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: 

Monitor machining process, interpret statistical process control charts, and rectify production problems 
SAQA US ID UNIT STANDARD TITLE
243025  Monitor machining process, interpret statistical process control charts, and rectify production problems 
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  7 
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 
This unit standard reflects the skills required to:
  • Monitor the process by means of statistical plots.
  • Recognise problems, and identify and rectify causes of machining problems.

    It also reflects the understanding of:
  • Problem solving techniques and approaches.
  • The relationship between statistics and the machining process.

    This unit standard would be assessed in the context of:
  • A machining centre.
  • A CNC lathe or turning centre.
  • Any other equipment in which material is removed to form the part, eg cutting, boring, grinding.

    The skills, knowledge and values reflected in this unit standard form part of the Exit Level Outcomes required for the National Certificate in CNC Production Machining: NQF Level 3. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    The following competencies are assumed:
  • Communication and Literacy, NQF Level 2
  • Mathematical Literacy, NQF Level 2.

    In addition, learners are assumed to have relevant skills at NQF Level 2 in the context of CNC machining processes using computer numeric controlled equipment. This includes and understanding of quality assurance processes and statistical process control plots.

    This assumption forms the basis for the allocation of credits for this unit standard. If a learner does not have such experience or qualifications, the learning time will be increased. The allocation of credits is also based on the assumption that the learner will be following a learning programme which integrates the required unit standards. 
    		•

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

    Rectify means implementing remedial actions and monitoring and evaluating the effect of changes and also includes reporting the problem where it is beyond the limits of the learner's authority. 

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Describe and explain the purpose of quality processes and the relationship to work activities. 
    OUTCOME RANGE 
    Quality processes include upper and lower process limits, critical characteristics, principles of statistical process control, measuring and checking methods, consequences of poor quality products. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Response to questioning indicates an understanding of the theoretical principles of statistical process control and the identification of out-of-control production conditions. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Understanding confirmed. 
    ASSESSMENT CRITERION RANGE 
    Key concepts include:
  • The purpose of X-bar and R charts.
  • Patterns in X-bar and R charts that indicate problems.
  • Typical conditions which cause unstable or out-of-control processes.
  • Control limits, samples, means and ranges.
     
    		•

    ASSESSMENT CRITERION 2 
    Response to questioning indicates an understanding of the common faults, their causes and how they can be rectified. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Understanding confirmed. 

    ASSESSMENT CRITERION 3 
    A problem solving technique can be described and applied and the purpose of such techniques can be explained. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Understanding confirmed. 
    ASSESSMENT CRITERION RANGE 
    The purpose of this assessment criterion is to establish if the learner can apply a systematic approach to problem solving. Problem solving techniques include any tool to systemise the problem solving process, eg fishbone diagrams, flowcharts, root cause analysis.
     

    SPECIFIC OUTCOME 2 
    Review statistical information and identify unstable processes. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Unstable processes, trends and error conditions are identified and a response to the problem is determined. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved. 

    ASSESSMENT CRITERION 2 
    Downtime and production losses are minimised. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 3 
    The learner's evidence shows that he/she has identified and interpreted a range of different unstable process conditions, trends and error conditions. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 4 
    A consistent and systematic approach is used to identify and determine a response to the problem. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 
    ASSESSMENT CRITERION RANGE 
    Response includes choices such as stopping the machining process, referring a problem to the appropriate person or making running adjustments.
     

    SPECIFIC OUTCOME 3 
    Analyse the process conditions in unstable processes and determine the cause of the problem. 
    OUTCOME RANGE 
  • Analysing the process conditions require a structured and systematic approach.
  • Determining the cause is limited to a set range of options to choose from i.e. operator, material, machine, tooling, fixtures and gauging. 
    		•

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The underlying cause of the problem is identified and recorded. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 2 
    The learner's evidence shows that he/she has identified and interpreted a range of different unstable process conditions, trends and error conditions. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 3 
    A consistent and systematic approach is used to identify problems and develop a solution. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    SPECIFIC OUTCOME 4 
    Implement remedial action, monitor and evaluate the effect of changes and record and report actions. 
    OUTCOME RANGE 
    Implement remedial action includes reporting the problem when the solution exceeds the person's authority or resources. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Remedial actions are appropriate to the cause and result in an ongoing resolution of the problem. 
    ASSESSMENT CRITERION NOTES 
  • Assessment criterion type: Results achieved.
  • Ongoing indicates that the root causes of the problem have been established and responded to within the limits of the learner's span of control. 
    		•

    ASSESSMENT CRITERION 2 
    All remedial actions are carried out with due care for the equipment, the materials and the quality of the final product. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    ASSESSMENT CRITERION 3 
    Remedial actions are communicated effectively and timeously to the appropriate person. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved. 

    ASSESSMENT CRITERION 4 
    Records are accurate and processed in line with organisational standards. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 

    SPECIFIC OUTCOME 5 
    Monitor the production process and ensure that it runs smoothly. 
    OUTCOME RANGE 
  • Monitor includes continuously checking product against drawings and process parameters, and monitoring operator activity.
  • Ensure that it runs smoothly includes making adjustments required, giving instructions to the operator, coaching the operator on process-related aspects, recommending operators for training.
  • Problems are restricted to common manufacturing problems related to the process or the product. 
    		•

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Downtime and production losses are minimised. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved. 

    ASSESSMENT CRITERION 2 
    The learner's evidence shows that he/she can anticipate problems. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 
    ASSESSMENT CRITERION RANGE 
    Problems are restricted to common manufacturing problems related to the process or the product.
     

    ASSESSMENT CRITERION 3 
    A consistent and systematic approach is used to check the various aspects of the process. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator. 
    ASSESSMENT CRITERION RANGE 
    Aspects of the process include equipment conditions, tooling and associated components, lubricant levels, stock levels and type of stock.
     


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
    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 the assessment is moderated.
  • How a learner can appeal against the outcome of the assessment.

    Any institution or company which offers learning to achieve the purpose of this unit standard must be accredited as a provider through the relevant ETQA.
    The integrated assessment should be based on a summative assessment guide. The guide will specify how the assessor will assess different aspects of the performance and will include:
  • Evaluating evidence in a portfolio of evidence, particularly projects which integrate various aspects of the unit standard and which demonstrate the integration of knowledge, skills and values, and the development of the critical outcomes.
  • Observing and listening to the learner at work, both in primary activities as well as in other interactions, or in relevant simulations.
  • Asking questions and initiating short discussions to test understanding and to verify other evidence.
  • Looking at records and reports.
  • Formative assessment.

    Assessment of competence for this unit standard is based on experience acquired by the learner in the workplace, within the particular machining context. The assessment process should cover the explicit tasks required for the unit standard as well as the understanding of the concepts and principles that underpin the process of monitoring the machining process, interpreting statistical process control charts, and rectifying production problems.

    Assessment criteria of the type 'Results achieved' should be regarded as critical to the achievement of this unit standard. The assessment process should also establish how the learning process has advanced the Critical Cross-field Outcomes.

    The learner may choose in which language he/she wants to be assessed. This should be established as part of a process of preparing the learner for assessment and familiarising the learner with the approach being taken.

    Assessors should also evaluate evidence that the learner has been performing consistently over a period of time.

    The assessment for this unit standard can be done in conjunction with the assessment of other unit standards related to a qualification, and in conjunction with the 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.

    Names & functions of:
  • Statistical process control charts
  • Range of common error conditions

    Purpose of:
  • Using statistical process control charts
  • Setting tolerances and parameters

    Attributes, descriptions, characteristics and properties:
  • Statistical process control charts
  • Range of common error conditions

    Processes and events:
  • Identify out-of-specification data
  • Determine cause of problem
  • Take corrective action

    Causes and effects, implications of:
  • Effect of inaccurate process control charts

    Procedures and techniques:
  • 'Interpret' statistical information
  • Systematic problem solving techniques, eg Ishikawa diagram, 8D-TOPS
  • Determine causes of problems
  • Taking corrective action
  • Recording issues and reporting to team

    Sensory cues:
  • Cues related to identifying out-of-specification operations.
  • Cues related materials and product quality, damage or fault detection and their interpretation.

    Regulations, legislation, agreements, policies, standards:
  • Related to safety, health and environment
  • Standards, operating procedures
  • Organisational policies and rules relating to routine operations

    Theory: rules, principles, laws:
  • Principles of the process.
  • Continuous improvement.
  • Contextualisation of concepts related to statistical process control and identifying non-conformances.
  • Principles of systematic problem solving.

    Relationships, systems:
  • Quality system, problem solving and customer satisfaction.
  • Reporting and recording of corrective actions and continuous improvement processes. 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems.
  • When analysing process conditions and determining the cause of the problem.
  • Taking a systematic approach to problem solving. 
    		•

    UNIT STANDARD CCFO WORKING 
    Work effectively with others.
  • When monitoring the production process and ensuring that it runs smoothly. 
    		•

    UNIT STANDARD CCFO ORGANISING 
    Organise and manage myself and my activities.
  • When reviewing statistical information and identifying unstable processes. 
    		•

    UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information.
  • When analysing process conditions. 
    		•

    UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively.
  • With rest of manufacturing team. 
    		•

    UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically.
  • Use statistical process control processes. 
    		•

    UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems.
  • Understand the implications of inaccurate analysis on the corrective action taken to remedy unstable manufacturing processes. 
    		•

    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 
    N/A 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  71989   National Certificate: Automotive Components: Manufacturing and Assembly  Level 3  NQF Level 03  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  MERSETA 
    Core  57877   National Certificate: CNC Production Machining  Level 3  NQF Level 03  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  MERSETA 
    Core  58779   Further Education and Training Certificate: Production Technology  Level 4  NQF Level 04  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  MERSETA 
    Elective  91926   National Certificate: Mechanical Engineering: Machining and Tooling  Level 3  NQF Level 03  Passed the End Date -
    Status was "Reregistered"     		 2023-06-30  As per Learning Programmes recorded against this Qual 
    Elective  79666   National Certificate: Metal and Engineering Manufacturing Processes  Level 3  NQF Level 03  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.