This Intermediate Apprenticeship for Lean Manufacturing is designed as a 12-month programme. It will equip you with skills and knowledge to work safely and to high quality standards in a fast-paced and efficient processing environment. It will also develop you to become a multi-skilled operator.
As part of your apprenticeship, you will be required to prepare, control, contribute to and complete manufacturing operations, and follow manufacturing processes and standard operating procedures (SOPs) whilst adhering to specific safe working policies and procedures.
As a Lean Manufacturing Operative, you will be responsible for maintaining Health and Safety requirements at all times e.g. wearing correct Personal Protective Equipment (PPE), correct use of equipment and tooling, safe stopping and resetting of machinery, maintaining an organised work area e.g. 5S (Sifting, Sorting, Sweeping, Spick and Span and Sustain), and ensuring the safe disposal of waste in line with environmental systems and regulatory requirements (ISO 14001).
You will also be required to contribute, develop and support improvement in the manufacturing operation using continuous improvement methods, kaizen tools, process visualisation using lean principles and problem-solving tools and techniques. You will carry out quality checks throughout the manufacturing operations to ensure quality is built in and that any defects or concerns are highlighted and dealt with in line with relevant quality standards (ISO 9002).
Typically, the duration of this apprenticeship is 12 months excluding your End-point Assessment (EPA). This duration may be reduced for a candidate with previous relevant experience or who is already part-qualified.
This course will be delivered entirely in the workplace.
Practical skills are considered as important as academic ability and the employer will set their own specific selection criteria. However, the candidate will be required to achieve qualifications at Level 2 in English and Mathematics within the period of apprenticeship if they have not already achieved these.
A Lean Manufacturing Operative will have the following knowledge and understanding of:
A Lean Manufacturing Operative will have the skill and understanding to:
You will also work towards your Level 2 Diploma in Manufacturing (Knowledge and Skills) and achieving Functional Skills in English and maths up to Level 2 if required.
There are three elements that will be assessed throughout your apprenticeship. These are: Knowledge, Skills and Behaviours. Technical knowledge and coaching on-role and off-role (20% off-the-job) will be supported by your employer and your assessor. Pre-assessments will be undertaken to determine your competence in these areas as you progress through your apprenticeship, for which feedback will be provided.
As an apprentice, you must complete the approved qualification mandated in the lean manufacturing occupational standard and the below requisites to be entered for EPA.
You End Point Assessment (EPA) will only start once all of the above pre-requisite gateway requirements have been met and can be evidenced to an End Point Awarding Organisation. Your employer must be satisfied (provide endorsement) that you are consistently working at or above the level set out in the occupational standard.
This must be completed within a typical period of 12 weeks after you have met the EPA gateway requirements. The EPA will be conducted by an external organisation approved to offer services against this apprenticeship standard and will consist of two distinct assessment methods.
The individual assessment methods will have the following grades:
Assessment method 1: Observation with question and answers
Assessment method 2: Professional discussion
Performance in the EPA will determine the overall apprenticeship standard grade of:
Apprentices will be expected to comply with their company's standard PPE dress code. All safety equipment and PPE will be addressed and provided by your employer.
There are numerous opportunities for Lean Manufacturing Operatives depending on the role selected at the start of the programme. Full-time employment opportunities in the below roles may become available:
- Assembly / Production / Inspection / Quality / Logistics / Material and Production Processing / Finishing Operative
- Team Supervisor / Leader
- Technical Support
For the above positions, and depending on your employer and route taken, there are numerous further qualifications pathways that can be undertaken.
Teenager Hitomi Ferguson is following in her father’s footsteps as she gains crucial engineering skills through Derby College.
The 18-year-old from Ilkeston is working on Derby College’s Performing Engineering Operations (PEO) NVQ Level 2 course at the Roundhouse – having previously completed a course in engineering and technology at the Ilkeston site.
She particularly loves the hands on work of welding, and In the long term hopes to gain an apprenticeship as the building block to her future career.
Hitomi was brought up in Sweden and only came to Derbyshire at GCSE age when her dad’s Rolls-Royce engineering job brought him to the UK.
The Roundhouse is brilliant – it has everything you need. In the long term I’m hoping to get onto an apprenticeship which hopefully could lead to the start of a good career.