Manufacturing, Engineering and Technology Manufacturing and Assembly

Support Activities Planning in Metal Production Training

SAQA US 259720 | NQF 2 | Credits 10 | Duration 7 Days
From $1,523 per delegate

Description

This course equips learners with the skills to plan and coordinate support activities essential for efficient metal production. Participants will learn to schedule resources, manage workflows, and ensure safety compliance within a metal production environment. The course is designed to enhance operational effectiveness and align support functions with production targets.

Learning Outcomes

  • Develop and document support activity plans that align with production schedules and resource availability.
  • Apply resource allocation techniques to optimise the use of personnel, equipment, and materials in support activities.
  • Evaluate potential risks and implement control measures to ensure safety and compliance during support operations.
  • Coordinate communication between production and support teams to minimise downtime and enhance workflow efficiency.
  • Monitor and adjust support activity plans based on real-time production feedback and performance data.
  • Demonstrate adherence to quality standards and continuous improvement principles in support activity planning.

Target Audience

This course is intended for production supervisors, team leaders, and support staff involved in metal production processes who are responsible for planning and coordinating support activities.

Prerequisites

None — open enrollment

Course Outline

Day 1: Introduction to Metal Production and Support Activities Planning

Objectives:
• Understand the metal production process and the role of support activities.
• Identify key stakeholders and their responsibilities in planning.
• Recognize relevant regulations and standards in the South African context.

Topics:
• Overview of metal production processes (ferrous and non-ferrous).
• Definition and scope of support activities (maintenance, logistics, quality control).
• Regulatory framework: OHS Act, SANS standards, SAQA requirements.
• Roles and responsibilities of planners, supervisors, and operators.
• Introduction to planning principles: scheduling, resource allocation, and risk management.

Day 2: Production Schedules and Resource Requirements

Objectives:
• Develop basic production schedules for support activities.
• Identify resource requirements (materials, equipment, personnel).
• Apply methods to estimate resource quantities and timing.

Topics:
• Types of production schedules: daily, weekly, and shift-based.
• Resource planning: raw materials, consumables, tools, and human resources.
• Techniques for estimating resource needs (historical data, standard times).
• Factors affecting resource availability (lead times, storage, budget).
• Practical exercise: create a simple schedule for a maintenance task.

Day 3: Risk Assessment and Safety Planning

Objectives:
• Conduct risk assessments for support activities in metal production.
• Develop safety plans to mitigate identified risks.
• Understand legal requirements for safety planning.

Topics:
• Hazard identification in metal production environments (heat, chemicals, machinery).
• Risk assessment methodologies (JSA, HAZOP, risk matrices).
• Developing control measures and safety procedures.
• Emergency response planning and first aid requirements.
• Case study: risk assessment for a furnace maintenance activity.

Day 4: Quality Control and Inspection Planning

Objectives:
• Plan quality control activities for support processes.
• Identify inspection points and testing requirements.
• Apply quality standards and documentation procedures.

Topics:
• Quality standards in metal production (ISO 9001, ASTM, SANS).
• Inspection and testing plans for raw materials, in-process, and final products.
• Non-destructive testing (NDT) methods and scheduling.
• Documentation: checklists, reports, and corrective action records.
• Practical exercise: design an inspection plan for a welding operation.

Day 5: Maintenance Planning and Shutdown Coordination

Objectives:
• Plan preventive and corrective maintenance for production equipment.
• Coordinate shutdowns and turnarounds effectively.
• Optimize maintenance schedules to minimize production downtime.

Topics:
• Types of maintenance: preventive, predictive, corrective.
• Maintenance planning tools: CMMS, work orders, and schedules.
• Shutdown planning: scope, resources, timeline, and critical path.
• Communication and coordination with production and other departments.
• Practical exercise: create a shutdown plan for a rolling mill.

Day 6: Logistics and Materials Handling Planning

Objectives:
• Plan logistics for material movement and storage.
• Optimize material handling to reduce waste and improve efficiency.
• Understand inventory management principles.

Topics:
• Material flow in metal production: from raw material to finished product.
• Storage requirements: safety, segregation, and space optimization.
• Transportation within the plant: cranes, forklifts, conveyors.
• Inventory management: reorder points, safety stock, and stocktaking.
• Practical exercise: design a material handling plan for a casting process.

Day 7: Integration, Continuous Improvement, and Assessment

Objectives:
• Integrate all planning elements into a comprehensive support plan.
• Apply continuous improvement techniques to planning processes.
• Demonstrate competence through a final assessment.

Topics:
• Creating a master support plan integrating schedule, resources, safety, quality, maintenance, and logistics.
• Continuous improvement tools: PDCA, Kaizen, and root cause analysis.
• Review of unit standard outcomes and assessment criteria.
• Final assessment: develop a support activities plan for a given scenario.
• Course wrap-up and feedback.

Practicals

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

Practical sessions allow learners to apply planning concepts to realistic metal production scenarios. These hands-on exercises reinforce scheduling, risk assessment, quality inspection, maintenance coordination, and logistics planning skills in a controlled environment.

Practical Activities
  • Production Schedule Development — Learners use a template to create a daily production schedule for a support activity (e.g., furnace relining), allocating resources and time. (4h)
  • Risk Assessment and Safety Plan — Learners conduct a risk assessment for a simulated maintenance task (e.g., replacing a conveyor belt) and draft a safety plan. (4h)
  • Inspection Plan for Welding Operation — Learners design an inspection plan for a welding operation, specifying inspection points, methods (e.g., visual, dye penetrant), and acceptance criteria. (4h)
  • Shutdown Plan for a Rolling Mill — Learners develop a shutdown plan for a rolling mill, including scope, timeline, resource list, and communication protocol. (5h)
  • Material Handling Plan for Casting Process — Learners design a material handling plan for a casting process, including storage layout, transport routes, and inventory control. (4h)

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
Online training — attend live sessions from anywhere via our virtual classroom.
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Fri 11 Sep 2026 Mon 21 Sep 2026 Virtual Spring 2026 $1,523 Register
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Tue 28 Dec 2027 Wed 05 Jan 2028 Virtual Summer 2027 $1,523 Register
Mon 17 Jan 2028 Tue 25 Jan 2028 Virtual Summer 2027 $1,523 Register
On-Campus training — face-to-face sessions at our training venues across Africa and beyond.
Showing all 498 sessions across 26 venues
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Mon 03 Aug 2026 Tue 11 Aug 2026 Dubai, UAE Winter 2026 $5,929 Register
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In-House training — we bring the trainer to your organisation, tailored to your team.
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Thu 25 Mar 2027 Fri 02 Apr 2027 Your Premises Autumn 2027 $1,982 Register
Wed 16 Jun 2027 Thu 24 Jun 2027 Your Premises Winter 2027 $1,982 Register
Tue 06 Jul 2027 Wed 14 Jul 2027 Your Premises Winter 2027 $1,982 Register
Mon 26 Jul 2027 Tue 03 Aug 2027 Your Premises Winter 2027 $1,982 Register
Fri 17 Sep 2027 Mon 27 Sep 2027 Your Premises Spring 2027 $1,982 Register
Thu 07 Oct 2027 Fri 15 Oct 2027 Your Premises Spring 2027 $1,982 Register
Wed 27 Oct 2027 Thu 04 Nov 2027 Your Premises Spring 2027 $1,982 Register
Thu 16 Dec 2027 Fri 24 Dec 2027 Your Premises Summer 2027 $1,982 Register
Wed 05 Jan 2028 Thu 13 Jan 2028 Your Premises Summer 2027 $1,982 Register
Tue 25 Jan 2028 Wed 02 Feb 2028 Your Premises Summer 2027 $1,982 Register
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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