.
  • Installation and removal phase.
  • Sequencing of steps.
     
    		•

    ASSESSMENT CRITERION 8 
    Discussions of issues demonstrate that I have an understanding of the key concepts and principles related to the set up process and product requirements and an understanding of how these relate to application in practice. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Understanding confirmed. 
    ASSESSMENT CRITERION RANGE 
    Issues, key concepts and principles include:
  • Design, construction, installation, set up and storage of tooling (Construction of tooling includes implications for and effects of different tooling materials, components, surface finishes, heat and chemical treatment process of the tooling materials, moving parts, tolerance, lubrication).
  • Relationship between the materials, the manufacturing process, the tooling and the requirements of the manufactured product (Materials includes polymers, additives, fillers or any other material which comes into contact with the tooling such as labels, lubrication, release agents).
  • Issues related to, and the impact of, damage to the tooling through incorrect settings, poor work practices, poor care and maintenance related to the installation, and inadequate training (Impact includes impact on quality, financial sustainability, health, safety and the environment both in-plant and in-use).
     
    		•


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
    To obtain credits I must be assessed. The assessment will be based on evidence that I produce. My assessment will be governed by the policies and guidelines of a relevant Education and Training Quality Assurance body (ETQA), which has jurisdiction over this field of learning. The policies and procedures of the relevant ETQA will also determine:
  • How my assessment is moderated.
  • How I can appeal against the outcome of the assessment.

    Any institution or company which offers learning that will enable me to achieve the purpose of this unit standard must be accredited as a provider through the relevant ETQA.

    My assessment against this standard should meet all the requirements of established principles. It should include practical assessment activities, which are appropriate to the contents of this unit standard. These activities should include an appropriate combination of self and peer assessment, practical and oral assessments, observations, etc.

    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 on all the specific outcomes, critical cross-field outcomes and essential embedded knowledge. The specific outcomes must be assessed in their own right, through oral and practical evidence. My assessment will not only be based on observation but also on other evidence which I compile into a portfolio of evidence. I cannot be assessed only through a written or oral test.

    The specific outcomes and essential knowledge will be assessed in relation to each other. If I am able to explain the items which fall under the heading of essential embedded knowledge, but am unable to perform the specific outcomes, then I cannot be assessed as 'competent'. Similarly, if I am able to perform tasks described under the specific outcomes, but cannot explain or justify them in terms of the fundamental concepts, principles and practice relevant to the level of the unit standard that underpins my skill, then I cannot be assessed as 'competent'.

    I will also be assessed on my ability to apply the principles and techniques related to the critical cross-field outcomes, not only in terms of what I can demonstrate, but also in terms of what I know and can discuss.

    My assessment for this unit standard can be done in conjunction with the assessment of other unit standards related to a qualification, and even in conjunction with my assessment for the qualification as a whole. 
    		•

    UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    The following items reflect the type of knowledge that the assessor will evaluate:

    1. Names and functions of:
  • Parts and components of the tooling, lifting equipment, installation tools, setting tools and instruments.
  • Components related to services attached to the tooling.

    2. Purpose of:
  • Procedures related to installation, removal, setting or care and maintenance.
  • Parts and components of the moulds, dies or forming devices.
  • The moulds, dies or forming devices.

    3. Attributes, descriptions, characteristics and properties:
  • Parts and components of the tooling.
  • The implications of the tooling parts and components for installation, removal, setting and storage.
  • Of the materials used to construct the tooling.
  • Raw materials and their impact on and interaction with the tooling.
  • Variations in the design of tooling.
  • Problems related to tool design, manufacture and wear and tear.

    4. Processes and events:
  • Tooling changeover preparation and planning.
  • Transport, lifting and lowering.
  • Installation and setting.
  • Cleaning, repair, fault diagnosing and correction.

    5. Causes and effects, implications of:
  • Implications of the installation process for product quality, costs and safety.
  • Possible problem areas, common problems.
  • Implication of heat on tooling, polymers and product quality.
  • Implication of over-stressing tooling components, especially over-tightening of nuts or bolts.
  • Implications of poor alignment for equipment and product.
  • Implications of various tooling construction materials.
  • Implications of the tooling parts and components for installation, removal, setting and storage.
  • Effect of tool design on material properties, e.g. heating, cooling, degradation, orientation, shrinkage, entrapment of air and volatiles, surface properties, welds.

    6. Procedures and techniques:
  • Procedures for ensuring safety and limiting damage.
  • Procedures for installation, setting and maintaining quality.
  • Procedures for storing (including preparation for storage), transporting, lifting and lowering tooling.

    7. Sensory cues:
  • Visual or sound cues which indicate misalignment or tooling malfunctions.
  • Smell of degrading or overheated materials.

    8. Regulations, legislation, agreements, policies, standards:
  • Regulations related to lifting and transport.
  • Regulations related to services, e.g. electricity, compressed air.
  • Company procedures and standards related to procedures and specific products or tooling.

    9. Theory: rules, principles, laws:
  • Physical properties of tooling materials, especially elasticity, hardness, expansion, thermal characteristics.
  • Force, pressure, torque.
  • Tooling design and construction principles.
  • Material flow path, material properties.

    10. Categories:
  • Tooling materials.
  • Polymeric materials.
  • Additives and fillers.

    11. Relationships, systems:
  • Impact of tooling design, construction and handling on product costing, tooling life, quality of the product.
  • Relationship between tooling design and manufactured product specifications. 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
  • Identify product faults related to the tooling and undertake appropriate action.
  • Identify and correct conditions or practices which will damage or reduce the life of the tooling. 
    		•

    UNIT STANDARD CCFO WORKING 
    Interact with designers, customers, toolmakers, machine operators, stores people and others associated with the production, use and maintenance of tooling. 

    UNIT STANDARD CCFO ORGANISING 
    Prepare, plan and sequence events and procedures. 

    UNIT STANDARD CCFO COLLECTING 
    Record and categorise problems, faults and downtimes related to the tooling. 

    UNIT STANDARD CCFO COMMUNICATING 
    Report on the performance of the tooling to a variety of interested parties. 

    UNIT STANDARD CCFO SCIENCE 
  • Physics principles such as torque, friction, heat, flow.
  • Relate physics principles to setting and installation. 
    		•

    UNIT STANDARD CCFO DEMONSTRATING 
    Solutions to problems reflect an awareness that tooling forms the key to precision, speed and quality of production. 

    UNIT STANDARD ASSESSOR CRITERIA 
    My assessor will be registered and have a plastics manufacturing qualification at NQF 6 or higher. In the absence of assessors with such qualifications, the ETQA can make interim arrangements. My assessor should also be active in the industry and be familiar with the materials, machinery, products and level of technology in which I have contextualised my skills and knowledge. 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    This unit standard replaces unit standard 13170, "Change and set tooling", Level 3, 16 credits. 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  49451   Further Education and Training Certificate: Plastics Manufacturing  Level 4  NQF Level 04  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  MERSETA 


    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.