Intermediate Occupational Certificate: Surface Coatings Processor

Purpose

The purpose of this qualification is to prepare a learner to function as a Surface Coatings Processor. Surface Coatings Processors manufacture surface coatings and allied products that conform to required specifications in a safe and cost-effective manner.

A qualified learner will be able to

• Produce surface coatings mixes taking chemical and physical properties of substances into account ensuring product conformance to specifications.
• Operate and maintain technology to achieve process optimisation and efficiency and compliance with safety regulations.
• Conduct quality control of the product through sampling, testing, analysis of results and problem solving.

Rationale

Advances in science and engineering both solve problems and generate new opportunities. Each technological breakthrough creates a demand for new materials, processes and technology needed to exploit it. Materials science and engineering generally, and surface coatings specifically, play a key role in commercialising laboratory breakthroughs. They enable what was previously impossible or impractical, for example by using surface coating to make light metals withstand highly corrosive and high temperature environments. Coatings also accelerate the development and adoption of new technologies. For example: pandemics such as COVID19 demanded the development of antiviral coatings for light alloys that could reduce disease transmission via metal surfaces. Surface coatings enable a much broader range of additively manufactured light metal components, enabling the approach to accelerate the production of complex parts for applications in industries such as medical, dental and aerospace. This motivates the need for suitably qualified Surface Coatings Processors to provide in the growing demand created by advances in technology. The qualification will enable new entrants to open small surface coatings manufacturing businesses. Learners can venture into different surface coatings and related products careers. More employment opportunities can be created including employee development and empowerment. In addition, society will benefit from advanced surface coatings technology in terms of clean surfaces, protection against disease and unnecessary wear and tear of assets.

The use of surface coatings to finish surfaces and objects is widespread in manufacturing. Applied as thin films, these coatings provide protection, durability, and/or decoration to part surfaces. They prevent corrosion. It can not only stand up to the processing material, but also prevent standard corrosion that may occur simply because of the material the machine is made from. They keep surfaces clean. These key products are provided to and used in various industries ranging from automobiles, sea faring vessels, construction, whether steel or concrete, manufacturing of engineering tools and equipment used in mining, earth moving machines, forestry and agriculture, space communication systems, and the list can go on. It is thus imperative that the surface coatings industry has enough qualified technicians to provide in the national demand for surface coatings and this qualification would contribute immensely to this initiative thus contributing to the national economic wellbeing of the country.

Typical learners targeted for this occupational qualification includes school leavers, unemployed youth and employees in the surface coatings industry without formal recognition for surface coatings competencies.

No registration by a professional body or licensing is needed for the Surface Coatings Processors to operate. Typical occupations the qualifying leaner will operate in includes Surface Coatings Process Technician, Surface Coatings Operator and Quality Controller, Chemical Technician or Surface Coatings Plant Technicians (small enterprises).

Recognition of Prior Learning (RPL)

• Learners will gain access to the qualification through RPL for Access as provided for in the QCTO RPL Policy. RPL for access is conducted by accredited education institution, skills development provider or workplace accredited to offer that specific qualification/part qualification.
• Learners who have acquired competencies of the modules of a qualification or part-qualification will be credited for modules through RPL.

RPL for access to the external integrated summative assessment

Accredited providers and approved workplaces must apply the internal assessment criteria specified in the related curriculum document to establish and confirm prior learning. Accredited providers and workplaces must confirm prior learning by issuing a statement of result.

Entry Requirements

• An NQF Level 2 qualification.

This qualification consists of the following compulsory Knowledge, Practical Skill and Work Experience Modules

Knowledge Modules

• 211301-004-00-KM-01, Basic Principles of Surface Coatings Technology, Level 3, 4 credits
• 211301-004-00-KM-02, Surface Coatings Manufacturing Processes, Level 3, 4 credits
• 211301-004-00-KM-03, Surface Types, Surface Preparation Surface Coatings Application, Level 3, 2 Credits.
• 211301-004-00-KM-04, Sampling Theory and Testing, Level 3, 8 Credits.
• 211301-004-00-KM-05, Dispersion of Powders in Liquids, Level 3, 8 Credits.
• 211301-004-00-KM-06, Tinting and Matching of Surface Coatings, 3, 8 Credits.
• 211301-004-00-KM-07, Surface Coatings Quality Control and Problem Solving, Level 3,

8 Credits.

• 211301-004-00-KM-08, Surface Coatings Manufacturing Technology and Routine Maintenance,

Level 3, 2 Credits.

• 211301-004-00-KM-09, Communication and Teamwork, Level 2, 2 Credits.
• 211301-004-00-KM-10, Workplace Fundamentals and Ethics, Level 3, 3 Credits.
• 211301-004-00-KM-11, Occupational Health and Safety, Risk and Environment, Level 3, 2 Credits.
• 211301-004-00-KM-12, Entrepreneurship, Level 3, 4 Credits.

Total number of credits for Knowledge Modules: 55

Practical Skill Modules

• 211301-004-00-PM-01, Apply an Understanding of Basic Surface Coatings Technology and Respective Applications, Level 3, 8 Credits.
• 211301-004-00-PM-02, Adhere to Occupational Health, Safety, Risk and Environmental Requirements, Level 3, 2 Credits.
• 211301-004-00-PM-03, Operate and Maintain Technology to Achieve Process Optimisation and Efficiency, Level 3, 8 Credits.
• 211301-004-00-PM-04, Disperse Powders in Liquids in a Batch Process Conforming to all Specifications, Level 3, 16 Credits.
• 211301-004-00-PM-05, Tint and Match Pigmented Surface Coatings, Level 3, 16 Credits.
• 211301-004-00-PM-06, Maintain Quality of Products through Sampling, Testing, Analysis of Results and Problem Solving, Level 3, 12 Credits.

Total number of credits for Practical Skill Modules: 62

Work Experience Modules

• 211301-004-00-WM-01, Surface Coatings and/or Related Products Manufacturing Processes, Level 3, 20 Credits.
• 211301-004-00-WM-02, Technology Operation Process Optimisation and Efficiency, Level 3, 12 Credits.
• 211301-004-00-WM-03, Surface Coatings Quality Control Processes, Level 3, 20 Credits.

Total number of credits for Work Experience Modules: 52

1. Demonstrate understanding of the chemical and physical properties of surface coatings substances.
2. Demonstrate the ability to manufacture surface coatings and/or related products to specification.
3. Apply procedures and techniques to operate and maintain technology to achieve process optimisation and efficiency and compliance with safety regulations.
4. Apply operational requirements to maintain health, safety and quality assurance practices in a surface coatings manufacturing environment.
5. Apply processes of analysis, synthesis and evaluation to interpret quality control of the product through sampling, testing, analysis of results and problem solving.

Associated Assessment Criteria for Exit Level Outcome 1

ELO 1: Demonstrate understanding of the chemical and physical properties of surface coatings substances.

prepare to manufacture surface coatings and/or related products to specification.

• Describe and explain the chemistry and process technology of surface coatings with examples.
• Explain the use and importance of sampling theory and practice.
• Provide the reason for the role and function of testing, the use of testing methods and interpreting results in achieving product quality.
• Understand continuous quality monitoring principles and explain the application thereof.
• Demonstrate an understanding of basic surface coatings technology (what ingredients for the paint to fulfil its function) and its applications.

Associated Assessment Criteria for Exit Level Outcome 2

ELO2: Apply procedures and techniques to operate and maintain technology to achieve process optimisation and efficiency and compliance with safety regulations.

• Manufacture surface coatings and/or related products to specification, and within the timeframes recognised as good practice.
• Disperse powders into liquids at the right quantity and quality according to the prescribed sequence to achieve the desired product outcome.
• Tint and match pigmented surface coatings products.
• Conduct end-of-batch procedures and package products in a manual or semi-automated packaging operation.
• Identify and resolve problems encountered during the manufacturing process within the scope of the job, using process chemistry and related technology.

Associated Assessment Criteria for Exit Level Outcome 3

ELO3: Apply operational requirements to maintain health, safety and quality assurance practices in a surface coatings manufacturing environment.

• Operate surface coatings machines according to relevant machine specifications and standard operating procedures.
• Make adjustments to the process and equipment to ensure product quality.
• Carry out maintenance on the machinery and equipment in accordance with set specifications.
• Take measures to ensure equipment is in good condition. e.g. after run, make sure the equipment is rinsed/flushed lines/vessels/pipework to prevent blockages.
• Ensure compliance with housekeeping requirements for prevention of contamination of raw materials and product.

Associated Assessment Criteria for Exit Level Outcome 4

ELO4: Apply processes of analysis, synthesis and evaluation to interpret quality control of the product through sampling, testing, analysis of results and problem solving.

• Explain and apply the importance and interactive role of safety regarding employer, employee and applicable legislation in accordance with set standards.
• Interpret identify material safety data sheets (MSDS) to identify the hazardous category of chemicals used in the manufacturing process.
• Mop up chemical spillages taking environmental safety into account.
• Adhere to good manufacturing practices (GMP).
• Apply in-process and product quality control in the manufacturing of surface coatings products in accordance with set standards.
• Take and submit representative in-process and product samples to laboratory for testing.
• Interpret test results to confirm product conformance.
• Take appropriate action to address any deviations or non-conformance of product and process.

INTEGRATED ASSESSMENT

Integrated Formative Assessment

The skills development provider will use the curriculum to guide them on the stipulated internal assessment criteria and weighting. They will also apply the scope of practical skills and applied knowledge as stipulated by the internal assessment criteria. This formative assessment together with work experience leads to entrance in the integrated external summative assessment.

Integrated Summative Assessment

An external integrated summative assessment, conducted through the relevant QCTO Assessment Quality Partner is required for the issuing of this qualification. The external integrated summative assessment will focus on the exit level outcomes and associated assessment criteria.

The assessment will be conducted through a technology enhanced theoretical assessment, a project assessment and the evaluation of practical tasks at decentralised approved assessment sites by a panel of assessors registered with the AQP.