|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 QUALIFICATION THAT HAS PASSED THE END DATE:|
|National Diploma: Inspection and Assessment (Non-Metallics)|
|SAQA QUAL ID||QUALIFICATION TITLE|
|60072||National Diploma: Inspection and Assessment (Non-Metallics)|
|SGB Plastics Manufacturing|
|PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY||NQF SUB-FRAMEWORK|
|MERSETA - Manufacturing, Engineering and Related Services Education and Training Authority||OQSF - Occupational Qualifications Sub-framework|
|National Diploma||Field 06 - Manufacturing, Engineering and Technology||Manufacturing and Assembly|
|ABET BAND||MINIMUM CREDITS||PRE-2009 NQF LEVEL||NQF LEVEL||QUAL CLASS|
|Undefined||241||Level 5||NQF Level 05||Regular-Unit Stds Based|
|REGISTRATION STATUS||SAQA DECISION NUMBER||REGISTRATION START DATE||REGISTRATION END DATE|
Passed the End Date -
Status was "Reregistered"
|LAST DATE FOR ENROLMENT||LAST DATE FOR ACHIEVEMENT|
|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 qualification does not replace any other qualification and is not replaced by any other qualification.
|PURPOSE AND RATIONALE OF THE QUALIFICATION|
This qualification is the third in a series of qualifications which recognise learning in respect of skills and knowledge needed to carry out inspection and assessment of thermoplastic and polymer composite (non-metallic) components and installations.
People who have achieved this qualification are able to verify the design and development of manufactured components, the quality of the quality documentation and manufacturers' or end-users' quality management systems against the requirements of the relevant code; evaluate non-conformances, approve concessions and recommend process rectification; and participate in dispute resolution processes.
This qualification represents the skills, knowledge and understanding required by competent practitioners to:
The achievement of this qualification would be an indicator that a candidate has the requisite knowledge and skills in order to engage in inspection and assessment activities. The practitioner at this level would typically carry out the duties of a competent person. The designation competent person may only be awarded by an accredited inspection authority. A competent person assures the quality of the design process and the quality assurance practices. The competent person would also evaluate non-conformances and play a role in dispute resolution.
The requirements for licensing of such a competent person, eg a number of inspections conducted under the supervision of a qualified inspector, would continue to be the responsibility of the bodies accredited to do this.
This series of qualifications builds the required manufacturing, inspection and assessment skills and knowledge in a systematic way. The three qualifications in the series correspond broadly to the different grades of inspectors, ie in-house inspector, competent person and inspector of pressure vessels. But they also go beyond the licensing requirements and develop the competence for a broader quality assurance function.
This and the related qualifications will act as a framework for providers, assessors and learners to plan, implement and measure the outcomes of suitable learning programmes, or the recognition of prior learning. These qualifications can also be used by the relevant accreditation authority to licence and register inspectors.
This qualification will also assist manufacturers, end-users and inspection authorities to inspect manufacturing processes and installations and to assess these against quality standards, especially where there is a need for an independent person to perform these activities. This qualification will also provide status for people involved in this function and will build a greater awareness of the need for quality assurance amongst manufacturing staff, customers and end-users.
This qualification forms the second stage of a qualification that begins with, and includes, the credits for the National Certificate in Inspection and Assessment (Non-Metallics): NQF Level 5.
The qualification is also designed to align with:
This qualification has been developed to address the lack of qualifications for the inspection and assessment of non-metallics. Non-metallics are relatively new polymeric materials. They are being increasingly used in the manufacture of installations, plant and equipment, including systems under pressure. These materials include thermoplastics, thermosets (including polymer composites) and elastomers which are used in a range of applications, in particular for their resistance to corrosion and a variety of chemicals. Applications include plant, equipment, vessels, piping, valves, linings, coatings, insulations and attachments. Complex installations are assembled from a variety of components and include systems under pressure.
Since these applications are generally safety critical in nature, quality assurance is required in the whole life cycle of the manufactured items, from their design to their disposal. Such quality assurance processes require qualified people to perform the inspections and assessments.
While the activity of inspection and assessment is an important component of quality assurance in the manufacturing field generally, it is particularly important for the manufacture of installations, including systems under pressure. Inspection and assessment is required during the design, manufacture, testing, installation and service life of the manufactured items.
The lack of suitably qualified people has resulted in numerous problems in the field, ranging from poor design to inadequate maintenance. Of particular concern is the fact that, because of the shortage of specialised inspectors for non-metallics, inspectors qualified in other materials or other industries are making judgements about materials of which they have little knowledge. As a result, non-metallic materials and the non-metallic manufacturing industry have suffered a loss of credibility.
This qualification, which is part of a series, is therefore designed to provide recognition for the skills, knowledge and values required for this important function of performing inspections and assessment in order to assure the quality of items manufactured from non-metallic materials.
At the time of development of this qualification there were no qualifications registered on the National Qualifications Framework for inspection and assessment activities. Since inspection and assessment are fairly generic activities found in a variety of industries, this qualification has been designed in such a way that it can also act as the basis for the development of qualifications for inspection and assessment in other contexts.
|LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING|
|It is assumed that learners are already competent in Communication and Mathematical Literacy at NQF Level 4.
The design of this qualification, the credits allocated to this qualification and the related unit standards are based on the assumption that the learner has already achieved the outcomes of the National Certificate in Inspection and Assessment (Non-Metallics): NQF Level 5.
This means that it is assumed that the learner will already have had extensive experience in, and be able to:
Recognition of Prior Learning:
This qualification may be obtained through the process of RPL. The learner should be thoroughly briefed prior to the assessment and support should be provided to assist the learner in the process of developing a portfolio. While this is primarily a work-based qualification, evidence from other areas of endeavour may be introduced if pertinent to any of the exit level outcomes.
Access to the Qualification:
There is open access to this qualification. While a component of the learning can be obtained through courses, the largest amount of learning in this qualification is based on real-life, real-time work experience, specialising in a particular manufacturing process and range of products in the non-metallic field. A workplace is, therefore, a prerequisite to obtaining the relevant work experience and evidence required for the Exit Level Outcomes.
|RECOGNISE PREVIOUS LEARNING?|
|EXIT LEVEL OUTCOMES|
|1. Assure that the component design, drawings and calculations comply with the relevant code.
2. Monitor and verify manufacturers' quality assurance systems and practices.
3. Evaluate non-conformances, approve concessions and recommend process rectification.
4. Communicate with a variety of parties to influence quality, present technical information and engage interactively with all role players in the field.
5. Compile quality plans and associated documentation, monitor and verify manufacturing and installation process and conduct third party inspections.
Critical Cross-field Outcomes:
These are embedded in the unit standards which make up this qualification and are thus also reflected in the Exit Level Outcomes and Associated Assessment Criteria for this qualification.
The Critical Cross-Field Outcomes are supported by the Exit Level Outcomes as follows:
|ASSOCIATED ASSESSMENT CRITERIA|
|Associated Assessment Criteria for Exit Level Outcome 1:
1. Design is signed off.
2. Verification of compliance is performed thoroughly and calculations are accurate.
3. Discussion and response to questioning demonstrates understanding of design principles and in-service stresses and strains.
Associated Assessment Criteria for Exit Level Outcome 2:
1. Compliance to auditing procedures and quality documentation is confirmed.
2. A review or audit report is signed.
3. Discussion and response to questioning demonstrates understanding of the implications and consequences of the monitoring and verification and auditing process.
Associated Assessment Criteria for Exit Level Outcome 3:
1. Positive or negative recommendations of concessions are made.
2. Reports documenting and justifying decisions are clear and succinct.
3. Disputes are resolved.
4. Discussion and response to questioning demonstrates understanding of the legal and financial implications of such decisions and the use of documents for legal processes.
Associated Assessment Criteria for Exit Level Outcome 4:
1. Communication style and content is adjusted to the level of the audience and the context.
2. Technical issues are explained in simple language.
3. Written materials and formal presentations make use of appropriate formats and effective lay out of the information.
4. Numerical and statistical data is presented in appropriate formats.
5. Active listening and focused reading and writing techniques are used to gather, record and summarise relevant information.
Associated Assessment Criteria for Exit Level Outcome 5:
1. State of inspected installation either correlates with specifications, or non-conformances are identified.
2. Production is certified in accordance with mandatory and statutory provisions and regulations.
3. The quality documentation leads to conformance with specification throughout the manufacturing process.
The integrated assessment must be based on a summative assessment guide. The guide must spell out how the assessor will assess different aspects of the performance and will include:
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.
While this is primarily a workplace-based qualification, evidence from other areas of endeavour may be presented if pertinent to any of the Exit Level Outcomes.
The assessment process should cover the explicit tasks required for the qualification as well as the understanding of the concepts and principles that underpin the activities. The assessment process should also establish how the learning process has advanced the Critical Cross-field Outcomes.
Assessors should also evaluate evidence that the learner has been performing consistently over a period of time.
|The competence profile for which this series of qualifications is designed, is aligned with local and international pressure equipment directives and regulations. The United States has a very mature inspection and assessment system and provides information for making the comparison. In addition an international organisation (the World Health Organisation) has also been chosen to provide additional information based on the fact that such competence profiles transcend national boundaries. In the absence of information for relatively new materials such as fabricated polymers and polymer composites, the following provide guidance and a basis for comparison:
In general these qualifications (ie 1 and 2, above) are not well-specified to enable comparisons of qualifications developed to meet SAQA requirements. They do, however, in general conform to the pattern described for the Certified Quality Technician (CQT) Program of the American Society for Quality. The applied competence is described as:
> Membership in ASQ or one of its foreign affiliates, or another society that belongs to the American Association of Engineering Societies or Accreditation Board for Engineering and Technology.
> Registration as a professional engineer; or c) obtaining the signatures of two persons -- either ASQ, foreign affiliate, other recognized professional society members -- verifying that the candidate is "a qualified practitioner of the quality sciences".
This submission deals with the first and third criteria discussed above. The inspection authority would take these into account when deciding on the second criterion.
This extract demonstrates, too, that this is a qualification for occupational competence. While courses play a role in the awarding of such a qualification, experience in a field or sub-field is an essential ingredient of the overall applied competence. A written examination is not enough on its own to prove competence.
As this extract demonstrates, there is little evidence of progression or career pathing for inspection and assessment practitioners.
A career path can be constructed using the different levels of inspection described by the World Health Organisation for inspection of pharmaceutical manufacturers:
The Boiler and Pressure Vessel Inspector job family has three levels of work which are distinguished by the complexity of job assignments, the extent of responsibility assigned and the level of expertise required for completion of assigned tasks.
Level I; Code: J16A; Salary Band: I.
This is the basic level where employees perform inspection and compliance duties with close supervision and receive specialized training on boilers, pressure vessels, steam lines, weld procedures and applicable rules, methods and techniques. Performs inspection and compliance duties with close supervision.
Knowledge, Skills and Abilities required at this level are knowledge of pressure retaining items such as boilers, pressure vessels and steam lines, of basic mechanical apparatus/equipment theory and operation, of inspection and investigative methods and procedures, of report writing, and of the application of safety concepts, rules and codes. Ability to conduct inspections and investigations; to write reports; to apply safety codes and standards; to establish and maintain effective working relationships with others; and to communicate effectively, both orally and in writing. Ability to learn complex mathematical formula. Ability to work in close, confined spaces and to work in high places.
Education And Experience requirements at this level consist of sixty semester hours of college, including twelve hours of mathematics or physical science and one year of experience in the construction, operation or inspection of boilers or pressure vessels, or production experience in the oil and gas industry or physical plant operation; or an equivalent combination of education and experience, substituting one year of experience in the construction, operation or inspection of pressure retaining items such as boilers, air tanks or pressure vessels for the sixty semester hours of college.
Level II; Code: J16B; Salary Band: J.
This is the career level where tasks are performed independently and incumbents are given some latitude technically with freedom to develop their own work sequence under established guidelines and policies. Incumbents also inspect and review quality control and safe operation standards evaluation and assessment, and evaluate the engineering and design capabilities as well as the configuration of the environment in which installation and operation occurs, using a variety of applicable standards and calculations.
Knowledge, Skills and Abilities required at this level include those identified in Level I, plus knowledge of quality control methods and procedures; and of mechanical engineering and scientific formula and their specific application to a variety of sophisticated devices and complex installations. Ability is required to provide consultation and advice; and to discern appropriate formulas and codes for complex applications.
Education and Experience requirements at this level consist of those included in Level I and possession of a valid Commission issued by the National Board of Boiler and Pressure Vessel Inspectors. (No substitution will be allowed for the valid Commission).
Level III; Code: J16C; Salary Band: L.
This is the leadership level of the job family where employees are assigned responsibility for planning, directing and supervising the work activities of inspectors who are conducting boiler and pressure vessel inspections and investigations. Positions are assigned responsibility for the supervision of Boiler and Pressure Vessel Inspectors, including reviewing and assigning work, providing training and evaluating performance. Some positions may provide direct supervision which includes responsibilities for employee development, approving leave and initiating disciplinary actions, as well as performing related administrative functions.
Knowledge, Skills and Abilities required at this level include those identified in Level II plus knowledge of supervisory principles and practices. Ability is required to direct the work of others and to conduct multiple projects simultaneously.
Education and Experience requirements at this level consist of those identified in Level II plus four years of experience in the inspection of boilers and pressure vessels to also include in-service inspections, accident and incident investigations and review of repair and alteration plans and computations, substituting the successful completion of the "B" endorsement examination, offered by the National Board of Boiler and Pressure Vessel Inspectors, for twelve months of the required experience.
The following table illustrates how the levels described above compare with our South African NQF Levels:
Level of inspector; NQF Level:
Courses for the inspection component range, for example, from:
> Basic aspects of inspection, Inspector's responsibilities, duties, attributes and the understanding of legislation, Boilers and Pressure equipment, Safety during Inspection, Methods of inspection, pressure equipment Inspection, Assessment of pressure equipment integrity, Materials, Manufacture, Common modes and causes of deterioration and failure, Repairs, alterations (modification), replacement and rerating, Documentation, Inspection and repair of specific pressure equipment (to AS/NZS3788).
4 semesters for a diploma or 8 semesters for a Bachelor of Science degree which cover all aspects of design, manufacturing and quality as a basis for career in inspection and assessment and result in the following outcomes:
> Mechanical Design; where knowledge and skill are required to conceive requirements, provide analysis, integrated design solutions, testing and verification of concept, and the ability to present the design using acceptable methods.
> Manufacturing; where knowledge and skill are required to develop manufacturing plans, design integrated production systems with quality, cost and safety requirements, and considering operation in national and global environments.
> Applied Thermal Science; where knowledge and skill are required to analyze, design, test and correct fluid and thermal systems involved in various industrial conversion processes, and in comfort control.
> Plastics and Composites; where knowledge and skill are required to establish design requirements, provide manufacturing plans and systems for optimized performance.
> Communication Skills; requiring the use of various media to communicate concepts, technical assessments and design solutions to a variety of audience including those with limited engineering knowledge.
> Ethics, Interpersonal and Social Skills; expected for professional practice in an environment requiring team effort, were decisions and actions can effect citizens and communities.
This latter qualification indicates some of the difficulties in designing a qualification for inspection and assessment. The inspection process is buried deep within the overall qualification which may have other purposes besides inspection. There are generally two routes to acquiring the competencies to perform inspection and assessment activities:
As a general rule, to gain experience and to qualify for registration, inspectors would have to perform inspections under the guidance of an experienced registered person at the same level or above. This is explained in relation to the pharmaceutical industry:
Embedded in the inspection and assessment competencies is the notion of maturity, as indicated by the American Society for Quality in relation to environmental analysts (who perform an inspection and assessment role in order to maintain safe and healthy working environments in factories, etc):
As part of the development of these qualifications, the contents of two local courses were reviewed and incorporated into the qualifications. These courses, which are run at the Vaal University of Technology and the Durban Institute of Technology, have also been benchmarked against similar international courses.
The comparison demonstrates that the competence profile of the South African qualification conforms to various similar inspection and assessment profiles internationally.
|This qualification articulates vertically with the National Diploma in Plastics Technology.
This qualification represents an end-point for the particular category of skills and knowledge it describes. It therefore does not have a direct vertical articulation with another qualification.
|Moderators for the qualification should be registered as assessors with the relevant ETQA.
To assure the quality of the assessment process, the moderation should cover the following:
|CRITERIA FOR THE REGISTRATION OF ASSESSORS|
|The following criteria should be applied by the relevant ETQA:
> Maintaining national standards.
> The interests of the learner.
> The need for transformation and redressing the legacies of the past.
> The cultural background and language of the learner.
|As per the SAQA Board decision/s at that time, this qualification was Reregistered in 2012; 2015.|
|ID||UNIT STANDARD TITLE||PRE-2009 NQF LEVEL||NQF LEVEL||CREDITS|
|Core||9904||Coordinate work group to produce product||Level 5||Level TBA: Pre-2009 was L5||8|
|Core||254034||Ensure design proposals, design realisation and installation operations meet standards||Level 5||Level TBA: Pre-2009 was L5||10|
|Core||252024||Evaluate current practices against best practice||Level 5||Level TBA: Pre-2009 was L5||4|
|Core||254014||Evaluate non-conformances, approve concessions and recommend process rectification||Level 5||Level TBA: Pre-2009 was L5||12|
|Core||13256||Maintain business processes||Level 5||Level TBA: Pre-2009 was L5||10|
|Core||253994||Monitor and verify adherence to quality documentation||Level 5||Level TBA: Pre-2009 was L5||12|
|Core||13237||Optimise the quality assurance system||Level 5||Level TBA: Pre-2009 was L5||6|
|Core||12459||Optimise the safety, health and environmental protection system||Level 5||Level TBA: Pre-2009 was L5||6|
|Core||253997||Perform a procedures audit||Level 5||Level TBA: Pre-2009 was L5||10|
|Core||116787||Plan, monitor and control the financial resources for a small company or business unit||Level 5||Level TBA: Pre-2009 was L5||10|
|Core||254015||Resolve manufacturing and quality-related disputes||Level 5||Level TBA: Pre-2009 was L5||16|
|Fundamental||252027||Devise and apply strategies to establish and maintain workplace relationships||Level 5||Level TBA: Pre-2009 was L5||6|
|Fundamental||117854||Facilitate meetings to deal with conflict situations||Level 5||Level TBA: Pre-2009 was L5||8|
|Fundamental||15226||Implement systems to meet the flow of information in a team, department or division||Level 5||Level TBA: Pre-2009 was L5||3|
|Fundamental||252025||Monitor, assess and manage risk||Level 5||Level TBA: Pre-2009 was L5||8|
|Fundamental||115790||Write and present for a wide range of purposes, audiences and contexts||Level 5||Level TBA: Pre-2009 was L5||5|
|Elective||120128||Apply the law of contract to insurance||Level 4||NQF Level 04||3|
|Elective||15231||Create and use a range of resources to effectively manage teams, sections, departments or divisions||Level 5||Level TBA: Pre-2009 was L5||4|
|Elective||116781||Develop and implement sustainable processes and procedures||Level 5||Level TBA: Pre-2009 was L5||10|
|Elective||117391||Investigate an incident||Level 5||Level TBA: Pre-2009 was L5||8|
|Elective||15136||Manage health and safety on a construction project||Level 5||Level TBA: Pre-2009 was L5||6|
|Elective||114716||Manage installation and maintenance contractors||Level 5||Level TBA: Pre-2009 was L5||16|
|LEARNING PROGRAMMES RECORDED AGAINST THIS QUALIFICATION:|
|PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS QUALIFICATION:|
|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.