1. 1 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Produce super- calendered paper or board

2. 2 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Produce super-calendered paper or board Modules Topics Total Notional Hours BE404Understanding the production of super-calender paper / board BE404Purpose of any auxiliary systems (incl. utilities) associated with the super-calender machine BE404Understanding Operating Procedures in supercalendering BE404Feedstock and final products of the super-calender process BE404Perform first line maintenance Notional Hours BE404Process variations in the super-calendering process BE404Applying SHE in the process BE404Implementing Standard Operating Procedures 24 6 16 8 24 16 10 120 P&P4EL Super-calendering Basics P&P4EL Maintenance P&P4EL Process variations P&P4EL SHE P&P4EL Standard Operating Procedures

3. 3 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 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: FC004Produce super-calendered paper or board BE404 Understanding the production of super-calender paper / board Be able to trace the paper / board flow through the machine Understand the fundamental operating principles of the super- calender machine Understand the purpose of this process and how it fits into the overall process Be able to identify each piece of equipment (the components of the machine)

4. 4 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE404 Understanding the production of super-calender paper / board 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 super- calender process as well as how it fits into the total process Are able to identify each part of the machine, its components and peripheral equipment Are able to trace the material flow through the plant Understand the fundamental operating principles of each part of the machine, its components and peripheral equipment. Assignment Description WHATWHAT HOW Notional Hours 24 Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation. 1.Learners are provided with relevant plant and equipment information / manuals 2.Inspect the plant and determine the flow of material through it 3.Draw a block diagram to show where the super-calender process fits into the paper/ board making process, specifically noting suppliers and customers of this plant 4.Draw a basic layout sketch of this area 5.In a discussion with a super-calender specialist, identify: the purpose of the process the different machines and peripheral equipment used in the process the fundamental operating principles of each piece of equipment 5.Complete questionnaire to indicate findings

5. 5 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 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: FC004Produce super-calendered paper or board Know the typical specifications for the feedstock and final products Understand the properties of the feedstock and final products BE404 Understanding the feedstock and final products of the super-calender process Be able to carry out quality checks on the feedstock and final products Know the suppliers of feedstock and the customers for each type of product produced

6. 6 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE404 Feedstock and final products of the super-calender 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 Develop recommendations Execute, test and evaluate Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the major feed material suppliers, their typical grades, properties and uses of these grades. Understand the specifications and properties of the super-calender product. Are able to carry out quality checks on super-calender material. Assignment Description WHATWHAT HOW 1.Learners are supplied with information on paper classification 2.Have a facilitated group discussion in the super-calender area to determine: by whom feed material is supplied the typical grades and properties of the supplied material the uses of the different grades the typical properties and specifications used for super-calender material 3.Draw-up a quality checklist for super- calender material 4.Carry out a quality check on super- calender material using the checklist and report results. Notional Hours 6 Individual or group training. Obtain basic product and supplier information by discussions with production experts. Apply knowledge in a practical quality check. Plant investigation Use checklists Job assignment Make presentation Draft a report Complete documents Complete a questionnaire

7. 7 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 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: FC004Produce super-calendered paper or board Know the effect of variations and deviations on the processes and products TC Understanding variations in the super-calendering processes Understand what process variations could occur in the processes Be able to complete all log sheets Understand how a deviation in the properties of the feedstock will impact on the processes Understand what feedstock variations could occur in the processes

8. 8 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE404 Variations in the super-calendering 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 Make presentation Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Are able to complete all log sheets. Understand what feedstock and process variations could occur in the process Understand how a deviation in the properties of the feedstock will impact on the process Know the effect of variations and deviations on the process and products 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 feed material variations that could occur and the effect each type of variation could have on the final product and / or in downstream processes or products 3.In a facilitated discussion at the super- calender machine, identify and list process deviations that could occur and the effect each type of deviation could have on the final product and / or in downstream processes or products 4.Tabulate all variations and deviations, their effects and the broad rectification action required Notional Hours 16 Individual or group training. Use feed material information obtained earlier to list quality variations. A facilitated discussion to identify possible process deviations and the downstream effects. Plant investigation Job assignment Draft a report Complete documents Complete a questionnaire

9. 9 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 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: FC004Produce super-calendered paper or board BE404 Understanding the purpose of any auxiliary systems (incl. utilities) associated with the super-calender machine Be able to trace the flows in the auxiliary system Be able to identify each piece of equipment (the components of the system) associated with the super- calender process Understand the fundamental operating principles associated with this auxiliary system Understand the purpose of the machine 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 4 Topic Specification: BE404 Purpose of any auxiliary systems in the super-calender process Collect Information Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Sketch Use checklists Develop recommendations Execute, test and evaluate Make presentation Complete documents Draft a report Complete a test/questionnaire Learning ActivitiesTopic assessment criteriaAssignment Description WHATWHAT HOW Notional Hours 8 The assessor will observe and confirm that learners: Understand the purpose of each auxiliary system as well as the fundamental operating principles associated with the system. Are able to identify the components and trace the flow of each auxiliary system. 1.Inspect the equipment and determine the interaction of each auxiliary system with the machine 2.Draw a block diagram showing the main components of each auxiliary system relevant to the machine. 3.In a discussion with a specialist on each auxiliary system, identify: what the purpose of the system is how it supports the process the different components of the system, and the fundamental operating principles of each auxiliary 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 Job assignment Summarise

11. 11 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 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: FC004Produce super-calendered paper or board BE404 Understanding Operating Procedures in the super-calendering process 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 Know the purpose of Standard Operating Procedures Understand the sequence and reasons for every pre- check Understand the reasons for having pre-check-, start-up-, normal running-, shutdown- and deviation correction procedures Understand the sequence and reason for shut-down and emergency shut-down procedures Understand the reason for maintaining normal running conditions and the consequences of losses caused by inefficient operation Understand the sequence and reason for correcting deviations Understand the sequence and reasons for start-up procedures

12. 12 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE404 Understanding “Standard Operating Procedures” 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 and the consequences of losses caused by inefficient operation shut-down and emergency 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 plant and individual equipment 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 theoretical test will proof competence Notional Hours a 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. 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 Complete a theoretical test Plant investigation Educational games

13. 13 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 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 BE404 Implementing Standard Operating Procedures in the process Be able to do pre-checks on the 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 US: U0003Understand the process and variables in drying paper, board and tissue products

14. 14 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE404 Implementing “Standard Operating Procedures” 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 any instrument readings monitor the process maintain normal running conditions bring process and product variations under control shut the process down 2.Complete any relevant pre-check, start-up, etc. reports as normally required 3.A practical test will proof competence Notional Hours a Group or individual training sessions where, through demonstration, the learner first observes the implementation of operating procedures and then implements the procedures himself under supervision Collect Information Use Multi media Self Study Media search Attend lectures Analyse, plan and make decisions Group Discussions Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a practical test Expert demonstration Plant investigation Summarise

15. 15 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 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: FC004Produce super-calendered paper or board Be able to carry out maintenance and pre-maintenance duties on the super- calender machine BE404 Perform first line maintenance Know documentation requirements for maintenance functions

16. 16 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE404Perform 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 super-calender 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 super-calender machine. 2.A discussion / demonstration of first line maintenance procedures and their sequence is facilitated at the super- calender 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 16 Plant investigation Expert demonstration Group Discussions Summarise

17. 17 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 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: FC004Produce super-calendered paper or board Know the safety standards, procedures and safety equipment relevant to the process Be able to identify all potential hazards and indicate actions to reduce/avoid hazards Know the relevant sections of the OHS Act BE404 Applying SHE in the process Understand the application of fire prevention and emergency procedures

18. 18 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 4 Topic Specification: BE404 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 super-calender 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 10 Learners obtain information through self study. Individuals evaluate the plant area for safety features, potential hazards and environmental impact. Plant investigation