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: 

Plan and set-up a metals production process 
SAQA US ID UNIT STANDARD TITLE
259685  Plan and set-up a metals production 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  13 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
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 activity is part of one of the most important tasks in the metal production environment. This standard constitutes a range of competencies because a production process is a relatively large-scale operation. It entails having knowledge of and coordinating/managing all the processes, equipment and systems related to a production process. In the iron and steel industry, for example, this entails managing all the activities around a blast furnace.

Generally the process controller's work begins from the time the materials are brought into the production process, sent through the conversion process itself, to the time a quality product is produced. It also involves problem solving techniques in the event of something going wrong, which in these industries could be extremely costly. This in essence means taking responsibility for the activities of the individuals who provide the support function and those who operate the main production process equipment. It also entails responsibility for the materials and consumables that are all part of the production process.

Learners credited with this standard will be able to:
  • Demonstrate an understanding of the production process.
  • Plan the production process.
  • Set-up the production process. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    Prepare, set up and operate process equipment in a production environment at NQF Level. 

    UNIT STANDARD 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.
  • For platinum, chrome and manganese, these may include tapping, metal casting, electrode joining, slag tapping, paste handling and baking. 

  • Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Demonstrate knowledge relating to the controlling of a production process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The principal aspects, components and systems of the production process are identified and their functions explained in terms of operational requirements. 

    ASSESSMENT CRITERION 2 
    The requirements pertaining to a safe and healthy work environment when controlling a production process and the consequences of not adhering to the above are explained in terms of specified requirements. 

    ASSESSMENT CRITERION 3 
    The importance of controlling a production process is explained in terms of achieving specified production requirements and up- and down stream operational requirements. 

    ASSESSMENT CRITERION 4 
    Hazards and associated risks pertaining to controlling a production process are identified through the relevant risk assessment procedures. 

    ASSESSMENT CRITERION 5 
    The actions to be taken should hazards and risks be encountered are explained in terms of legal and operational requirements. 

    ASSESSMENT CRITERION 6 
    The actions to be taken, should sub-standard conditions and problems pertaining to controlling a production process be encountered, are explained in terms of legal and operational requirements. 

    ASSESSMENT CRITERION 7 
    The communication requirements pertaining to controlling a production process and the consequences of non-compliance are explained in terms of legal and operational requirements. 

    SPECIFIC OUTCOME 2 
    Plan the production process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The process sequence, activities and resources are planned against production schedule requirements. 

    ASSESSMENT CRITERION 2 
    The product and material requirements and specifications are determined according to quality standards of the product. 

    ASSESSMENT CRITERION 3 
    The availability and condition of material, tools and equipment necessary for the production process are checked and any shortage or problem is resolved according to standard operating procedure. 

    SPECIFIC OUTCOME 3 
    Set-up the production process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The pre-programmed process parameters are set-up, checked and adjusted in terms of operational requirements. 
    ASSESSMENT CRITERION RANGE 
    Process parameters include but not limited to temperature, flow (air, water, gas, metal), pressure, emissions, cycle times, tonnage, consumption of auxiliary services, quality specifications, casting speed, chemical compositions.
     

    ASSESSMENT CRITERION 2 
    Materials, tools, equipment and tasks are allocated to the personnel in the production process work area and utilised according to operational requirements. 

    ASSESSMENT CRITERION 3 
    Requirements for the production process to take place efficiently are communicated to appropriate personnel to ensure common understanding within the team. 

    ASSESSMENT CRITERION 4 
    Information related to the planning is discussed to ensure consistent understanding among the production process team. 

    ASSESSMENT CRITERION 5 
    The process is started up as per standard operating procedures. 


    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 ETQA.
  • Any institution offering learning that will enable the achievement of this unit standard must be accredited as a provider with the relevant ETQA.
  • Assessment and moderation of assessment will be overseen by the relevant ETQA according to the ETQA policies and guidelines for assessment and moderation.
  • Moderation must include both internal and external moderation of assessments at exit points of the qualification, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described both in individual unit standards as well as the integrated competence described in the qualification. 

  • UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
    Names and functions of:
  • Consumables.
  • Materials.
  • Components, controls, instruments and equipment.
  • Hydraulic, pneumatic, heating, cooling, electrical, oxygen and gas systems.
  • Product.

    Attributes, descriptions, characteristics and 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.

    Sensory cues:
  • Cues for different defects (visual, noise, smell, vibration) related to the setting up of manufacturing equipment.

    Purpose of:
  • Monitoring equipment indicators.
  • Product changeovers.
  • Set up procedures.
  • Quality procedures.
  • Health and safety procedures.

    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.

    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.

    Regulations, legislation, agreements, policies, standards:
  • Regulations related to safety and health.
  • Regulations appropriate to the product.
  • Provisions of applicable acts.

    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.

    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 in which responses display that responsible decisions using critical and creative thinking have been made when:
  • Making relevant adjustments to production and material requiremnt.
  • Making adjustments to the process parameters.
  • Checking equipment, materials, consumables and final product.
  • Identifying risks and hazards and dealing with them. 

  • UNIT STANDARD CCFO WORKING 
    Work effectively with others as a member of a team, group, organisation, community to:
  • Ensure that production process is planned and set-up as per standard operating procedure.
  • Deal with problems.
  • Ensure that the safety of all personnel and equipment is maintained. 

  • UNIT STANDARD CCFO ORGANISING 
    Organise and manage oneself and one's activities responsively and effectively when:
  • Interpreting production schedules.
  • Planning the production process.
  • Communicating with personnel and allocating tasks.
  • Checking the quality of materials, consumables and the final product.
  • Problem solving. 

  • UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information to:
  • Solve problems by making adjustments to the planning and set-up process. 

  • UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively using visual, mathematical and/or language skills in the modes of oral and/or written presentation to:
  • Ensure the efficient functioning of the equipment and systems of the production process.
  • Resolve problems as quickly as possible. 

  • UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically, showing responsibility towards the environment and the health of others by:
  • Coordinating the use of the equipment according to manufacturer's instructions and standard operating procedure. 

  • 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  64209   Further Education and Training Certificate: Metals Production  Level 4  NQF Level 04  Reregistered  2023-06-30  As per Learning Programmes recorded against this Qual 


    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.
     
    1. ArcelorMittal South Africa Ltd (VANDERBIJLPARK) (TP) 
    2. College of Production Technology 
    3. Samancor Chrome Ltd T/A Khuphuka Training & Development (MIDDELBURG) ( 



    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.