SAQA

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SOUTH AFRICAN QUALIFICATIONS AUTHORITY

REGISTERED UNIT STANDARD THAT HAS PASSED THE END DATE:

Prepare and process plastics materials for manufacturing

SAQA US ID	UNIT STANDARD TITLE
119186	Prepare and process plastics materials for manufacturing
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	12
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
12662	Prepare and process raw materials	Level 4	NQF Level 04	10

PURPOSE OF THE UNIT STANDARD

In order for me to perform effectively in the field of plastics manufacturing, I will be able to:

Prepare materials for the manufacturing process

Look after materials during the manufacturing process.

I will also know and understand:

How material properties impact on all aspects of production processes

How material properties relate to the performance of the end-product.

The activities reflected in this unit standard may not form a part of my day to day activities. The knowledge and skills will, however, enable me to understand the role and purpose of testing and to respond to test results appropriately.
I can be assessed against this unit standard in the context of any volume plastics manufacturing process, eg

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.
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.
This unit standard does not include compounding or alloying. The skills, knowledge and values required for these are contained in a companion unit standard.

Specific Outcomes and Assessment Criteria:

SPECIFIC OUTCOME 1

Determine product, preparation and process requirements and obtain the materials.

OUTCOME RANGE

Materials include polymer (virgin, recycled or regenerated), pigments, additives, fillers, concentrates or masterbatch.

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, and

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

Prepare weighing and blending equipment and prepare material for the manufacturing process.

OUTCOME RANGE

Prepare material can include: determining mass or quantity of material from recipes for specific batches; blending according to recipe or formula; preheating; drying; cutting to shape; removing dust.

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, and

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

Carry out quality checks on the prepared materials; label and store material.

OUTCOME RANGE

Quality checks include inspect and test material against requirements and inspect or test product conformance in terms of material defects.

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, and

SPECIFIC OUTCOME 4

Monitor the use of the materials during the manufacturing process and arrange for material to be transported at appropriate intervals.

OUTCOME RANGE

Monitor the use of the materials includes the rate of usage, protection from contamination, avoidance of spillages and wastage, avoidance of exposure to excessive heat or moisture

Arrange includes interacting with others to achieve a constant flow of materials

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, and

SPECIFIC OUTCOME 5

Record, summarise and report material-related data, incidents and events.

OUTCOME NOTES

Summarise includes overall material consumption, percentage of scrap or wastage.

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, and

SPECIFIC OUTCOME 6

Explain and discuss materials and material properties related to preparation, processing and end-product properties.

OUTCOME RANGE

Properties include physical, chemical, thermal, optical and electrical properties; grades, blends; rheological properties, amorphous and semi-crystalline states, thermoplastic and thermosetting behaviour; particle size and shape; resin consistency and properties; impact of additives, processing aids, colorants, pigments, fillers, re-inforcers and extenders; effect of heat history on the polymeric materials.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

A constant flow of the correct materials for the manufacturing process is maintained.

ASSESSMENT CRITERION NOTES

Assessment criterion type: Results achieved

ASSESSMENT CRITERION 2

Materials are handled according to general manufacturers' specifications and according to specific worksite procedures.

ASSESSMENT CRITERION NOTES

Assessment criterion type: Indicator

ASSESSMENT CRITERION 3

Calculations to determine ingredient requirements for various batch sizes are demonstrated.

ASSESSMENT CRITERION NOTES

Assessment criterion type: Indicators

ASSESSMENT CRITERION RANGE

Calculations should include percentages, parts per hundred (resin) or ratios.

ASSESSMENT CRITERION 4

All safety, health and environmental procedures and guidelines are observed and enforced.

ASSESSMENT CRITERION NOTES

Assessment criterion type: Indicator

ASSESSMENT CRITERION RANGE

Safety, health and environmental includes the handling and disposal of materials; use of protective equipment such as masks; flammability; contamination; degradation and decomposition

Since thermoplastic pellets and granules can have an impact on birdlife specifically, special attention should be paid to recovering spilt pellets and preventing them from entering watercourses, both within the factory environment and outside during delivery.

ASSESSMENT CRITERION 5

The quality and the output of the manufacturing process are not affected by poor communication or poor material-related practices.

ASSESSMENT CRITERION NOTES

Assessment criterion type: Indicator

ASSESSMENT CRITERION 6

Activities reflect an ongoing concern with optimising the use of materials.

ASSESSMENT CRITERION NOTES

Assessment criterion type: Indicator

ASSESSMENT CRITERION RANGE

Optimising the use of materials includes reducing spillage and waste; protecting materials from contamination; maintaining a steady flow of materials through the manufacturing process; cleanliness of preparation equipment and good housekeeping; protecting health, safety and the environment.

ASSESSMENT CRITERION 7

Records and reports are accurate, up-to-date and timeously produced.

ASSESSMENT CRITERION NOTES

Assessment criterion type: Indicator

ASSESSMENT CRITERION 8

Discussions of issues demonstrate an understanding of materials and material properties, an understanding of the key concepts and principles related to their preparation, processing and end-product properties 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:

The manufacturer's specifications

Properties of additives

Batches and grades variations in materials

Blending procedures and techniques

Consequences of incorrect blending, handling and storage of materials

Spillage and wastage

Contamination

The differences between formulations expressed as percentage, parts per hundred (resin) or ratios

Safety, health and environmental matters

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

Names and functions of:

Materials, grades, modifications

Additives, reinforcing agents, processing aids, density modifiers, fillers, extenders

Purpose of:

Additives, blends

Material preparation, conditioning

Attributes, descriptions, characteristics and properties:

Thermal, chemical, optical, physical properties of materials

Grades, blends

Rheological properties, amorphous and semi-crystalline states

Thermoplastic and thermosetting behaviour

Particle size and shape or resin consistency and properties

Impact of additives, processing aids, colorants, pigments, fillers, re-inforcers and extenders on the properties of polymeric materials

Effect of heat history on polymeric materials

Processes and events:

Preparation and blending processes

Incidents and events which impact on the properties of materials

Causes and effects, implications of:

Impact of additives on process, properties and end-product performance

Short- and long-term implications of wrong blends, incorrect additive levels

Incorrect handling and storage of materials, spillage and wastage, contamination

Procedures and techniques:

For blending materials

For storage

Calculating amounts: percentage, ratios, parts-per-hundred (resin)

Sensory cues:

To indicate various grades and types of polymeric materials, additives and fillers

To indicate degradation and decomposition

Regulations, legislation, agreements, policies, standards:

Health, safety and environmental regulations

Standards for handling and blending materials

Theory: rules, principles, laws:

Formulations (ratios, percentage, parts-per-hundred resin)

Units of measure

Principles related to material properties

Basics of polymer chemistry and related physical science concepts

Categories:

Additives and fillers

Polymeric materials

Relationships, systems:

Relationship between material, machinery and product

Relationship of additive to preparation, process and end-product performance

UNIT STANDARD DEVELOPMENTAL OUTCOME

N/A

UNIT STANDARD LINKAGES

N/A

Critical Cross-field Outcomes (CCFO):

UNIT STANDARD CCFO IDENTIFYING

Related to the preparation and blending of materials

Identify different materials and variations of materials

Adapt practices to suit different types, grades or variations of material

UNIT STANDARD CCFO WORKING

Interact with others to ensure constant flow of materials.

UNIT STANDARD CCFO ORGANISING

Organise my activities so as to optimise material usage.

UNIT STANDARD CCFO COLLECTING

Use senses and tests to determine material quality.

UNIT STANDARD CCFO COMMUNICATING

Report material-related data, incidents and events

Communicate with others to ensure the quality and the output of the manufacturing process

UNIT STANDARD CCFO SCIENCE

Process formulae and recipes

Use blending equipment

Use measuring and testing instruments

UNIT STANDARD CCFO DEMONSTRATING

Recognise and optimise the relationship between additives, material, machinery and product end-performance.

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 12662, which is 'Prepare and process raw materials', Level 4, 10 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
Core	57898	Further Education and Training Certificate: Printing and Manufacture of Packaging	Level 4	NQF Level 04	Passed the End Date - Status was "Reregistered"	2015-06-30	FPMSETA

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.

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