Manufacturing, Engineering and Technology Manufacturing and Assembly

Making Operations in Engineering Manufacturing Training

SAQA US 243682 | NQF 2 | Credits 36 | Duration 33 Days
From $5,114 per delegate

Description

This course equips learners with the practical skills and theoretical knowledge required to perform making operations in an engineering manufacturing environment. It covers safe work practices, material handling, and the operation of basic manufacturing equipment. Successful learners will be able to produce components according to specifications while adhering to health and safety regulations.

Learning Outcomes

  • Demonstrate safe working practices and identify hazards related to making operations.
  • Interpret engineering drawings and specifications to plan the making process.
  • Select and use appropriate tools, equipment, and materials for making operations.
  • Perform making operations such as cutting, drilling, and assembling to achieve required tolerances.
  • Inspect completed work for quality and conformance to specifications.
  • Complete workplace documentation and report any deviations or non-conformances.

Target Audience

This course is designed for engineering manufacturing operators, artisans, and technicians who are involved in making operations such as cutting, shaping, assembling, or finishing components. It is also suitable for apprentices and trainees entering the manufacturing sector.

Prerequisites

None — open enrollment. However, learners should be physically fit for manual work and have basic literacy and numeracy skills.

Course Outline

Day 1: Introduction to Operations in Engineering Manufacturing

Objectives:
• Understand the scope and importance of operations in engineering manufacturing.
• Identify key terms and concepts related to manufacturing operations.
• Recognize the role of quality and safety in manufacturing.
• Describe the typical workflow in an engineering manufacturing environment.

Topics:
• Overview of engineering manufacturing sectors
• Definition of operations management
• The manufacturing process: inputs, processes, outputs
• Introduction to quality management principles
• Health and safety fundamentals in manufacturing
• Roles and responsibilities of operations personnel

Day 2: Manufacturing Processes and Techniques

Objectives:
• Differentiate between various manufacturing processes.
• Explain the principles of forming, machining, and joining.
• Identify common materials used in engineering manufacturing.
• Understand the importance of process selection.

Topics:
• Casting and molding processes
• Metal forming: rolling, forging, extrusion
• Machining: turning, milling, drilling
• Joining: welding, brazing, adhesive bonding
• Material properties and selection
• Process capability and limitations

Day 3: Production Planning and Scheduling

Objectives:
• Describe the elements of production planning.
• Explain scheduling techniques and their applications.
• Understand capacity planning and load balancing.
• Identify factors affecting production schedules.

Topics:
• Production planning objectives
• Master production schedule (MPS)
• Material requirements planning (MRP)
• Capacity requirements planning (CRP)
• Scheduling methods: forward, backward, finite
• Gantt charts and critical path method

Day 4: Inventory Management in Manufacturing

Objectives:
• Define inventory types and their roles.
• Apply inventory control techniques.
• Calculate economic order quantity (EOQ).
• Understand just-in-time (JIT) principles.

Topics:
• Raw materials, work-in-progress, finished goods
• Inventory carrying costs
• ABC analysis
• EOQ model and reorder points
• Safety stock and lead time management
• JIT and lean inventory concepts

Day 5: Quality Control and Assurance

Objectives:
• Differentiate between quality control and quality assurance.
• Apply statistical process control (SPC) tools.
• Understand sampling plans and inspection methods.
• Identify continuous improvement methodologies.

Topics:
• Quality management systems (ISO 9001)
• Control charts for variables and attributes
• Process capability indices (Cp, Cpk)
• Acceptance sampling (AQL)
• Root cause analysis
• Kaizen and Six Sigma overview

Day 6: Maintenance Strategies in Manufacturing

Objectives:
• Describe different maintenance approaches.
• Explain preventive and predictive maintenance.
• Understand total productive maintenance (TPM).
• Identify key performance indicators for maintenance.

Topics:
• Reactive, preventive, predictive, proactive maintenance
• Reliability-centered maintenance (RCM)
• TPM pillars and autonomous maintenance
• Overall equipment effectiveness (OEE)
• Maintenance planning and scheduling
• Spare parts management

Day 7: Health, Safety, and Environment (HSE)

Objectives:
• Recognize legal requirements for HSE in manufacturing.
• Identify common hazards and risk assessment methods.
• Understand emergency response procedures.
• Apply environmental management principles.

Topics:
• Occupational Health and Safety Act (OHSA)
• Hazard identification and risk assessment (HIRA)
• Personal protective equipment (PPE)
• Incident reporting and investigation
• Environmental management systems (ISO 14001)
• Waste minimization and recycling

Day 8: Lean Manufacturing Principles

Objectives:
• Define lean manufacturing and its core concepts.
• Identify the seven wastes (Muda).
• Apply value stream mapping (VSM).
• Understand 5S methodology.

Topics:
• Lean philosophy and history
• Value-added vs. non-value-added activities
• Seven wastes: overproduction, waiting, transport, etc.
• Value stream mapping symbols and steps
• 5S: Sort, Set in order, Shine, Standardize, Sustain
• Kanban systems

Day 9: Supply Chain Management in Manufacturing

Objectives:
• Describe the components of a manufacturing supply chain.
• Understand supplier selection and evaluation.
• Explain logistics and distribution strategies.
• Identify challenges in supply chain integration.

Topics:
• Supply chain structure and flows
• Supplier relationship management (SRM)
• Make-or-buy decisions
• Logistics: transportation, warehousing
• Inventory positioning and postponement
• Risk management in supply chains

Day 10: Process Improvement and Problem Solving

Objectives:
• Apply problem-solving methodologies (PDCA, DMAIC).
• Use root cause analysis tools.
• Understand process mapping and flowcharts.
• Implement corrective and preventive actions.

Topics:
• PDCA cycle
• DMAIC (Define, Measure, Analyze, Improve, Control)
• Fishbone diagram and 5 Whys
• Process mapping: SIPOC, swimlane
• Failure mode and effects analysis (FMEA)
• Standard operating procedures (SOPs)

Day 11: Automation and Technology in Manufacturing

Objectives:
• Identify types of automation used in manufacturing.
• Understand the role of robotics and PLCs.
• Explain Industry 4.0 concepts.
• Evaluate the impact of technology on operations.

Topics:
• Fixed, programmable, and flexible automation
• Robotics in manufacturing
• Programmable logic controllers (PLCs)
• SCADA systems
• Internet of Things (IoT) in manufacturing
• Digital twins and smart factories

Day 12: Cost Management and Financial Metrics

Objectives:
• Differentiate between fixed and variable costs.
• Calculate break-even point and contribution margin.
• Understand budgeting and variance analysis.
• Apply cost reduction strategies.

Topics:
• Cost classification: direct/indirect, fixed/variable
• Break-even analysis
• Cost-volume-profit (CVP) analysis
• Budgeting process: operational and capital
• Standard costing and variance analysis
• Target costing and value engineering

Day 13: Human Factors and Team Management

Objectives:
• Understand the importance of human factors in operations.
• Apply motivation theories to manufacturing teams.
• Describe effective communication and conflict resolution.
• Recognize the role of training and development.

Topics:
• Human factors: ergonomics, fatigue, shift work
• Motivation: Maslow, Herzberg, expectancy theory
• Team dynamics and leadership styles
• Communication barriers and strategies
• Conflict resolution techniques
• Skills matrix and training plans

Day 14: Data Analysis and Decision Making

Objectives:
• Collect and interpret manufacturing data.
• Use basic statistical tools for decision making.
• Understand key performance indicators (KPIs).
• Apply data-driven decision-making frameworks.

Topics:
• Data collection methods: check sheets, sensors
• Descriptive statistics: mean, median, mode, range
• Graphical analysis: histograms, Pareto charts
• KPIs: throughput, yield, downtime, OEE
• Dashboards and visual management
• Decision-making models: rational, bounded rationality

Day 15: Regulatory Compliance and Standards

Objectives:
• Identify relevant regulations and standards in manufacturing.
• Understand ISO standards and certification processes.
• Explain the role of audits in compliance.
• Apply documentation and record-keeping requirements.

Topics:
• ISO 9001, ISO 14001, ISO 45001 overview
• SANS standards for engineering
• Legal compliance: labour, environment, safety
• Internal and external audits
• Document control and traceability
• Non-conformance and corrective action

Day 16: Project Management for Operations

Objectives:
• Apply project management principles to operational projects.
• Use work breakdown structure (WBS) and network diagrams.
• Understand resource allocation and risk management.
• Monitor and control project progress.

Topics:
• Project life cycle: initiation, planning, execution, closure
• Work breakdown structure (WBS)
• Network diagrams: PERT, CPM
• Resource levelling and smoothing
• Risk identification and mitigation
• Project monitoring: earned value management

Day 17: Sustainability and Green Manufacturing

Objectives:
• Define sustainability in manufacturing context.
• Identify opportunities for energy and resource efficiency.
• Understand life cycle assessment (LCA).
• Implement green manufacturing practices.

Topics:
• Triple bottom line: people, planet, profit
• Energy management systems (ISO 50001)
• Water and waste reduction strategies
• Life cycle assessment (LCA) methodology
• Eco-design and remanufacturing
• Carbon footprint and reporting

Day 18: Advanced Manufacturing Technologies

Objectives:
• Explore additive manufacturing (3D printing) applications.
• Understand advanced materials and composites.
• Describe the role of artificial intelligence in manufacturing.
• Evaluate the impact of nanotechnology.

Topics:
• Additive manufacturing: processes and materials
• Composite materials: types and applications
• AI and machine learning in quality and maintenance
• Nanotechnology in coatings and sensors
• Cyber-physical systems
• Future trends in manufacturing

Day 19: Integrated Operations Management

Objectives:
• Synthesize knowledge from previous days into a cohesive operations strategy.
• Develop a balanced scorecard for manufacturing.
• Apply lean and Six Sigma tools in a simulated scenario.
• Create a continuous improvement plan.

Topics:
• Operations strategy alignment with business goals
• Balanced scorecard: financial, customer, process, learning
• Lean Six Sigma project selection
• Simulation of a manufacturing improvement project
• Change management principles
• Developing a continuous improvement culture

Day 20: Final Review and Assessment

Objectives:
• Consolidate all key concepts from the course.
• Demonstrate understanding through a comprehensive assessment.
• Identify areas for further development.
• Apply learning to real-world scenarios.

Topics:
• Review of core topics: processes, quality, maintenance, lean
• Case study analysis
• Written assessment (multiple choice and short answer)
• Practical demonstration of skills (if applicable)
• Feedback and course evaluation
• Certificate of completion preparation

Practicals

60 hours of practicals To be conducted online or on-campus or in-house
Overview

The practicals component provides hands-on experience in key manufacturing operations, including process simulation, quality inspection, maintenance tasks, and lean implementation. Learners will apply theoretical knowledge in a controlled workshop environment to develop competence in real-world manufacturing scenarios.

Practical Activities
  • Practical 1: Manufacturing Process Simulation — Learners simulate a production line using a model assembly kit, performing tasks such as forming, machining, and joining to understand workflow and process interaction. (16h)
  • Practical 2: Quality Control Inspection and SPC — Learners inspect manufactured parts using measuring instruments, construct control charts, and calculate process capability indices to assess quality. (12h)
  • Practical 3: Preventive Maintenance Task Execution — Learners perform scheduled maintenance on a trainer machine, including lubrication, belt tensioning, and filter replacement, following a maintenance plan. (12h)
  • Practical 4: Lean Implementation – 5S and Kaizen Event — Learners apply 5S methodology to a cluttered workshop area, then conduct a kaizen blitz to eliminate waste and improve workflow. (12h)
  • Practical 5: Integrated Operations Improvement Project — Teams undertake a mini-project to improve a simulated production process using lean and quality tools, presenting their recommendations. (8h)

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

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Practicals 30% + Daily Average 20% + Final Test 50%).

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.

Upcoming Training Sessions
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Training Discounts
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% off per 5 delegates, up to 40% for 100+

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