Occupational Certificate:
Production Process Controller

NQF

4

SAQA ID

119977

MIN CREDITS

140

EST DURATION

12 - 18 MONTHS (INCLUDING WORKPLACE EXPERIENCE)

QCTO

MERSETA

How is the programme aligned?

This programme is a QCTO occupational qualification and consists of knowledge modules, practical modules and work experience modules, as detailed in the qualification rules.

Unit Standards

  • SAQA 119977
  • Curriculum code 313916001

Who is the target audience?

This qualification is aimed at individuals who are either currently employed or aspiring to work in the production and manufacturing sectors. It is ideal for those seeking to develop or formalise their skills in monitoring, operating and controlling production process plants.

What are the entry requirements?

Learners may access this qualification if they have:

  • An NQF Level 3 qualification with Mathematical Literacy or
  • Occupational Certificate: Production Process Machine Operator and Assembler, NQF Level 3, SAQA ID 102580.

What is the purpose of the programme?

The purpose of this qualification is to equip learners with the knowledge, practical skills and workplace experience required to function as Production Process Controllers.
A Production Process Controller performs a variety of operational, administrative and monitoring tasks to ensure the safe and efficient running of a production process plant. This role involves working with technologies such as electrical, electronic, mechanical, hydraulic, pneumatic and computer systems. The function includes adhering to occupational health, safety, and environmental standards, complying with organisational procedures, and performing basic maintenance where necessary.

What are the learning outcomes?

The qualified learner will be able to achieve the following outcomes:

  • Carry out production plant operational and administrative processes, duties and functions.
  • Operate, monitor and control production plant operations.

How is the programme structured?

The qualification is structured into five Learning Programmes which cover the following knowledge and practical curriculum modules in an integrated manner:

Knowledge Modules:

  • Occupational health and safety and environment, Level 04, Credits 8
  • Process plant management, Level 4, Credits 24

Total number of credits for Knowledge Modules: 32

Practical Skill Modules:

  • Carry out operational and administrative processes, duties and functions, Level 4, Credits 16
  • Operate monitor and control production plant operations, Level 4, Credits 32

Total number of credits for Practical Skill Modules: 48

This qualification also requires the following Work Experience Modules:

  • Manufacturing production process plant operations, Level 4, 60 Credits.

Total number of credits for Work Experience Modules: 60

How will the course be delivered and assessed?

Facilitation strategy

For the knowledge modules and practical modules, KVR Training offers our clients various facilitation methods based on specific needs. This can include in-person, on-line, virtual facilitation methods or a combination of any of these. Various learning techniques, such as simulations, roleplays and presentations are used. Facilitators give feedback on participation, strengths, and areas for improvement. Practical application is crucial, requiring learners to apply knowledge in their daily work under supervision.

For the work experience modules, learners will be provided with a detailed work experience guide. This will enable learners to complete the required work experience modules under the guidance of a workplace coach/mentor.

Assessment strategy

  • Formative assessment for the knowledge modules and practical modules is conducted throughout the programme during the facilitated sessions. Assessment activities are included in the Formative Assessment Workbook and will be checked by the facilitator. Learners are expected to complete all the activities in their workbooks.
  • Summative assessment is conducted at the end of each module. Learners are expected to complete summative assessment activities in the workplace. These will be assessed by KVR Training.
  • Statement of work experience: KVR Training will declare a learner ready for the External Integrated Summative Assessment (EISA) once the formative and summative activities are completed and a statement of work experience with supporting evidence is compiled in the learner’s workplace.
  • The external integrated summative assessment (EISA) will be conducted through the relevant Quality Council for Trades and Occupations (QCTO) Assessment Quality partner. The EISA will focus on the exit level outcomes and associated assessment criteria. The EISA will be conducted by means of a combination of a written assessment (paper or online) at an approved assessment site and the external assessment of the evidence produced during the workplace experience at an approved assessment site by an Assessment Quality Partner (AQP) registered assessor. The assessments will test the candidate’s ability to communicate, solve problems and make decisions in relation to a set of typical situations and circumstances which are: encountered stock storage area when moving, packing, picking, counting and maintaining stock and the ability to pack, pick and count stock in a stock storage area while minimising losses.
  • EISA Preparation: KVR will allocate time in the programme schedule for EISA preparation. Focus will be given to exam techniques, past papers, and remedial coaching.

What are the workplace requirements?

The work experience modules must be completed in the workplace. The workplace must provide the resources (both physical and human resources) to ensure that the following critical aspects of the workplace requirements can be assessed:
The learners’ ability to:

  • Operate, monitor, and control production process plant operations in accordance with operational requirements.
  • Carry out production plant operational and administrative duties, including reporting, record-keeping, and compliance with organisational standards.
  • Apply occupational health, safety and environmental principles during all operational activities.
  • Perform basic fault-finding, routine/minor/first-line maintenance, and participate in shutdown and lockout procedures where applicable.
  • Implement and comply with quality assurance and control procedures, including sampling, inspections, and testing of input and output materials.
  • Interpret production schedules, adjust operations as required, and contribute to production optimisation initiatives.
  • Apply basic risk management, problem-solving, and productivity improvement techniques within the production environment.
  • Contribute to operational planning activities and participate in continuous improvement processes related to production plant performance.

Physical Requirements:

The following physical resources are required:

  • Learning and development resources
  • Learner assessment resources
  • Production process plant with full production and organisational operating facilities

Human Resource Requirements:

  • The workplace mentor, facilitator and assessor must be a subject-matter expert.

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