|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|
|Further Education and Training Certificate: Carbonate Materials Manufacturing Processes|
|SAQA QUAL ID||QUALIFICATION TITLE|
|57692||Further Education and Training Certificate: Carbonate Materials Manufacturing Processes|
|SGB Mining and Minerals|
|PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY||NQF SUB-FRAMEWORK|
|MQA - Mining Qualifications Authority||OQSF - Occupational Qualifications Sub-framework|
|Further Ed and Training Cert||Field 06 - Manufacturing, Engineering and Technology||Fabrication and Extraction|
|ABET BAND||MINIMUM CREDITS||PRE-2009 NQF LEVEL||NQF LEVEL||QUAL CLASS|
|Undefined||170||Level 4||NQF Level 04||Regular-Unit Stds Based|
|REGISTRATION STATUS||SAQA DECISION NUMBER||REGISTRATION START DATE||REGISTRATION END DATE|
|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 will enable qualifying learners with the necessary knowledge, understanding and competence to 'Burn" (manufacture) cement or lime in accordance with specified requirements. It provides an opportunity for learners to learn and apply skills in the workplace.
Cement and lime manufacturing are complex processes far beyond the mere reduction or separation of minerals, which impacts on the environment and the occupational safety of people. There are also potential dangers due to the extremely high temperatures of material in the kiln and explosions in electrostatic precipitators.
Process Controllers in modern cement or lime plants control the entire manufacturing process from centralised control rooms by means of state-of-the-art process technology. This involves production stages such as reclaiming of raw materials, materials transport (handling), raw milling, burning and finish milling. Their knowledge of, and application of cement technology scans a wide range of topics such as relevant chemistry, information technology, refractories and materials handling.
Learners acquiring this qualification will have an improved understanding of their role, acquire the applied competencies to consistently and effectively execute their duties by contributing to the manufacturing process and adhering to quality and occupational safety requirements.
This qualification will have a positive impact on society through the products produced (cement and lime). Furthermore, cement and lime plants and their associated quarries are often situated in rural areas, and have a direct and indirect impact on the economies of the towns and rural areas in the vicinity.
People credited with this qualification are able to:
The need for this qualification was identified by means of a number of processes and realities:
This qualification will give recognition for the skills and competencies of process controllers, who up to now have been trained and developed on an informal basis only. The associated status of a nationally recognised qualification will serve as a motivation for high-level learners to enter the career of process controlling.
Current process operators, particularly, will benefit from the opportunities of assessment and subsequent recognition presented by RPL (Recognition of Prior Learning).
Learners entering this qualification will typically come from cement or lime manufacturing operations, working as Process Attendants, Operator Support or in support services such as Routine Testers in laboratories. In some cases learners can come from industries with similar materials handling processes and equipment (e.g. base metals). Learners from other industries would however have to become familiar with the cement or lime manufacturing materials, equipment and processes before they can proceed with this qualification.
Another potential source of Learners for the qualification is qualified artisans (e.g. Electricians, Fitters or Millwrights). There is a great deal of merit in multiskilling qualified artisans as process Operators.
This qualification prepares learners for possible appointment as Process Operators (Often called "Burners") in cement or lime manufacturing operations, controlling the entire manufacturing process by means of technologically advanced process control systems whereby minerals (limestone, silica, magnetite etc.) are processed (Manufactured) into final products (cement and lime respectively).
The process control function often called "Burning" is considered to be the "heart" of the cement/lime manufacturing industry due to the high level of investment in fixed plant, raw materials and processing costs involved. The contribution to the cement/lime manufacturing process and the associated potential losses due to non-conformance are enormous in terms of operating costs, occupational health and safety implications, impact on the environment, quality of product and potential waste due to non conforming product.
Cement and lime are both final products used in other industries for various purposes. Both these products play a vital role in the South African economy and even beyond our borders.
|LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING|
|It is assumed that learners are already competent in:
The following unit standards:
Recognition of Prior Learning:
This qualification can be achieved wholly or in part through recognition of prior learning in terms of the criteria laid out above.
Evidence can be presented in a variety of forms, including international or previous local qualifications, reports, testimonials mentioning functions performed, work records, portfolios, videos of practice and performance records.
Access to the qualification:
Access to this qualification is open bearing in mind learning assumed to be in place.
|RECOGNISE PREVIOUS LEARNING?|
|The Qualification consists of a Fundamental, a Core and an Elective Component.
To be awarded the Qualification, learners are required to obtain a minimum of 170 credits as detailed below.
The Fundamental Component consists of Unit Standards in:
It is compulsory therefore for learners to do Communication in two different South African languages, one at NQF Level 4 and the other at NQF Level 3.
All Unit Standards in the Fundamental Component are compulsory.
The Core Component consists of Unit Standards to the value of 58 credits all of which are compulsory.
The Elective Component consists of Unit Standards in two specializations each with its own set of Unit Standards. Learners are to choose a specialization area and Elective Unit Standards at least to the value of 45 credits.
Cement Manufacturing (total 45 credits):
Lime Manufacturing (total 45 credits):
A further 11 credits are to be chosen from the rest of the electives to make up a minimum of 170 credits for the qualification.
|EXIT LEVEL OUTCOMES|
|1. Communicate in the workplace.
2. Solve problems by applying mathematical practical applications in a variety of ways.
3. Adhere to occupational health, safety and environmental standards in the workplace.
4. Manufacture product using relevant process technology in accordance with quality requirements.
> Range: Product refers to cement or lime.
5. Demonstrate an understanding of quality management requirements and apply them in the manufacturing process.
6. Coordinate work operations and lead teams within the manufacturing context.
> Range: Manufacturing context refers to cement or lime.
Consistency of Exit Level Outcomes with Critical Crossfield Outcomes
The following CCFO's have been addressed in this qualification as per the unit standards outlined in the Annexure.
SAQA Critical Cross-Field Outcomes; Equivalent Exit Level Outcome
> Reflecting on and exploring a variety of strategies to learn more effectively.
> Participating as responsible citizens in the life of local, national and global communities.
> Being culturally and aesthetically sensitive across a range of contexts.
> Exploring education and career opportunities.
> Developing entrepreneurial opportunities.
|ASSOCIATED ASSESSMENT CRITERIA|
> Range: Material refers to burnt lime and clinker.
> Raw materials quality.
> In-process materials quality.
> Finished product quality.
> Reporting and dealing with non conformances.
> Record keeping.
> Range: Manufacturing process refers to cement or lime.
Integrated assessment at the level of the qualification provides an opportunity for learners to show they are able to integrate concepts, actions and ideas achieved across a range of unit standards and contexts.
Integrated assessment must evaluate the quality of observable performance as well as the thinking behind the performance, and must be based on a summative assessment guide. The guide will spell out how the assessor will assess different aspects of the performance and will include:
In some cases interference will be necessary to determine competence depending on the nature and context within which performance takes place.
The learner may choose in which language s/he 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 introduced if pertinent to any of the exit-level outcomes. The assessment process should cover both the explicit tasks required for the qualification as well as the understanding of the concepts and principles that underpin the activities associated with manufacturing cement or lime.
|The manufacture of cement or lime occurs in a large number of countries world-wide. Therefore the countries chosen to benchmark this qualification against, were selected based on proven best practice within the field of cement or lime manufacture and those are New Zealand, Southern California and Arabian countries.
New Zealand: (http://www.nzqa.govt.nz/nqfdocs/quals/doc/0474.doc)
A relevant qualification - National Certificate in Minerals Processing was found. The following is an outline of the qualification with a broad range of electives.
Unit Standard Titles:
Favorable comparisons were found in terms of Occupational Health and Safety. The unit standard outcomes in "Operate a lime mill processing plant" compares well to the unit standards in this FETC " Clear hot, dry blockages in a mineral process" and "Demonstrate knowledge of Lime quality".
The FETC Cement Lime Manufacturing compares favorably in terms of structure and levels, both being Level 4 qualifications; however the unit standards in the New Zealand qualification span varying levels while this FETC is on Level 3 and 4 unit standards.
Portland Cement Association (PCA) - Regional programs run in Southern California, the Midwest and Texas, and Georgia:
The following customised training courses were found:
This course covers much technical ground and is specifically designed for those entering the cement industry from other technical fields.
The following is the outline of the program.
This course is designed to give learners a thorough understanding of cement manufacturing processes and enable them to make intelligent decisions affecting quality and production efficiency. Rather than focusing on the specifics of daily kiln operation, the sessions emphasize the much larger picture of how to maximize kiln efficiency.
While similar elements of competence were found, similar qualifications were not found. The outcomes of these two training programmes match closely with the outcomes of the unit standards incorporated in this FETC Cement and Lime Manufacture.
Arab Union for Cement and Building Materials: (http://www.aucbm.org/english/activiti/trains/trains.htm)
Training courses are conducted in "Quality Control in Cement Production" at the training center of The Jordan Cement Factories Co and Qatar.
These are some courses conducted:
Here again, the outcomes are very similar to the outcomes within this FETC:
Similarly, the courses offered in "Refractory lining in cement kilns, Operating pre-heater kilns, Total Quality Management & ISO 9 000, Kiln Maintenance, Cement Chemistry and Quality Control" compare closely to the outcomes of the following unit standards:
These entire units standard are used respectively in this FETC Cement and Lime Manufacturing.
No relevant qualifications could be found in other Southern African countries, although all the major cement/lime companies in South Africa have factories in other Southern African countries. For development of this FETC there was representation from the various leading cement producers. Their training and development interventions occur countrywide and thus best practices have been incorporated in the development of this FETC.
In conclusion whilst this qualification does not compare to any international qualifications as a whole, there is a degree of comparison with the individual building blocks (unit standards) and programs of the countries compared with. This information was utilised wherever possible when developing the related Unit standards for this qualification, therefore ensuring that the learners will acquire competencies which can be applied in other external countries.
|This qualification allows for both vertical and horizontal articulation.
Vertical articulation exists with:
Horizontal articulation exists between the two specialisation areas (cement and lime) or to other minerals processing applications such as base minerals, chrome and industrial minerals. E.g. FETC: Minerals Processing NLRD ID: 49042, 49050, 49051.
|CRITERIA FOR THE REGISTRATION OF ASSESSORS|
|Assessors should be in possession of:
|As per the SAQA Board decision/s at that time, this qualification was Reregistered in 2012; 2015.|
|Range: Carbonate materials refers to Cement or Lime.|
|ID||UNIT STANDARD TITLE||PRE-2009 NQF LEVEL||NQF LEVEL||CREDITS|
|Core||10457||Clear hot, dry material blockages in a mineral process||Level 3||NQF Level 03||4|
|Core||7117||Contribute to and improve on the operation of a quality assurance system||Level 4||NQF Level 04||6|
|Core||10461||Manufacture calcined products in a rotary kiln||Level 4||NQF Level 04||36|
|Core||10981||Supervise work unit to achieve work unit objectives (individuals and teams)||Level 4||NQF Level 04||12|
|Fundamental||119472||Accommodate audience and context needs in oral/signed communication||Level 3||NQF Level 03||5|
|Fundamental||119458||Analyse and respond to a variety of literary texts||Level 3||NQF Level 03||5|
|Fundamental||119457||Interpret and use information from texts||Level 3||NQF Level 03||5|
|Fundamental||119465||Write/present/sign texts for a range of communicative contexts||Level 3||NQF Level 03||5|
|Fundamental||9015||Apply knowledge of statistics and probability to critically interrogate and effectively communicate findings on life related problems||Level 4||NQF Level 04||6|
|Fundamental||119462||Engage in sustained oral/signed communication and evaluate spoken/signed texts||Level 4||NQF Level 04||5|
|Fundamental||119469||Read/view, analyse and respond to a variety of texts||Level 4||NQF Level 04||5|
|Fundamental||9016||Represent analyse and calculate shape and motion in 2-and 3-dimensional space in different contexts||Level 4||NQF Level 04||4|
|Fundamental||119471||Use language and communication in occupational learning programmes||Level 4||NQF Level 04||5|
|Fundamental||7468||Use mathematics to investigate and monitor the financial aspects of personal, business, national and international issues||Level 4||NQF Level 04||6|
|Fundamental||119459||Write/present/sign for a wide range of contexts||Level 4||NQF Level 04||5|
|Elective||242751||Control limestone stockpile quality||Level 3||NQF Level 03||10|
|Elective||13974||Demonstrate an understanding of the refractory materials, products and processes||Level 3||NQF Level 03||5|
|Elective||10476||Demonstrate knowledge of Cement quality||Level 3||NQF Level 03||6|
|Elective||10479||Demonstrate knowledge of lime quality||Level 3||NQF Level 03||6|
|Elective||13975||Install and maintain castable/mouldable refractory materials||Level 3||NQF Level 03||5|
|Elective||13976||Install and maintain refractory brickwork/blockwork||Level 3||NQF Level 03||12|
|Elective||11454||Install ceramic fibre materials||Level 3||NQF Level 03||7|
|Elective||13977||Install gunite materials for refractory linings||Level 3||NQF Level 03||10|
|Elective||13941||Apply the budget function in a business unit||Level 4||NQF Level 04||5|
|Elective||242756||Burn carbonate material in a kiln||Level 4||NQF Level 04||36|
|Elective||120341||Conduct a Task Analysis and take appropriate action to address identified risks||Level 4||NQF Level 04||4|
|Elective||10462||Demonstrate an understanding of cement technology||Level 4||NQF Level 04||22|
|Elective||10464||Demonstrate an understanding of lime technology||Level 4||NQF Level 04||16|
|Elective||10475||Hydrate burnt lime by means of a lime hydration plant||Level 4||NQF Level 04||23|
|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.
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