Integrated Melting Operations Control And Management Training

Learning Outcomes

• Apply integrated melting operations principles to plan and control production schedules.
• Analyze melting process parameters to optimize efficiency and product quality.
• Evaluate operational data to identify areas for improvement and implement corrective actions.
• Demonstrate effective leadership and communication skills to manage melting operations teams.
• Implement safety and quality management systems in accordance with industry standards.

Target Audience

This course is designed for production supervisors, team leaders, and operations managers in the metals and manufacturing industries who are responsible for overseeing melting processes and ensuring operational efficiency.

Prerequisites

None — open enrollment

Course Outline

Practicals

Overview

Hands-on practical sessions are essential for learners to apply theoretical knowledge to real melting operations. Learners will operate simulated control systems, troubleshoot process issues, and practice safety procedures in a controlled environment.

Practical Activities

• Furnace Start-up and Shutdown Procedures — Learners simulate the start-up and shutdown of an electric arc furnace, following standard operating procedures and safety protocols. (5h)
• Process Control and Instrumentation Calibration — Learners calibrate temperature sensors and pressure transmitters, and configure a basic control loop on a simulator. (5h)
• Melting Process Optimization Exercise — Learners adjust charge composition and power input to optimize melt time and metal quality, analyzing data from a simulated melt. (5h)
• Troubleshooting and Emergency Response Drill — Learners respond to simulated process upsets such as temperature runaway or refractory failure, implementing corrective actions. (3h)
• Integrated Control System Operation — Learners operate an integrated SCADA system to manage a complete melting cycle from charging to tapping. (3h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total

Component	Out of	Weight
Practical Assignments (rubric-scored)	100%	30%
Daily Average (multiple choice)	100%	20%
Final Test (multi-answer multiple choice)	100%	50%
Final Total	—	100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

How it works

• Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
• Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
• You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
• If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.

Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates	Discount
5	3% off
10	6% off
15	9% off
20	12% off
25	15% off
30	18% off
50	30% off
75	35% off
100	40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.