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: 

Make ready or change over and set up equipment for printing and converting processes 
SAQA US ID UNIT STANDARD TITLE
243180  Make ready or change over and set up equipment for printing and converting processes 
ORIGINATOR
SGB Printing and Packaging 
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  16 
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:
  • Make ready or change over and setup equipment to make quality product within the standard time.
  • Install correct equipment which conforms to specifications and is ready for production.
  • Identify and respond to problems and faults.

    It also reflects the understanding of:
  • Equipment design and construction principles.
  • Critical quality and safety issues related to equipment.
  • Typical issues that arise during production.

    This unit standard would be assessed in the following printing and packaging processes e.g.:

    Printing:
  • Letterpress.
  • Screen printing.
  • Flexography.
  • Gravure.
  • Lithography.
  • Continuous stationery.
  • Roll label.
  • Rotary offset.

    Manufacture of packaging, with or without in-line printing processes:
  • Bag making (self opening bag).
  • Sack making (both tubing & bottoming).
  • Carton making.
  • Can and end making.
  • Laminating.
  • Coating.
  • Corrugated board manufacturing.
  • Tubing.
  • Wrapping.
  • Over printing.
  • Envelope making.
  • File manufacturing. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    The following competencies are assumed to be in place:
  • Communication and Mathematical Literacy, at NQF Level 3. 
    		•

    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. 

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Determine product and process requirements and plan the make ready or change over process. 
    OUTCOME RANGE 
    Product and process requirements includes the type of materials: runs, run lengths. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Process documentation and instructions are read and interpreted as per requirements. 

    ASSESSMENT CRITERION 2 
    Further documentation is prepared for the printing and converting process. 

    ASSESSMENT CRITERION 3 
    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 RANGE 
    Concepts include, changeover and setting up processes, productivity, meeting production standards, procedures and their purpose; housekeeping; safety; working with others.
     

    ASSESSMENT CRITERION 4 
    The changeover and setup process is planned and prepared while observing all safety, health and environmental rules and regulations. 
    ASSESSMENT CRITERION RANGE 
    Safety, health and environmental rules and regulations include the handling and disposal of materials, use of protective equipment such as masks, flammability, contamination, degradation and decomposition.
     

    ASSESSMENT CRITERION 5 
    Instructions and reports are clear, concise and comprehensive. 
    ASSESSMENT CRITERION RANGE 
    Includes Verbal and written communication, involving both job instructions and status reports, shift handover procedures.
     

    SPECIFIC OUTCOME 2 
    Inspect and prepare tools, materials and equipment. 
    OUTCOME RANGE 
    Inspection and preparation includes prepress work, making up knives, paster belts, folding equipment, digital printing; preparation may also include briefing the team involved in the change over. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Tools, materials and equipment are inspected and prepared in accordance with specifications. 

    ASSESSMENT CRITERION 2 
    The correct equipment is installed, conforms to specifications and is ready for production. 
    ASSESSMENT CRITERION RANGE 
    The equipment is ready for production in terms of conditions such as: alignment, mechanical movements (speeds, pressures), temperature, services are connected and functioning and safety devices are operating.

    Assessment of 'ready for production' may includes first off products, make ready sheets, proofing (pass sheets) meeting required standard or specification and colour matching.
     

    ASSESSMENT CRITERION 3 
    Equipment is made ready for production within the standard time for the specific process or product. 

    ASSESSMENT CRITERION 4 
    All work is performed with due care for the materials, tools and equipment. 

    SPECIFIC OUTCOME 3 
    Co-ordinate the storing and transporting of tools, materials and equipment. 
    OUTCOME RANGE 
    Transporting includes: lifting, moving and lowering. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    Resources are organised and utilised as per requirements. 
    ASSESSMENT CRITERION RANGE 
    Resources include, human resources, materials, tools and equipment, ancillary equipment, services.
     

    ASSESSMENT CRITERION 2 
    Set-up process and product requirements are discussed with other parties within the printing and conversion context. 

    ASSESSMENT CRITERION 3 
    Set-up is evaluated in accordance with specified requirements. 

    ASSESSMENT CRITERION 4 
    Records and reports related to storing and transportation of tools, materials and equipment are discussed with other parties. 
    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.
     
    		•

    SPECIFIC OUTCOME 4 
    Recognise and respond to problems related to the equipment, settings or the condition of machinery and equipment. 
    OUTCOME RANGE 
    Responding includes informing appropriate parties or taking corrective action. 

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    The replacement equipment and related services are set up and installed in accordance with specifications. 
    ASSESSMENT CRITERION RANGE 
  • Services includes electricity, water, air, steam, gas, vacuum, and hydraulics.
  • Set up includes ink and roller setting, pressures, timing, temperatures and computer terminals.
     
    		•

    ASSESSMENT CRITERION 2 
    Appropriate action is taken to remedy the faults that have occurred with the equipment. 
    ASSESSMENT CRITERION RANGE 
    Appropriate action includes removal of tooling and request for repair, resetting or adjustments.
     

    ASSESSMENT CRITERION 3 
    Work is carefully planned, and is carried out systematically and consistently. 
    ASSESSMENT CRITERION RANGE 
    Work includes:
  • Preparation phase.
  • Installation and removal phase.
  • Sequencing of steps.
     
    		•


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • Anyone assessing a learner or moderating the assessment of a learner against this unit standard must be registered as an assessor with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Any institution offering learning that will enable the achievement of this unit standard must be accredited as a provider with the relevant Education, Training, Quality, Assurance (ETQA) Body, or with an ETQA that has a Memorandum of Understanding with the relevant ETQA.
  • Assessment and moderation of assessment will be overseen by the relevant Education, Training, Quality, Assurance (ETQA) Body, or by an ETQA that has a Memorandum of Understanding with the relevant ETQA, according to the ETQA's policies and guidelines for assessment and moderation.
  • Moderation must include both internal and external moderation of assessments, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described in the Unit Standard.
  • Anyone wishing to be assessed against this unit standard may apply to be assessed by any assessment agency, assessor or provider institution that is accredited by the relevant ETQA. 
    		•

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

    Names and functions of:
  • Machine parts, rollers and cylinders.
  • Tools, equipment.
  • Specifications, instructions.
  • Consumables and raw materials, services.
  • Maintenance and safety functions on the equipment.
  • Standards.
  • Time frames.
  • Efficiency.
  • Wastage or spoilage.

    Purpose of:
  • Changeovers, setting up.
  • First offs, pass or make ready sheets.
  • Output.
  • Procedures.
  • Test pieces.
  • Machine efficiency.
  • Safety equipment.

    Attributes, descriptions, characteristics and properties:
  • Raw materials.
  • Consumables.
  • Materials used in the construction of equipment.
  • Machine parts.
  • Services.
  • Safety equipment.
  • Sheet size, paper travel.

    Processes and events:
  • Alarms.
  • Preparation, changeover, setting up, quality assurance, testing, maintenance.
  • Fires.
  • Evacuation drills.
  • Power failures.

    Causes and effects, implications of:
  • Injuries.
  • Damage to equipment.
  • Effect of poor settings.
  • Incorrect substandard materials or consumables, machinery, equipment.
  • Power failures.
  • Unforeseen circumstances.
  • Oxidation.
  • Incorrect storage of materials, equipment.
  • Humidity and temperature control.
  • Poorly trained personnel.
  • Poor lighting, housekeeping.
  • Substrate dust.
  • Poor machine layout.
  • Poor ventilation or extraction.

    Procedures and techniques:
  • Safety procedures.
  • Set up or make ready.
  • Housekeeping.
  • Quick change over techniques.
  • Use of tools.
  • Setting cylinder and roller pressures and distances.
  • Measuring and positioning parts and equipment.
  • Preparing and loading substrates.
  • Wash-up.
  • Sheet size, paper travel.

    Sensory cues:
  • Colour perception.
  • Gauge tightness of fasteners.
  • Sensory cues related to set up, changeover, wear, damage or fault detection.

    Regulations, legislation, agreements, policies, standards:
  • Related to safety, health and environment.
  • Standards, operating procedures.
  • Organisational policies and rules relating to make ready or change over.
  • Product standards.

    Theory: rules, principles, laws:
  • Principles of the process.
  • Contextualisation of scientific concepts related to the printing and packaging manufacturing process, tools and equipment, substrates and other materials used in the processes.

    Categories:
  • Hazardous materials; substrate; personnel; tools, equipment.

    Relationships, systems:
  • Stores, conversion, dispatch, maintenance departments relationship and integration.
  • Value chain.
  • Corrective action reporting and continuous improvement.
  • Communication.
  • Work group. 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems:
  • Recognise and respond to problems related to the equipment, settings or the condition of machinery and equipment.
  • Evaluate set-up and engage in discussions with other parties on issues related to the set-up process and product requirements. 
    		•

    UNIT STANDARD CCFO WORKING 
    Work effectively with others:
  • Co-ordinate the storing and transporting of tools, materials and equipment.
  • Evaluate set-up and engage in discussions with other parties on issues related to the set-up process and product requirements. 
    		•

    UNIT STANDARD CCFO ORGANISING 
    Organise and manage myself and my activities:
  • Determine product and process requirements and plan the make ready or change over process.
  • Requisition, inspect and prepare tools materials and equipment.
  • Co-ordinate the storing and transporting of tools, materials and equipment.
  • Remove existing equipment and install and set up the replacement equipment and related services.
  • Recognise and respond to problems related to the equipment, settings or the condition of machinery and equipment.
  • Evaluate set-up and engage in discussions with other parties on issues related to the set-up process and product requirements. 
    		•

    UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information:
  • Determine product and process requirements and plan the make ready or change over process.
  • Requisition, inspect and prepare tools materials and equipment.
  • Co-ordinate the storing and transporting of tools, materials and equipment.
  • Remove existing equipment and install and set up the replacement equipment and related services.
  • Recognise and respond to problems related to the equipment, settings or the condition of machinery and equipment.
  • Evaluate set-up and engage in discussions with other parties on issues related to the set-up process and product requirements. 
    		•

    UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively:
  • Co-ordinate the storing and transporting of tools, materials and equipment.
  • Evaluate set-up and engage in discussions with other parties on issues related to the set-up process and product requirements. 
    		•

    UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically:
  • Determine product and process requirements and plan the make ready or change over process.
  • Requisition, inspect and prepare tools materials and equipment.
  • Co-ordinate the storing and transporting of tools, materials and equipment.
  • Remove existing equipment and install and set up the replacement equipment and related services.
  • Recognise and respond to problems related to the equipment, settings or the condition of machinery and equipment. 
    		•

    UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems:
  • Determine product and process requirements and plan the make ready or change over process.
  • Requisition, inspect and prepare tools materials and equipment.
  • Co-ordinate the storing and transporting of tools, materials and equipment.
  • Remove existing equipment and install and set up the replacement equipment and related services.
  • Recognise and respond to problems related to the equipment, settings or the condition of machinery and equipment.
  • Evaluate set-up and engage in discussions with other parties on issues related to the set-up process and product requirements. 
    		•

    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  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.
     
    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.