EXTERNAL INTEGRATED SUMMATIVE ASSESSMENT EXEMPLAR

Assessment outcomes

Pass 60 - 100

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Fail 0 - 59

Unfortunately, your current submission does not meet the required competency standards. In order to proceed toward obtaining your QCTO Certification of Competency, please complete a second or third attempt. Should you have any inquiries, we encourage you to discuss them with your facilitator. Best regards.

Completed 60 - 100

Congratulations! Your current attempt has successfully demonstrated the required competency. To proceed to your QCTO Certification of Competency, please complete the EISA-Practical Demonstrations. Should you have any inquiries, we encourage you to discuss them with your facilitator. Best wishes on your journey!

Block 1, 2 question(s), maximum score 0

Question Block - 1

GENERAL EISA RULES

1. Learners are only allowed to use the supplied EISA booklets (Applicable  exclusively to paper-based assessments) and the use of a black pen is compulsory.

2.  Learners are only allowed to use a tablet/PC for their answers (Applicable only  to electronic assessments).

3. Learners must ensure that their full name(s), surname, and EISA registration  number appears on the front of your EISA booklet.

4. This is a closed book examination; therefore, no other material or belongings  are to be brought into the assessment centre. Should you bring any other material or belongings into the assessment centre, you will be required to leave such at the front of the assessment centre examination room. The assessment centre will not be held liable for any loss or damage to property brought into the assessment centre examination room.

5. All EISA booklets must be handed back to the invigilator fully intact. No pages may be removed or torn off from the EISA booklet.

6. All EISA eAssessments must be submitted before the designated deadline.

7. The removal of EISA booklets from the examination room is prohibited.

8. Learners may make use of a calculator in this EISA.

9. Unless this is an online examination where access to a tablet/computer will be made available to you; the use of any communication devices, including smart watches, cellular phones, iPads, headphones and laptops are prohibited.

10. All cellular phones must be switched off for the duration of the EISA.

11. The invigilator will not assist you with the explanation of questions related to  the EISA.

12. Learners are prohibited from conversing in any manner with other learners.

13. Learners must leave the examination venue as soon as their EISA booklets have been handed in BUT they may not leave the examination venue less than one hour after the stipulated time of the examination of commencement and during the last 10 minutes of the allotted examination period.

14. Learners who are found to be disruptive and unruly in the assessment centre will be requested to leave the assessment centre by the invigilator.

15. Possession of notes or any other unauthorised material, that could in any way assist in the answering of questions, is prohibite.

16. The instructions or directives of the invigilator may not be disregarded.

CANDIDATE INSTRUCTIONS

• Candidates must complete all questions in this EISA.

• Candidates must ensure that they use only a black pen when completing this EISA (Applicable exclusively to paper-based assessments).

• Should you require additional space to complete your answer, please request additional paper from your invigilator. Ensure that you indicate your full name(s), surname and EISA registration number at the top of the additional paper. Also   ensure that the question number is clearly marked on your additional paper (Applicable exclusively to paper-based assessments).

1 of 2

Question ID: 100011950523

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1. Learner Name(s) & Surname 

2. ID Number                        

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2 of 2

Question ID: 100011950536

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Question type File upload not supported

Block 2, 26 question(s), maximum score 26

Question Block - 2

SECTION 1: QUESTION 1:

This Section will cover the following Exit Level outcomes:

• ELO 01: Prepare and set up the man-made fibre extrusion machine for production or new quality. 

• ELO 02: Start and operate the man-made fibre extrusion machine to optimum output levels. 

TOTAL WEIGHTING: 26 MARKS 

TIME: 26 MINUTES

1 of 26

Question ID: 100012228947

Is the following statement True or False:                                                                                                                                         (1 Mark)

A wide range of extruded filament yarns can be used for men’s formal shirts.

 (a) 

True

 (b) 

False

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 1.
  
  

2 of 26

Question ID: 100012228948

Is the following statement True or False:                                                                                                                                         (1 Mark)

Merge identification is important because it could affect future dyeing recipes.

 (a) 

True

 (b) 

False

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

3 of 26

Question ID: 100012228949

Which of the following is not a synthetic polymer?                                                                                                                                 (1 Mark)

 (a) 

Nylon

 (b) 

Polypropylene

 (c) 

Silk

 (d) 

Polyester

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

4 of 26

Question ID: 100012228950

Which of the following raw material specifications do not apply to a typical extrusion process?                                                           (1 Mark)

 (a) 

Polymer type

 (b) 

Yarn count

 (c) 

Polymer colour

 (d) 

Twist direction

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

5 of 26

Question ID: 100012228951

Raw materials need to be handled with care for the following reason:                                                                                                  (1 Mark)

 (a) 

It is expensive

 (b) 

To avoid contamination

 (c) 

All of the above

 (d) 

None of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

6 of 26

Question ID: 100012228956

Which of the following is not a typical extrusion raw material?                                                                                                              (1 Mark)

 (a) 

High density polyethylene (HDPE)

 (b) 

Polypropylene (PP)

 (c) 

Polyester (PES)

 (d) 

Viscose

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

7 of 26

Question ID: 100012228958

Is the following statement True or False:                                                                                                                                         (1 Mark)

Merge identification is important when loading the machine because it could affect future dyeing recipes. 

 (a) 

True

 (b) 

False

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

8 of 26

Question ID: 100012228960

Would you agree with the following statement:                                                                                                                                (1 Mark)

Temperature settings are critical when loading the machine for producing consistent yarns

 (a) 

Yes

 (b) 

No

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

9 of 26

Question ID: 100012228962

Machine loading and set up could include which of the following actions:                                                                                             (1 Mark)

 (a) 

Verify that the correct programme is displayed on the micro-processes as detailed on the specification 

 (b) 

Fill in start-up procedure documents 

 (c) 

Prestart checklist completed and signed off by the senior official

 (d) 

All of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

10 of 26

Question ID: 100012228963

When setting up the machine which of the following is not important for the operator to give attention to?                                          (1 Mark)

 (a) 

The polymer manufacturer’s labels

 (b) 

Pertinent information is recorded in the shift log

 (c) 

The machine operator’s name

 (d) 

The department atmospheric conditions

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

11 of 26

Question ID: 100012228966

A prestart check list would include which of the following?                                                                                                                    (1 Mark)

 (a) 

Correct polymer colour is loaded

 (b) 

All machine guards in place   

 (c) 

All machine sensors fitted and in good condition   

 (d) 

All of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

12 of 26

Question ID: 100012228967

What needs to be checked immediately after start-up?                                                                                                                         (1 Mark)

 (a) 

The thread lines

 (b) 

The yarn package build

 (c) 

Both of the above

 (d) 

None of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

13 of 26

Question ID: 100012228975

Is the following statement True or False:                                                                                                                                         (1 Mark)

MOST extrusion machines have a spinneret or spinnerets.

 (a) 

True

 (b) 

False

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

14 of 26

Question ID: 100012228976

Would you agree with the following statement:                                                                                                                                (1 Mark)

When cleaning with solvents it is necessary to wear gloves and a dust mask.

 (a) 

Yes

 (b) 

No

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

15 of 26

Question ID: 100012228978

Which of the following statements is NOT true:                                                                                                                                     (1 Mark)

 (a) 

Extrusion – the process of producing a filament of textile fibre

 (b) 

Spinneret – The attachment with small holes for extruding the filaments

 (c) 

Godet Roller – a device for maintaining the required yarn tension

 (d) 

None of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

16 of 26

Question ID: 100012228979

Would the godet speed be measured in:                                                                                                                                                (1 Mark)

 (a) 

Meters per Minute (mpm)

 (b) 

Meters per Shift (mps)

 (c) 

Revolutions per Minute (rpm)

 (d) 

Revolutions per Hour (rph)

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

17 of 26

Question ID: 100012228980

Which of the following would not be considered part of basic maintenance?                                                                                        (1 Mark)

 (a) 

Cleaning godet rollers

 (b) 

Torquing of spinnerets

 (c) 

Cleaning of yarn guides

 (d) 

Replacing noisy machine or pump motor bearings

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 1.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

18 of 26

Question ID: 100012228981

Which of the following production parameters will a machine control system usually not be able to monitor:                                      (1 Mark)

 (a) 

Yarn tension

 (b) 

Heating temperature

 (c) 

Yarn/Filament count

 (d) 

Cooling temperature

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

19 of 26

Question ID: 100012228982

A prestart check list could include which of the following?                                                                                                                     (1 Mark)

 (a) 

The correct program is set on the monitoring computer

 (b) 

All machine guards in place   

 (c) 

All machine sensors fitted and in good condition 

 (d) 

All of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

20 of 26

Question ID: 100012228983

What does not need to be checked immediately after start-up?                                                                                                            (1 Mark)

 (a) 

The thread lines

 (b) 

The yarn package build

 (c) 

The atmospheric conditions in the department

 (d) 

None of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

21 of 26

Question ID: 100012228984

Codes and labels are necessary after doffing the machine for which of the following reasons?                                                           (1 Mark)

 (a) 

Improve machine efficiency

 (b) 

Avoid mixing of different qualities

 (c) 

Satisfy customer requirements

 (d) 

Decrease risk of overproduction  

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 1.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

22 of 26

Question ID: 100012228985

What action would you not take, after identifying dirty spinnerets?                                                                                                       (1 Mark)

 (a) 

Stop all the faulty machines

 (b) 

Report to the supervisor immediately 

 (c) 

Both of the above

 (d) 

None of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

23 of 26

Question ID: 100012228986

The machine specific doffing procedure must be correctly performed, primarily for the following reasons:                                          (1 Mark)

 (a) 

To prevent delays in delivery

 (b) 

To maintain good efficiency

 (c) 

To avoid unnecessary waste

 (d) 

To avoid any injury to the operator

 (e) 

All of the above

 (f) 

None of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 1.
  
  

• If choice f is selected, set score to 0.
  
  

24 of 26

Question ID: 100012228987

When identifying a non-conformance product while doffing the machine, what must be recorded?                                                      (1 Mark)

 (a) 

The fault codes     

 (b) 

The machine numbers      

 (c) 

The quantity     

 (d) 

The date and time

 (e) 

The type of fault     

 (f) 

All of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 0.
  
  

• If choice f is selected, set score to 1.
  
  

25 of 26

Question ID: 100012228989

Which of the following operating procedures would be included in the duties for a typical extrusion operator?                                    (1 Mark)

 (a) 

Clean the machines as required   

 (b) 

Enter quality details on the production sheet

 (c) 

Verify that the correct programme is displayed on the micro-processors as detailed on the work instruction    

 (d) 

Load the polymer in the hopper

 (e) 

All of the above

 (f) 

None of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 1.
  
  

• If choice f is selected, set score to 0.
  
  

26 of 26

Question ID: 100012228990

Problems during the starting process could include which of the following:                                                                                          (1 Mark)

 (a) 

Incorrect polymer supply

 (b) 

Blocked filter boxes

 (c) 

Incorrect speeds

 (d) 

Incorrect temperature settings  

 (e) 

All of the above

 (f) 

None of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 1.
  
  

• If choice f is selected, set score to 0.
  
  

Block 3, 50 question(s), maximum score 50

Question Block - 3

SECTION 2: QUESTION 2:

This Section will cover the following Exit Level outcome:

• ELO 03: Patrol and monitor the man-made fibre extrusion machine and process for efficiency. 

TOTAL WEIGHTING: 50 MARKS 

TIME: 50 MINUTES

1 of 50

Question ID: 100012228991

Is the following statement True or False:                                                                                                                                         (1 Mark)

Patrolling and monitoring mean the same thing.

 (a) 

True

 (b) 

False

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 1.
  
  

2 of 50

Question ID: 100012228992

Is the following statement True or False:                                                                                                                                         (1 Mark)

Correct patrolling sequence in the extrusion department will ensure any abnormalities can be identified and rectified as soon as possible. 

 (a) 

True

 (b) 

False

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

3 of 50

Question ID: 100012228993

Which of the following is achieved by following the correct patrolling sequence?                                                                                 (1 Mark)

 (a) 

Fire risks are reduced

 (b) 

Improves the housekeeping requirements

 (c) 

Ensures any abnormalities can be identified and rectified as soon as possible

 (d) 

Improves machine utilisation 

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

4 of 50

Question ID: 100012228994

The correct patrolling route and frequency are important for the following main reason:                                                                      (1 Mark)

 (a) 

To keep the operator busy

 (b) 

To identify process faults as soon as possible

 (c) 

To control waste

 (d) 

To identify unsafe conditions

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 1.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

5 of 50

Question ID: 100012228995

Why is patrolling of the extrusion machines and processes important:                                                                                                 (1 Mark)

 (a) 

Results in fewer processing faults

 (b) 

Keeps the operator active while waiting for the process to end

 (c) 

Prevents accidents

 (d) 

Provides information for the operator to report on the shift log 

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6 of 50

Question ID: 100012228996

When must patrolling be carried out by the Operator?                                                                                                                          (1 Mark)

 (a) 

At the end of the shift

 (b) 

When instructed by the Supervisor

 (c) 

At the beginning of the shift

 (d) 

None of the above

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7 of 50

Question ID: 100012228997

If Process patrolling techniques are accurately applied, there should be fewer:                                                                                   (1 Mark)

 (a) 

Fire hazards

 (b) 

Job losses in the industry

 (c) 

Processing faults

 (d) 

Machine breakdowns 

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8 of 50

Question ID: 100012228998

If filament variations are noticed while patrolling, what could be the possible causes?                                                                         (1 Mark)

 (a) 

Incorrect godet settings

 (b) 

Incorrect temperature setting 

 (c) 

Wrong machine speeds 

 (d) 

All of the above

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9 of 50

Question ID: 100012228999

A patrol checklist will usually include which of the following:                                                                                                                 (1 Mark)

 (a) 

Polymer type

 (b) 

Required dtex

 (c) 

Product type

 (d) 

All of the above

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10 of 50

Question ID: 100012229000

Extrusion process machines must be patrolled as specified, in order to ensure which of the following:                                               (1 Mark)

 (a) 

Consistency of quality 

 (b) 

Consistency planned productivity  

 (c) 

Waste is kept to a minimum

 (d) 

All of the above

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11 of 50

Question ID: 100012229001

Is the following statement True or False?                                                                                                                                        (1 Mark)

Extrusion process conditions must be monitored and maintained as specified, in order to ensure consistency of quality and productivity 

 (a) 

True

 (b) 

False

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12 of 50

Question ID: 100012229002

Would you agree with the following statement:                                                                                                                                (1 Mark)

It is important to monitor temperature and speed settings, since they are the main cause of low tenacity.

 (a) 

Yes

 (b) 

No

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13 of 50

Question ID: 100012229003

Is the following statement True or False:                                                                                                                                         (1 Mark)

The correct yarn package build is important to monitor, because it must meet customer requirements.

 (a) 

True

 (b) 

False

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14 of 50

Question ID: 100012229004

Is the following statement True or False:                                                                                                                                         (1 Mark)

If Process monitoring techniques are accurately applied, there should be fewer processing faults. 

 (a) 

True

 (b) 

False

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15 of 50

Question ID: 100012229005

Is the following statement True or False:                                                                                                                                         (1 Mark)

It is important to monitor the relative speeds of the godet rollers, since they have the main impact on the orientation of the extruded fibres.

 (a) 

True

 (b) 

False

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16 of 50

Question ID: 100012229006

Would you agree with the following statement:                                                                                                                                (1 Mark)

The ability to replenish the machine is the responsibility of the supervisor.

 (a) 

Yes

 (b) 

No

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17 of 50

Question ID: 100012229007

Is the following statement True or False:                                                                                                                                         (1 Mark)

Correct monitoring will ensure any abnormalities during the extrusion process can be identified and rectified as soon as possible.

 (a) 

True

 (b) 

False

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18 of 50

Question ID: 100012229009

Is the following statement True or False:                                                                                                                                         (1 Mark)

Monitoring and patrolling the man-made fibre extrusion process is essential for ensuring safety compliance and optimizing machine utilization.

 (a) 

True

 (b) 

False

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19 of 50

Question ID: 100012229011

Is the following statement True or False:                                                                                                                                         (1 Mark)

Incorrect speed settings will only affect the rate of production.

 (a) 

True

 (b) 

False

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20 of 50

Question ID: 100012229012

Is the following statement True or False:                                                                                                                                         (1 Mark)

Deviations of the process means the process is not running according to specifications.

 (a) 

True

 (b) 

False

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21 of 50

Question ID: 100012229014

Which of the following would be classified as machine faults?                                                                                                              (1 Mark)

 (a) 

Excessive dust

 (b) 

Noisy motor bearings

 (c) 

Wrong polymer feed

 (d) 

All of the above

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22 of 50

Question ID: 100012229016

When recording non-conformance of extruded filament, it must include which of the following:                                                           (1 Mark)

 (a) 

The type of fault     

 (b) 

The fault codes     

 (c) 

The date and time

 (d) 

All of the above

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23 of 50

Question ID: 100012229021

What would you say is the main cause of product contamination in the extrusion department?                                                           (1 Mark)

 (a) 

Incorrect temperature settings

 (b) 

Incorrect speed setting 

 (c) 

No thorough cleaning between quality changes

 (d) 

Wrong polymer feed 

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24 of 50

Question ID: 100012229025

Which of the following would be regarded as a mechanical defect:                                                                                                       (1 Mark)

 (a) 

Noisy bearings

 (b) 

Leaking pumps

 (c) 

Machine vibrations

 (d) 

All of the above

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25 of 50

Question ID: 100012229028

Basic quality control principles in the extrusion department would include which of the following:                                                       (1 Mark)

 (a) 

Various physical tests on the processed filaments

 (b) 

Formalised staff training    

 (c) 

Standardised machine settings     

 (d) 

All of the above

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26 of 50

Question ID: 100012229030

What would you say is the main cause of filament variations?                                                                                                              (1 Mark)

 (a) 

Incorrect godet settings

 (b) 

Incorrect temperature setting 

 (c) 

Wrong machine speeds 

 (d) 

All of the above

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27 of 50

Question ID: 100012229033

What will you do when you identify a product fault?                                                                                                                              (1 Mark)

 (a) 

Stop the machine immediately

 (b) 

Report to the supervisor immediately and await instruction

 (c) 

Report it at the shift changeover

 (d) 

Fix it yourself 

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28 of 50

Question ID: 100012229039

What could be the consequences of yarn produced from process faults in extrusion?                                                                         (1 Mark)

 (a) 

Incorrect Tex

 (b) 

Variable yarn strength

 (c) 

Variations in yarn uniformity

 (d) 

All of the above

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29 of 50

Question ID: 100012229053

What should you do when an alarm for a product fault is identified on the microprocessor?                                                                (1 Mark)

 (a) 

Stop the machine immediately

 (b) 

Report to the supervisor immediately and await instruction

 (c) 

Fix it yourself 

 (d) 

None of the above

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30 of 50

Question ID: 100012229056

What are typical settings on the micro-processor?                                                                                                                                (1 Mark)

 (a) 

Product type

 (b) 

Speed range

 (c) 

Temperature range

 (d) 

All of the above

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31 of 50

Question ID: 100012229065

When would you suggest is the best time to correct product quality faults reported on the micro-processor?                                      (1 Mark)

 (a) 

After completing the patrol sequence 

 (b) 

At the end of the shift so that it sorted for the next shift

 (c) 

Immediately

 (d) 

After completing all necessary administrative duties

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32 of 50

Question ID: 100012229068

Control panel readings could influence which of the following:                                                                                                              (1 Mark)

 (a) 

Melt flow rate 

 (b) 

Tenacity

 (c) 

Elongation

 (d) 

Lustre

 (e) 

All of the above

 (f) 

None of the above

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33 of 50

Question ID: 100012229079

Which parameter is essential for ensuring the quality of extruded fibres during production?                                                                (1 Mark)

 (a) 

Humidity levels

 (b) 

Colour of raw materials 

 (c) 

Machine speed

 (d) 

Cooling temperature

 (e) 

Machine efficiency

 (f) 

Employee satisfaction

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34 of 50

Question ID: 100012229085

How will you respond to micro-processor information?                                                                                                                          (1 Mark)

 (a) 

Take immediate action if necessary

 (b) 

Carry out minor adjustments as required by a skilled operator

 (c) 

Report to the supervisor if necessary

 (d) 

Adjust nothing if all the readings are correct

 (e) 

All of the above

 (f) 

None of the above

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35 of 50

Question ID: 100012229090

What actions would ensure that production capacity is optimized?                                                                                                       (1 Mark)

 (a) 

All correct settings on the micro-processor 

 (b) 

Good production planning

 (c) 

Reduced absenteeism

 (d) 

Operator training

 (e) 

All of the above

 (f) 

None of the above

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36 of 50

Question ID: 100012229106

Is the following statement True or False:                                                                                                                                         (1 Mark)

The relative speeds of the godet rollers have the main impact on the machine optimisation. 

 (a) 

True

 (b) 

False

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37 of 50

Question ID: 100012229151

Which machine defects could have a major impact on machine optimisation?                                                                                     (1 Mark)

 (a) 

Noisy bearings

 (b) 

Leaking pumps

 (c) 

Incorrect godet speeds

 (d) 

All of the above

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38 of 50

Question ID: 100012229175

Which of the following factors will have an impact on machine optimisation?                                                                                       (1 Mark)

 (a) 

The manager ensuring there is an adequate of supply of polymer

 (b) 

Preparing in advance the polymer for the next batch to ensure a continuous process flow, without unnecessary machine stoppages

 (c) 

Both of the above

 (d) 

None of the above

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39 of 50

Question ID: 100012229177

If the production target is 800 kg per hour, but only 600 kg is produced, what would the efficiency be?                                               (1 Mark)

 (a) 

80%

 (b) 

75%

 (c) 

70%

 (d) 

60%

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40 of 50

Question ID: 100012229179

Which of the following would also contribute to machine optimisation?                                                                                                 (1 Mark)

 (a) 

An adequate supply of raw material

 (b) 

An adequate supply yarn formers (cheeses) are checked ensuring sufficient quantity for the full production run

 (c) 

Both of the above

 (d) 

None of the above

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41 of 50

Question ID: 100012229180

Which of the following would have a negative effect on machine optimisation?                                                                                    (1 Mark)

 (a) 

Incorrect threading

 (b) 

Incorrect polymer supply

 (c) 

Incorrect temperature settings  

 (d) 

All of the above

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42 of 50

Question ID: 100012229182

Who has responsibility to replenish the machine when needed to ensure machine optimisation?                                                        (1 Mark)

 (a) 

The supervisor

 (b) 

The operator

 (c) 

The person in charge of maintenance

 (d) 

The manager

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 1.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

43 of 50

Question ID: 100012229184

All machine faults on a typical extrusion machine will need to be attended by which department?                                                      (1 Mark)

 (a) 

The laboratory department

 (b) 

The maintenance department

 (c) 

The production department

 (d) 

The training department 

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 1.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

44 of 50

Question ID: 100012229188

What action would you take after identifying a shortage of raw material that could seriously affect machine optimisation in the extrusion department? (1 Mark)

 (a) 

Stop all the machines

 (b) 

Report to the supervisor in the texturizing department

 (c) 

Stop some of the machines affected and report to the supervisor immediately

 (d) 

Report to management immediately  

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

45 of 50

Question ID: 100012229190

When would you recommend is the best time to correct product quality faults?                                                                                   (1 Mark)

 (a) 

After completing all necessary administrative duties  

 (b) 

After completing the patrol sequence 

 (c) 

At the end of the shift so that it sorted for the next shift

 (d) 

Immediately

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

46 of 50

Question ID: 100012229191

What action would you take, after identifying production targets are not going to be achieved?                                                           (1 Mark)

 (a) 

Speed up all the machines

 (b) 

Report to the supervisor 

 (c) 

Try to identify the main reason and report accordingly

 (d) 

Report to the costing department immediately 

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

47 of 50

Question ID: 100012229194

Where is the best place for production targets to be displayed?                                                                                                           (1 Mark)

 (a) 

On the machine

 (b) 

On the notice board

 (c) 

In the supervisor’s office

 (d) 

On a huge screen in the department for all to see

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

48 of 50

Question ID: 100012229197

Which basic quality control principles will have an impact on machine optimisation?                                                                           (1 Mark)

 (a) 

Standardised machine settings     

 (b) 

Various physical tests on the processed filaments to ensure there are no none- conformance issues

 (c) 

Formalised staff training    

 (d) 

Controls within the purchasing of raw materials   

 (e) 

Documented standard operating procedures   

 (f) 

All of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 0.
  
  

• If choice f is selected, set score to 1.
  
  

49 of 50

Question ID: 100012229198

Which of the following faults would not have an effect on machine optimisation?                                                                                 (1 Mark)

 (a) 

Incorrect melt temperature

 (b) 

Noisy motor bearings

 (c) 

Wrong godet speeds

 (d) 

Incorrect humidity settings

 (e) 

All of the above

 (f) 

None of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 0.
  
  

• If choice f is selected, set score to 1.
  
  

50 of 50

Question ID: 100012229199

What actions would you recommend to achieve optimum machine efficiency?                                                                                     (1 Mark)

 (a) 

Good production planning

 (b) 

Reduced absenteeism

 (c) 

Preventative maintenance

 (d) 

Operator training 

 (e) 

All of the above

 (f) 

None of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 1.
  
  

• If choice f is selected, set score to 0.
  
  

Block 4, 18 question(s), maximum score 18

Question Block - 4

SECTION 3: QUESTION 3:

This Section will cover the following Exit Level outcome:

• ELO 04: Inspect, monitor and maintain the quality of the man-made extruded fibre. 

TOTAL WEIGHTING: 18 MARKS 

TIME: 18 MINUTES

1 of 18

Question ID: 100012229212

Would you agree with the following statement:                                                                                                                                (1 Mark)

Codes and labels are necessary to avoid mixing of different extruded filaments which may look the same. 

 (a) 

Yes

 (b) 

No

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

2 of 18

Question ID: 100012229213

Extruded filaments non-conformity can be related to:                                                                                                                            (1 Mark)

 (a) 

Count

 (b) 

Number of filaments

 (c) 

All of the above

 (d) 

None of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

3 of 18

Question ID: 100012229216

Product codes could include which of the following?                                                                                                                             (1 Mark)

 (a) 

HDPE

 (b) 

PP 

 (c) 

PES

 (d) 

All of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

4 of 18

Question ID: 100012229222

Why is it important to identify product and company established codes to record?                                                                               (1 Mark)

 (a) 

The shipping department needs this information

 (b) 

It is needed to measure the productivity

 (c) 

Purchasing department need to be informed to ensure a consistent supply of raw materials

 (d) 

All of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

5 of 18

Question ID: 100012229226

If product and company established codes are not recorded correctly, what could be some of the consequences?                            (1 Mark)

 (a) 

Late deliveries

 (b) 

Loss of customers 

 (c) 

Loss of jobs

 (d) 

Production delays

 (e) 

All of the above

 (f) 

None of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 1.
  
  

• If choice f is selected, set score to 0.
  
  

6 of 18

Question ID: 100012229248

When recording non-conformance of the product, it must include which of the following:                                                                     (1 Mark)

 (a) 

The fault codes     

 (b) 

The machine numbers      

 (c) 

The quantity     

 (d) 

The date and time

 (e) 

All of the above

 (f) 

None of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 1.
  
  

• If choice f is selected, set score to 0.
  
  

7 of 18

Question ID: 100012229254

Is the following statement True or False:                                                                                                                                         (1 Mark)

Non-conformance of the extruded filaments means the product is not being produces according to specifications.

 (a) 

True

 (b) 

False

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

8 of 18

Question ID: 100012229255

What could be some causes for non-conforming extruded filaments?                                                                                                  (1 Mark)

 (a) 

Contamination of raw materials 

 (b) 

Wrong temperature setting

 (c) 

Incorrect Godet speed

 (d) 

All of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

9 of 18

Question ID: 100012229257

When recording non-conformance of extruded filament, it does not need include which of the following:                                            (1 Mark)

 (a) 

The fault codes     

 (b) 

The machine numbers      

 (c) 

The supervisor’s name

 (d) 

The date and time

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

10 of 18

Question ID: 100012229260

To identify non-conforming extruded filaments from first grade product, you can do which of the flowing:                                           (1 Mark)

 (a) 

Use your experience

 (b) 

Ask fellow operators their opinion

 (c) 

Both of the above

 (d) 

None of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

11 of 18

Question ID: 100012229265

All machine faults on a typical extrusion machine will need to be attended to by which employee or department?                              (1 Mark)

 (a) 

The supervisor

 (b) 

The maintenance department

 (c) 

The laboratory

 (d) 

The sales department

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 1.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

12 of 18

Question ID: 100012229269

What corrective action would you take for identified non-conformance filaments?                                                                                (1 Mark)

 (a) 

Ensure segregation in designated containers

 (b) 

Fill in necessary reports

 (c) 

Inform the supervisor as soon as possible

 (d) 

Stop the machine if instructed to do so.

 (e) 

Offer suggestions on the possible causes

 (f) 

All of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 0.
  
  

• If choice f is selected, set score to 1.
  
  

13 of 18

Question ID: 100012229279

Is the following statement True or False:                                                                                                                                         (1 Mark)

‘Accurate records of faults are important in order to ensure waste can be kept to a minimum. 

 (a) 

True

 (b) 

False

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

14 of 18

Question ID: 100012229283

Is the following statement True or False:                                                                                                                                         (1 Mark)

‘One of the main reasons for generating process reports in a legible manner is to ensure misinformation is not circulated’.

 (a) 

True

 (b) 

False

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

15 of 18

Question ID: 100012229287

What could be some corrective action for product faults on extruded filaments?                                                                                  (1 Mark)

 (a) 

Recheck correct polymer was loaded in the hopper

 (b) 

Check for dirty spinnerets

 (c) 

Check temperature setting

 (d) 

All of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

16 of 18

Question ID: 100012229291

To identify product faults on the extruded filaments, you can do which of the flowing:                                                                          (1 Mark)

 (a) 

Check against the master sample

 (b) 

Ask the quality controller the check a sample 

 (c) 

Both of the above

 (d) 

None of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 1.
  
  

• If choice d is selected, set score to 0.
  
  

17 of 18

Question ID: 100012229296

Most product faults on a typical extrusion machine will need to be attended to by which employee or department?                           (1 Mark)

 (a) 

The supervisor

 (b) 

The maintenance department

 (c) 

The laboratory

 (d) 

The sales department

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

18 of 18

Question ID: 100012229300

What could be some causes for product faults on extruded filaments?                                                                                                 (1 Mark)

 (a) 

Incorrect polymer loaded in the hopper

 (b) 

Contamination in the hopper 

 (c) 

Dirty spinnerets

 (d) 

Wrong temperature setting

 (e) 

All of the above

 (f) 

None of the above

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 0.
  
  

• If choice e is selected, set score to 1.
  
  

• If choice f is selected, set score to 0.
  
  

Block 5, 6 question(s), maximum score 6

Question Block - 5

SECTION 4: QUESTION 4:

This Section will cover the following Exit Level outcome:

• ELO 05: Perform safety, housekeeping and waste control and maintain accurate records for the extrusion machine. 

TOTAL WEIGHTING: 06 MARKS 

TIME: 06 MINUTES

1 of 6

Question ID: 100012229306

Would you say the following statement is always true:                                                                                                                    (1 Mark)

In the case of an emergency, all employees should immediately evacuate the building. 

 (a) 

Yes

 (b) 

No

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 1.
  
  

• If choice b is selected, set score to 0.
  
  

2 of 6

Question ID: 100012229308

Which of the following safety procedures would apply to most extrusion departments?                                                                       (1 Mark)

 (a) 

Comply with all the health and safety precautions related to hazardous chemicals    

 (b) 

Use necessary personal protective equipment where required     

 (c) 

Ensure the machine lock-out procedures are applied    

 (d) 

All of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

3 of 6

Question ID: 100012229312

Is the following statement True or False:                                                                                                                                         (1 Mark)

‘Accurate records of waste are important in order to establish the selling price’. 

 (a) 

True

 (b) 

False

Meta Tags:

Level of Question (Lower Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 1.
  
  

4 of 6

Question ID: 100012229313

Waste control interventions could include which of the following:                                                                                                          (1 Mark)

 (a) 

Clean material waste being fed back into the production system

 (b) 

Visible waste control records displayed in the department

 (c) 

Clear identification and separation of waste

 (d) 

All of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

5 of 6

Question ID: 100012229316

Production performance reports may be useful for which of the following:                                                                                            (1 Mark)

 (a) 

Determining future processing costs

 (b) 

Considering alternative processing methods     

 (c) 

Identifying operator training needs     

 (d) 

All of the above

Meta Tags:

Level of Question (Middle Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

6 of 6

Question ID: 100012229318

If the production target is 1,000 kg per hour but only 700 kg is produced, what would the efficiency be?                                             (1 Mark)

 (a) 

90%

 (b) 

80%

 (c) 

75%

 (d) 

70%

 (e) 

60%

 (f) 

55%

Meta Tags:

Level of Question (Higher Order)

Outcomes:

• If choice a is selected, set score to 0.
  
  

• If choice b is selected, set score to 0.
  
  

• If choice c is selected, set score to 0.
  
  

• If choice d is selected, set score to 1.
  
  

• If choice e is selected, set score to 0.
  
  

• If choice f is selected, set score to 0.