1. 1 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Produce bales of waste paper using a baling machine

2. 2 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Produce bales of waste paper using a baling machine P&P2EL Maintenance Modules Topics TE212Understanding the waste paper baling process TE212The purpose of the hydraulic system in the baling machine TE212Properties of the waste paper feedstock and the baled paper TE212Performing first line maintenance TE212Process variations in the waste paper baling process Notional Hours TE212Applying SHE in the process TE212Understanding “Standard Operating Procedures” in the production of waste paper bales Total Notional Hours TE212Implementing “Standard Operating Procedures” in the waste paper baling process 4 3 4 3 12 16 4 50 P&P2EL Basics of waste paper baling P&P2EL Auxiliary systems P&P2EL SHE P&P2EL Standard Operating Procedures

3. 3 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: RM006Produce bales of waste paper using a baling machine TE212 Understanding the waste paper baling process Be able to identify the different components of the baling machine Understand the fundamental operating principles associated with each component of the waste paper baling process Understand the purpose of this process and how it fits into the overall process

4. 4 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Topic Specification: TE212 Understanding the waste paper baling process Collect Information Use Multi media Self Study Plant investigation Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Sketch Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a questionnaire Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Understand the purpose of the baling process as well as how it fits into the total process Understand the fundamental operating principles of each part of the plant/machine, its components and peripheral equipment. Are able to identify each component of the machine Assignment Description WHATWHAT HOW 1.Learners are provided with relevant machine information or manuals. 2.Inspect the equipment and determine the flow of material through the machine 3.Draw a block diagram to show where the baling process fits into the papermaking process, specifically noting suppliers and customers of this plant 4.In a discussion with a specialist on the waste paper baling process, identify: the purpose of the process the different components of the baling machine, and the fundamental operating principles of each component and the total plant 5.Learners complete a questionnaire to confirm understanding of the process Notional Hours 4 Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation.

5. 5 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: RM006Produce bales of waste paper using a baling machine Know the typical specifications for the baled waste paper Understand the properties of the waste paper and baled product TE212 Properties of the waste paper feedstock and the baled paper Be able to carry out quality checks on the baled paper Know the major waste paper suppliers, their typical grades and the uses of different waste paper grades

6. 6 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Topic Specification: TE212 The properties of the waste paper feedstock and baled paper Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Draft a report Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the major waste paper suppliers, their typical grades, properties and uses of these grades. Understand the specifications and properties of the baled product. Are able to carry out quality checks on baled paper. Assignment Description WHATWHAT HOW 1.Learners are supplied with information on paper classification 2.Have a facilitated group discussion in the waste paper area to determine: by whom waste paper is supplied the typical grades and properties of the supplied paper the uses of the different grades the typical properties and specifications used for baled paper 3.Draw-up a quality checklist for baled paper 4.Carry out a quality check on bales of paper using the checklist and complete relevant documentation. Notional Hours 3 Individual or group training. Obtain basic product and supplier information by discussions with production experts. Apply knowledge in a practical quality check. Plant investigation Complete documents Complete a questionnaire

7. 7 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: RM006Produce bales of waste paper using a baling machine Understand what waste paper variations could occur Know the effect of variations and deviations on the process and products TE212 Understanding process variations in the waste paper baling process Understand what process deviations could occur in the process Be able to complete all log sheets

8. 8 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Topic Specification: TE212Process variations in the waste paper baling process Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies Checklists / tabulate Develop recommendations Execute, test and evaluate Job assignment Make presentation Draft a report Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Are able to complete log sheets. Understand what waste paper variations and process deviations can occur. Know what the effect of variations and deviations on the process and products is. Know the broad rectification action required Assignment Description WHATWHAT HOW 1.Learners are supplied with log sheets and assisted to complete them with the help of a production specialist. 2.Individually list the waste paper variations that could occur and the effect each type of variation could have on the paper bales and / or in downstream processes or products 3.In a facilitated discussion at the baling machine, identify and list process deviations that could occur and the effect each type of deviation could have on the paper bales and / or in downstream processes or products 4.Tabulate all variations and deviations, their effects and the broad rectification action required 5.Learners prepare a short presentation on their findings Notional Hours 4 Individual or group training. Use waste paper information obtained earlier to list quality variations. A facilitated discussion to identify possible process deviations and the downstream effects. Plant investigation Complete documents Complete a questionnaire

9. 9 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: RM006Produce bales of waste paper using a baling machine TE212 Understanding the purpose of the hydraulic system in the baling machine Be able to trace the flows in the hydraulic system Be able to identify the components of the hydraulic system associated with the baling machine Understand the fundamental operating principles associated with the hydraulic system Understand the purpose of the hydraulic system and how it fits into the process

10. 10 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Topic Specification: TE212 The purpose of the hydraulic system in the baling machine Collect Information Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Sketch Summarise Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Learning ActivitiesTopic assessment criteriaAssignment Description WHATWHAT HOW Notional Hours 3 The assessor will observe and confirm that learners: Understand the purpose of the hydraulic system as well as the fundamental operating principles associated with the system. Are able to identify the components and trace the flow of the hydraulic system. 1.Inspect the equipment and determine the interaction of the hydraulic system with the machine 2.Draw a block diagram showing the main components of the hydraulic system relevant to the baling machine. 3.In a discussion with a specialist on the hydraulic system, identify: what the purpose of the system is how it supports the baling process the different components of the system, and the fundamental operating principles of the hydraulic system 4.Compile all the obtained information in a short report Use Multi media Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation. Plant investigation

11. 11 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: RM006Produce bales of waste paper using a baling machine Understand the different responsibilities in terms of compiling, authorization, layout / format and safety procedures contained in the Standard Operating Procedures Know any other plant / process rules and regulations applicable to the plant TE212 Understanding “Standard Operating Procedures” in the production of waste paper bales Know the purpose of Standard Operating Procedures Understand the reasons and sequence of different pre-checks Understand the reasons for having pre-check-, start-up-, normal running-, shutdown- and deviation correction procedures Understand the reason and sequence of shut-down procedures Understand the reason for maintaining normal running conditions Understand the reason for correcting deviations Understand the reasons and sequence of start-up procedures

12. 12 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Topic Specification: TE212 Understanding “Standard Operating Procedures” Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Summarise Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Practical test Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the purpose of these procedures Know other applicable plant rules and regulations Understand the reason for responsibility control and document control procedures Understand the reasons for having pre-checks start-up procedures maintaining normal running condition procedures shut-down procedures correcting deviation procedures Know procedures and sequences in detail or in terms of key steps as required Assignment Description WHATWHAT HOW 1.Learners are supplied with the operating procedures for the baling machine and any other relevant plant rules and regulations 2.In a facilitated group, the document control system is shortly explained. The purpose of the procedures, responsibility control, document control and having procedures for each operating phase (pre-check, etc.) is discussed and summarised. 3.Procedures and sequences are studied in detail (esp. emergency procedures) or in terms of key steps as required. Practical understanding and knowledge is essential. 4.Learners should compile a file containing an index (with subheadings / keywords as necessary) of each procedure 5.A practical test will proof competence Notional Hours 12 A facilitated group discussion is used to clarify the logic behind controlled procedure systems. Individual procedures are studied in detail or in terms of key steps as indicated. Indices and summaries for procedures are created for easy future reference. Plant investigation Educational games

13. 13 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: RM006Produce bales of waste paper using a baling machine Be able to do pre-checks on the process TE212 Implementing “Standard Operating Procedures” in the waste paper baling process Be able to shut the process down Be able to start the process up Be able to maintain normal running conditions Be able to monitor the process Be able to bring process variations under control Be able to bring product variations under control Be able to use and interpret instrument readings

14. 14 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Topic Specification: TE212 Implementing “Standard Operating Procedures” Collect Information Use Multi media Self Study Media search Expert demonstration Attend lectures Analyse, plan and make decisions Group Discussions Case studies Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Are able to: use and interpret instrument readings do pre-checks on the process start the process up monitor the process maintain normal running conditions bring process and product variations under control shut the process down Assignment Description WHATWHAT HOW 1.By using relevant checklists and operating procedures, learners will first observe and then, under supervision, implement the following procedures: do pre-checks on the process start the process up use and interpret instrument readings monitor the process maintain normal running conditions bring process variations under control bring product variations under control shut the process down 2.Complete any relevant pre-check, start-up, etc. reports as normally required. Notional Hours 16 Group or individual training sessions where, through demonstration, the learner first observes the implementation of operating procedures and then implement the procedures himself under supervision Plant investigation Summarise Use checklists

15. 15 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: RM006Produce bales of waste paper using a baling machine Be able to carry out maintenance and pre-maintenance duties on the plant TE212 Perform first line maintenance Understand the documentation requirements for maintenance functions

16. 16 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Topic Specification: TE212Perform first line maintenance Collect Information Use Multi media Self Study Media search Attend lectures Analyse, plan and make decisions Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Understand the documentation requirements for the maintenance function on the waste paper baling machine. Are able to carry out maintenance and pre-maintenance duties on the machine. Assignment Description WHATWHAT HOW Individual or group training. Study given materials regarding first line maintenance. A discussion / demonstration of first line maintenance duties are facilitated at the machine. Carry out first line maintenance under supervision. 1.Learners are supplied with documentation required for first line maintenance on the baling machine. 2.A discussion / demonstration of first line maintenance procedures and their sequence is facilitated at the baling machine 3.A checklist is drawn up 4.Under supervision, carry out pre- maintenance and maintenance duties on the machine as prescribed 5.Complete pre-maintenance and maintenance reports / log sheets Notional Hours 4 Expert demonstration Plant investigation Group Discussions Summarise

17. 17 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: RM006Produce bales of waste paper using a baling machine Know the safety standards, procedures and safety equipment in the waste paper plant Be able to identify all potential hazards in the process and indicate actions to reduce / avoid / minimise hazard impact Understand the potential environmental impact of the process Know the relevant sections of the OHS Act TE212 Applying SHE in the process Understand the application of fire prevention, lock-out and emergency procedures in a waste paper plant

18. 18 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 2 Topic Specification: TE212 Applying SHE in the process Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the relevant OHS Act, safety standards, procedures, and equipment in the waste paper plant. Understand the application of fire prevention, lock-out and emergency procedures in the plant, as well as the potential environmental impact of the process. Are able to identify all potential hazards in the process and indicate actions to reduce / avoid / minimise the impact of hazards. Assignment Description WHATWHAT HOW 1.Learners are supplied with a copy of the safety procedures and the relevant section of the OHS Act 2.Learners individually undertake a plant inspection and identify all potential hazards. They also assess the potential impact of the plant on the environment. 3.Learners should also sketch the area and indicate the position of all safety equipment and safety features (e.g. alarm button, emergency exists) on it. 4.Recommendations are made to reduce / avoid these hazards the impact of possible hazards and the plant’s impact on the environment. 5.A short presentation on the findings is made. Notional Hours 4 Learners obtain information through self study. Individuals evaluate the plant area for safety features, potential hazards and environmental impact. Plant investigation