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SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD: 

Develop a metal casting process 
SAQA US ID UNIT STANDARD TITLE
264074  Develop a metal casting 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 5  Level TBA: Pre-2009 was L5  30 
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 unit standard is for people who work, or intend to work in a manufacturing process or similar environment where foundry moulds are required for the metal product casting process. The skills, knowledge and values reflected in this unit standard will contribute towards the achievement of a National Certificate in Foundry Operations at NQF Level 5. Equipment operated in this unit standard is against a set of specific instructions.

People credited with this unit standard are able to:
  • Determine the requirements for metal casting.
  • Design casting process for making casting.
  • Evaluate casting process.
  • Establish casting process and work plans. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    The credits allocated to this unit standard assume that the learner has a National Certificate in Foundry Operations NQF Level 4 or an equivalent qualification. It also assume that the learner is working towards a qualification as part of a learning programme, which integrates all the required unit standards.

    The learning time will increase if the learner does not have:
  • A relevant NQF Level 4 qualification.
  • Experience in a relevant field.
  • Demonstrated competence in the interpretation of technical drawings and method cards.
  • Demonstrated competence in producing complex moulds.

    The learning time will be decreased if the learner has experience in this field because:
  • The learning programme will be adjusted to build on what the learner already knows.
  • The learner can apply to have prior learning recognised. 

  • UNIT STANDARD RANGE 
    The scope and level of this unit standard is indicated by range statements related to the specific outcomes:
  • Developing casting processes covers both ferrous and non-ferrous metal processes.
  • Planning knowledge includes but is not limited to planning methods, identifying production constraints and taking corrective action.
  • Production constraints include shortage of consumables, delays in core production, delays in molten metal availability, lack of space on foundry floor, crane delay. 

  • Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Determine the requirements for metal casting. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Customer requirements for castings are clarified according to standard operating procedures. 
    ASSESSMENT CRITERION RANGE 
    Customer requirements include casting size, shape, cost and quantity.
     

    ASSESSMENT CRITERION 2 
    Casting requirements are analysed in relation to customer needs. 
    ASSESSMENT CRITERION RANGE 
    Casting requirements include metal specification, surface finish, internal integrity, weight and number.
     

    ASSESSMENT CRITERION 3 
    Moulding mediums are evaluated in line with production and customer's requirements. 
    ASSESSMENT CRITERION RANGE 
    Moulding mediums include sand, permanent moulds, die casting, ceramics and investments.
     

    ASSESSMENT CRITERION 4 
    Casting medium is established that will meet customer's and production requirements. 

    SPECIFIC OUTCOME 2 
    Design the metal casting process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Pouring system is established for casting process according to standard operating procedures. 
    ASSESSMENT CRITERION RANGE 
    Pouring system includes pressurised, un-pressurised or filtration and in-mould inoculation requirements.
     

    ASSESSMENT CRITERION 2 
    Runner system requirements are calculated according to standard operating procedures. 
    ASSESSMENT CRITERION RANGE 
    Runner system includes runners and ingates, pouring velocity, feeding range, feeding design and contact area.
     

    ASSESSMENT CRITERION 3 
    Feeding system is established for casting process according to standard operating procedures. 
    ASSESSMENT CRITERION RANGE 
    Feeding system includes material solidification, thermal gradient, contact area, chill requirements, yield requirements and down stream processes.
     

    ASSESSMENT CRITERION 4 
    Casting arrangements and drawings for pattern and tooling specification are established according to standard operating procedures. 

    ASSESSMENT CRITERION 5 
    Cost of production is confirmed with customer within the required period of time. 

    SPECIFIC OUTCOME 3 
    Evaluate the metal casting process. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Production yield is evaluated according to standard operating procedures. 

    ASSESSMENT CRITERION 2 
    Trial castings are evaluated for yield, cost and quality according to standard operating procedures. 

    ASSESSMENT CRITERION 3 
    Casting process documentation is completed according to standard operating procedures. 

    SPECIFIC OUTCOME 4 
    Establish the casting process and work plans. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Casting process is determined in line with production and customer's requirements. 

    ASSESSMENT CRITERION 2 
    Process plans are prepared according to standard operating procedures. 

    ASSESSMENT CRITERION 3 
    Plans and costing are provided to customer in line with production and customer's requirements. 


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • An assessor, accredited with a relevant NQF Level 4 or higher qualification, will assess the learner's competency. Only an Assessor with suitable first hand experience in process operations will assess the learner's competency.
  • Anyone assessing a learner or moderating the assessment of a learner against the qualification 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 qualification 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 associated unit standards.
  • Anyone wishing to be assessed against this qualification 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 
    Things I know and can explain:

    Names and functions of:
  • Moulding mediums.
  • Pouring systems.
  • Runner systems.
  • Feeding system.

    Attributes, descriptions, characteristics and properties:
  • Casting requirements.
  • Moulding mediums.
  • Pouring systems.
  • Runner systems.
  • Feeding system.

    Sensory cues:
  • Relating to developing metal casting process.

    Purpose of:
  • Determining customer requirements.

    Processes, events, causes and effects, implications:
  • Implications of a metal casting process that does not meet the customer's needs.

    Procedures and techniques:
  • Clarifying customer requirements.
  • Analysing casting requirements.
  • Evaluating moulding mediums.
  • Establishing casting requirements.
  • Establishing pouring system.
  • Calculating runner system requirements.
  • Establishing feeding system.
  • Calculating cost of production.
  • Applicable worksite procedures.

    Regulations, legislation, agreements, policies, standards:
  • Applicable safety, health and environmental legislation and regulations.

    Theory; rules, principles, laws:
  • Applicable mathematical rules, principles and laws.

    Relationships, systems:
  • The relationship between a quality product, competitive costing and customer relations. 

  • UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems; Relating to determining metal casting process. 

    UNIT STANDARD CCFO WORKING 
    Work with others as a member of ateam group; To achieve the metal casting development process objectives. 

    UNIT STANDARD CCFO ORGANISING 
    Orgarnise and manage my activities and myself; By clarifying customer needs before establishing metal casting process needs and cost. 

    UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information; By questioning and clarifying customer needs. 

    UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively; With customer to establish their needs. 

    UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically; To calculate metal casting process costs. 

    UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems; How developing a cost effective metal casting process affects customer relationships. 

    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  66489   Further Education and Training Certificate: Foundry Operations  Level 4  NQF Level 04  Passed the End Date -
    Status was "Reregistered" 
    2013-11-07  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.
     
    1. QTE Training & Consulting cc T/A QTE (GERMISTON) (TP) 



    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.