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:

Prepare material chemically for input

SAQA US ID	UNIT STANDARD TITLE
119051	Prepare material chemically for input
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	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 does not replace any other unit standard and is not replaced by any other unit standard.

PURPOSE OF THE UNIT STANDARD

Learners who are involved in preparing input material chemically for cold-formed steel tube and pipe manufacturing processes require the skills, values and knowledge reflected in this unit standard. Qualifying learners can prepare for and chemically prepare input materials for the cold-formed production process. They will understand how chemicals are used to achieve this, the associated dangers and the use of chemicals on the environment. This will include monitoring the chemical treatment process, identifying non-conformances and taking corrective action. The learning outcomes in this unit standard also contribute to the exit level outcomes required for the National Certificate in Steel Tube and Pipe Manufacturing (Seamless Hot-Finished, Welded or Cold-Formed) (NQF level 4) and related qualifications.

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING

It is assumed that learners are competent in: Communication and mathematical literacy at NQF Level 3 or equivalent The unit standard "Set up process for tube and pipe production"

UNIT STANDARD RANGE

The learner should be able to work autonomously with minimal supervision and according to worksite and manufacturer specifications and occupational safety, health and environmental legislation. Work is generally, but not exclusively, carried out in a team environment The chemical preparation process includes degreasing, acid washing, rinsing, phosphating and soaping Production quantity goals are met Product coating complies with production and customer specifications Material preparation cycle time meets production process requirements. Process, equipment and consumables are utilised according to operational requirements Accurate production data is recorded, process documentation is timeously processed and affected parties liased with Continuous quality product flow is maintained Non-conformances in process and defects in equipment is timeously identified, actioned and continuously monitored to minimise health, environment and quality effects Applicable procedures are followed and understood Strategies, options and choices are described an discussed

Specific Outcomes and Assessment Criteria:

SPECIFIC OUTCOME 1

Plan the process.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Interpret job instructions and determine a sequence of operation

ASSESSMENT CRITERION 2

Acquire associated documentation

ASSESSMENT CRITERION 3

Plan process against production schedule requirements

ASSESSMENT CRITERION 4

Communicate product quantity and quality requirements with appropriate personnel

ASSESSMENT CRITERION RANGE

Process plan includes planning for product and shift changeover situations Materials include hydrochloric acid, phosphates and soap Documentation includes worksite procedures, production reports, material schedules and non-conformance records

SPECIFIC OUTCOME 2

Select and check availability of consumables, materials, tools and equipment necessary for process.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Check availability of consumables, materials and equipment

ASSESSMENT CRITERION 2

Select appropriate consumables, materials and equipment

ASSESSMENT CRITERION RANGE

Consumables include degreaser acids, phosphates, soaps and rinsing agents

SPECIFIC OUTCOME 3

Prepare and chemically treat input material.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Pre-check, start up and shut down material preparation equipment

ASSESSMENT CRITERION 2

Chemically treat material

ASSESSMENT CRITERION 3

Manage waste

ASSESSMENT CRITERION 4

Control costs to within budget

ASSESSMENT CRITERION 5

Record activities and process results

ASSESSMENT CRITERION RANGE

Material treatment processes include acid wash and descaling, phosphating, soaping and rinsing Results include settings and adjustments made to ensure repeatability

SPECIFIC OUTCOME 4

Analyse process chemicals, determine and affect required adjustments.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Analyse chemical solutions

ASSESSMENT CRITERION 2

Determine additions to the solution

ASSESSMENT CRITERION 3

Make required solution concentration changes

ASSESSMENT CRITERION RANGE

Chemical checks include percentage free acid, refractometer readings on concentrations and Ph levels in rinse water

SPECIFIC OUTCOME 5

Identify defects, non-conformances and hazardous conditions and take corrective action.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Defects, non-conformances and hazardous conditions are identified

ASSESSMENT CRITERION 2

Corrective action and preventative methods for the non-conformances are applied and taken.

SPECIFIC OUTCOME 6

Work safely with due care for self, fellow workers, equipment, materials and the environment.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

Apply safety, health, environmental and quality procedures

ASSESSMENT CRITERION 2

Appropriate safety equipment and clothing are utilised

ASSESSMENT CRITERION RANGE

Environmental aspects include the effect of discharge and spillage of consumables

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

1. Names and functions of: Consumables Components, controls, instruments and equipment Hydraulic, pneumatic, heating, cooling, electrical, oxygen and gas systems Process 2. Attributes, descriptions, characteristics & properties: Typical process non-conformances Chemicals used in process Equipment Chemical treatment process Process capacity Chemical surface treatment Preventive maintenance Common causes of equipment failure Common areas of wear and tear on equipment 3. Purpose of: Chemically preparing input material Monitoring equipment indicators P re-operational checks Quality procedures Health, safety and environmental procedures Analysing chemical solutions 4. Sensory cues Cues for different defects (visual, noise, smell, vibration) related to the chemical preparation of material 5. Processes, events, causes and effects, implications: Temperature and state changes Things going wrong, e.g. accidents, power and service failure, wrong or poorly prepared materials, change of plan or schedules Impact of early diagnosis on fluctuating chemical levels Shift changeover Causes and effects / implications and costs of not managing constraints 6. Procedures and techniques: Business procedures and policies Emergency Company (worksite) Safety, health and environmental Document processes Process controlling Material chemical treatment practices Quality Problem solving and continuous improvement Chemical checking Analysing test results Pre-check, start up and shut down preparation process Measurement Monitoring Communication Team work Recording and reporting Shift changeover 7. Regulations, legislation, agreements, policies, standards: Regulations related to safety, health and environment Provisions of applicable acts 8. Theory: rules, principles, laws: Chemical principles related to the process, e.g. chemical concentration Process principles, e.g. heating, cooling and oxidation Units of measure e.g. parts per million 9. Relationships, systems: Relationship between consumables, process and environment Auxiliary services influences on quality Relationships between process, control and final product Impact of troubleshooting and diagnosing malfunctions on equipment on production efficiencies Preventative / predictive maintenance system Quality, safety and environmental systems

UNIT STANDARD DEVELOPMENTAL OUTCOME

N/A

UNIT STANDARD LINKAGES

N/A

Critical Cross-field Outcomes (CCFO):

UNIT STANDARD CCFO IDENTIFYING

Identify and solve problems Identify process deviations and take appropriate corrective action Identify and correct conditions or practices which will damage or reduce the life of the machinery and equipment Identify conditions or practices that will impact on the properties of the material to be prepared and correct

UNIT STANDARD CCFO WORKING

Work effectively with others Interact with workgroup members to effect efficient and problem free material preparation and changeovers Interact with maintenance specialists to troubleshoot and determine most effective ways of repairing problems / optimising material preparation process

UNIT STANDARD CCFO ORGANISING

Organise and manage myself and my activities Acquire and follow appropriate production schedule Prepare, plan and sequence material preparation events

UNIT STANDARD CCFO COLLECTING

Collect, analyse, organise and critically evaluate information Compare identified input material with work order requirements Collect data, analyse it for trends and identify opportunities for continuous improvement, then record changes to operational settings for repeatability

UNIT STANDARD CCFO COMMUNICATING

Communicate effectively Communicate with team members to ensure continuous material preparation

UNIT STANDARD CCFO SCIENCE

Use science and technology effectively and critically Safe use of material preparation equipment and chemicals

UNIT STANDARD CCFO DEMONSTRATING

Demonstrate an understanding of the world as a set of related systems Understanding of the impact of own actions on the total production process

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
Elective	49403	Further Education and Training Certificate: Steel Tube and Pipe Manufacturing (Seamless Hot-Finished OR Welded OR Cold-Formed)	Level 4	NQF Level 04	Passed the End Date - Status was "Reregistered"	2012-06-30	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

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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.