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SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD THAT HAS PASSED THE END DATE: 

Set and adjust plastics manufacturing machine conditions to produce quality finished product 
SAQA US ID UNIT STANDARD TITLE
119155  Set and adjust plastics manufacturing machine conditions to produce quality finished product 
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  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 replaces: 
US ID Unit Standard Title Pre-2009 NQF Level NQF Level Credits Replacement Status
12663  Set production equipment  Level 4  NQF Level 04  8   

PURPOSE OF THE UNIT STANDARD 
In order for me to perform effectively in the field of plastics manufacturing, I will be able to:
  • Perform product changeovers
  • Set plastics manufacturing equipment
  • Adjust the machine setting in response to changes in the process, the operating conditions or faulty product

    I will also know and understand:
  • The principles which govern the process settings, the machine conditions, the equipment and the control system design
  • The principles which govern the behaviour of plastic materials, additives and fillers
  • The impact of machine settings on the material being processed and the quality of the end product

    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.
  • In some other countries, eg the United Kingdom, the setting process is called 'machine conditioning'.
  • The skills, knowledge and values reflected in this unit standard only cover the setting and adjusting of machine conditions and do not reflect the skills, knowledge and values required for installing tooling. These are reflected in a companion unit standard. 
    		•

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Determine product and process requirements, plan the setting process and collect the necessary tools, instruments and materials. 
    OUTCOME RANGE 
  • Product and process requirements include all specifications, setting and any other procedures, work instructions, production planning documentation, reading of drawings and sketches, applicable standards eg ISO 9000 and 14000
  • Plan includes performing calculations; preparing documentation such as requisitions; organising and arranging with other persons, such as assistants and operational staff
  • Tools include hand and power tools
  • Instruments include measuring equipment, pyrometers, gauges, scales, polarising filters, ultra violet lights 
    		•

    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 
    Set process parameters and start up manufacturing equipment to manufacture first offs. 
    OUTCOME RANGE 
  • Process parameters include pressures, speeds, timers, movement control, temperature settings for heating and cooling, safety devices
  • First offs include any representative sample of manufactured product which can be used to verify product quality 
    		•

    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 
    Conduct quality checks on manufactured products, determine conformance to standards and adjust machine settings for any deviations. 
    OUTCOME RANGE 
    Conducting quality check on products includes
  • Dimensions, mass, density and shape
  • Requirements for specific materials
  • Specific product properties, eg, absence of leaks, surface finish, hardness, colour, printing and welding
  • Reviewing data from relevant laboratory tests, eg, tensile, tear, impact and hardness properties, stress crack resistance 
    		•

    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 4 
    Identify and resolve product-and process-related problems and respond to emergency situations or critical events. 
    OUTCOME RANGE 
  • Emergency situations include injury, fire, serious equipment malfunctions, temperature overruns with heat-sensitive materials
  • Critical events include power failures, other equipment malfunctions 
    		•

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    See the consolidated assessment criteria for this unit standard which are listed under the last outcome. 
    ASSESSMENT CRITERION RANGE 
    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 5 
    Hand-over the process to production staff, complete all relevant documentation and report incidents or issues. 
    OUTCOME RANGE 
    Hand-over process includes:
  • Briefing production staff
  • Cleaning and returning tools and instruments
  • Any activity related to moving from a setting operation to full production 
    		•

    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 
    		•

    SPECIFIC OUTCOME 6 
    Engage in discussions with other parties on issues related to the setting process. 
    OUTCOME RANGE 
  • Issues include the interrelationship between process settings, variables which influence processing conditions, eg temperature changes, changes in material from batch to batch; principles which underpin the setting process; the influence of machine conditions on the plastic materials being processed and the final product quality
  • Other parties include maintenance personnel, managers, operators, colleagues, etc 
    		•

    ASSESSMENT CRITERIA     

    ASSESSMENT CRITERION 1 
    A high level of quality production is maintained and applicable quality standards are met. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Results achieved 
    ASSESSMENT CRITERION RANGE 
  • For summative assessment I should prepare a portfolio which reflects that I am capable of performing such process setting and adjustment with a variety of products of varying complexity.
  • If my workplace does not offer sufficient variety I may have to perform such setting and adjustment processes in another plant.
     
    		•

    ASSESSMENT CRITERION 2 
    Machine is set according to procedures and meets production standards. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator 

    ASSESSMENT CRITERION 3 
    Setting process is completed according to relevant worksite procedures and within the standard time allowed for the specific product. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator 

    ASSESSMENT CRITERION 4 
    Setting and adjustment processes are performed safely and without compromising the health of myself and others, or of the environment in general, and with due care for the manufacturing equipment, tooling, plastic materials and the final product. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator 

    ASSESSMENT CRITERION 5 
    Records and reports are accurate and complete and made timeously. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator 
    ASSESSMENT CRITERION RANGE 
  • Records include both written and electronically stored information
  • Reports could be oral or written, including the completion of any related documentation
     
    		•

    ASSESSMENT CRITERION 6 
    Work is carefully planned, systematic and consistently done. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator 

    ASSESSMENT CRITERION 7 
    Where faults have occurred, appropriate action has been taken to resume quality production within a reasonable period of time. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator 
    ASSESSMENT CRITERION RANGE 
  • Appropriate action includes adjustments, shutting down and requesting repairs or maintenance, requesting assistance where the problem exceeds my authority, reporting or briefing other personnel
  • Reasonable period of time lies within the discretion of my assessor to determine and depends on the context and the nature of the problems experienced. I should provide evidence of problems I have resolved over a period of time prior to the summative assessment.
     
    		•

    ASSESSMENT CRITERION 8 
    Relevant calculations are performed to arrive at process settings and production rates. 
    ASSESSMENT CRITERION NOTES 
    Assessment criterion type: Indicator 

    ASSESSMENT CRITERION 9 
    Discussions of issues demonstrate that I have an understanding of the key concepts and principles related to the setting process 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:
  • Responses to emergency situations or critical events (If I have experienced such situations or events I can present records of my responses as part of my portfolio)
  • Consequences of poor planning, poor practices and incorrect settings
  • The relationship between the materials, the manufacturing process, the process settings, the tooling and the requirements of the manufactured product
    Discussions can include explanations and demonstrations if appropriate
     
    		•


    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 
    The following items reflect the type of knowledge that the assessor will evaluate
    Names and functions of:
  • Plastic materials
  • Parts, controls, instruments and equipment
  • Measurements and units of measurement
  • Hydraulic, pneumatic, heating (including steam), cooling, electrical systems
  • Tooling, product

    Purpose of:
  • Setting and adjustment processes
  • Health and safety procedures
  • Setting and changeover procedures
  • Quality standards, including quality procedures
  • Recording machine and environmental conditions

    Attributes, descriptions, characteristics and properties:
  • Materials to be processed
  • Materials used for equipment, machines and tooling
  • Attributes of the product
  • Properties and characteristics of tools, equipment and services
  • Various types of quality standard
  • Control systems

    Processes and events:
  • Preparations and planning
  • Machine setting
  • Quality checking and adjustments
  • Responding to emergencies and critical events

    Causes and effects, implications of:
  • Temperature and state changes
  • Pressure changes
  • Oil temperature changes
  • Calibration process
  • Product mass
  • Impact of settings on product cost
  • Things going wrong, eg accidents, power and service failure
  • Wrong or poorly prepared material
  • Poor planning procedures
  • Changes of plan or schedules

    Procedures and techniques:
  • Quality
  • Safety
  • Company
  • Setting and running
  • Shutting down
  • Internal ordering (requisition)

    Sensory cues:
  • Noises, smells or vibration related to correct and incorrect setting or changes in settings

    Regulations, legislation, agreements, policies, standards:
  • Regulations related to safety, health and the environment
  • Regulations appropriate to the product
  • Quality standards

    Theory: rules, principles, laws:
  • Temperature, changes of state, melt properties
  • Pressure, torque, viscosity, fluid dynamics
  • Electricity, current, power, resistance, circuits, components
  • Behaviour of gases, fluids and solids
  • Pressure, vacuum
  • Principles related to the setting and adjustment process

    Categories:
  • Materials
  • Faults
  • Machines and equipment

    Relationships, systems:
  • Pre- and post-processes related to the material properties
  • Relationship between materials, process and the environment
  • Environmental influences on quality
  • Relationship between materials, processes and final product 
    		•

    UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
  • Identify product faults related to setting and undertake appropriate action
  • Identify and correct conditions or practices which will damage or reduce the life of the machinery and equipment
  • Identify conditions or practices which will impact on the properties of the material to be processed or the end-product performance 
    		•

    UNIT STANDARD CCFO WORKING 
    Interact with workgroup members to effect efficient and problem-free changeovers and settings. 

    UNIT STANDARD CCFO ORGANISING 
    Prepare, plan and sequence events and procedures. 

    UNIT STANDARD CCFO COLLECTING 
  • Record and categorise problems, faults and down times related to settings and changeovers
  • Collect and record changes to settings 
    		•

    UNIT STANDARD CCFO COMMUNICATING 
  • Discuss issues related to requesting or instructing workgroup members and associated people to co-ordinate and effect settings or changeovers
  • Report on the impact of settings on the performance of the process equipment and the properties of the material and end-product 
    		•

    UNIT STANDARD CCFO SCIENCE 
  • Relate physics principles such as torque, friction, heat and flow to the implications of these for setting and installation
  • Analyse collected data for possible solutions to problems 
    		•

    UNIT STANDARD CCFO DEMONSTRATING 
  • Solutions to problems reflect an awareness that setting forms the key to quality, output and cost-effectiveness
  • The relationship of time taken for changeovers or setting and production cost factors 
    		•

    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 12663, which is 'Set production equipment', Level 4, 8 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 


    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.