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Apprenticeship Lean Manufacturing Operative ST0420 Standard Level 2

This Intermediate Apprenticeship for Lean Manufacturing is designed as a 12-month programme

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Course Summary

Subject Area: Engineering
Apprenticeships
Location: Workplace
Full Time or Part Time: FT
Level: 2
Number Of Years: 2
Interview Required?: Y
Workplace

Apply now at: https://www.derby-college.ac.uk/course/apprenticeship-lean-manufacturing-operative-st0420-standard-level-2
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Course Information for Students

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.

Core Knowledge

A Lean Manufacturing Operative will have the following knowledge and understanding of:

  • Health and Safety: Relevant statutory, organisational and health and safety regulations relating to lean manufacturing operations and safe practices
  • Environment: Compliance procedures/systems in line with regulatory requirements e.g. ISO 14001 or other relevant environmental standards
  • Production: Their individual role and responsibilities within the organisation and the flexibility required to deliver products to meet customers’ costs/delivery targets/requirements e.g. Just in time (JIT)
  • Lean Manufacturing Operations: Manufacturing standard operation procedures (SOPs) adherence and development of lean processes
  • Quality Control: Process equipment monitoring, data collection, error proofing and operating procedures e.g. ISO 9002 or other relevant quality standards
  • Problem Solving: The tools and methods of effective problem solving using data, reports and documents to resolve production related issues, e.g. A3 report, graphs, matrices, and escalate concerns
  • Continuous Improvement: How to study and identify ways to improve safety, quality, cost or process efficiency using lean manufacturing tools e.g. kaizen
  • Communication: How to share information using a range of methods within the manufacturing environment e.g. oral, written, electronic, information boards, visual displays
  • Workplace Organisation: How to maintain a safe and efficient work site through workplace organisation e.g. 5s and process ownership

Core Skills

A Lean Manufacturing Operative will have the skill and understanding to:

  • Health and Safety: Work safely at all times, complying with health and safety legislation, regulations, and other relevant guidelines. Identify risks within their processes and support/carry out counter-measure activities to improve safe working. Manage tooling, equipment and materials daily in-line with supplier standards e.g. COSHH (Control of Substances Hazardous to Health)
  • Environment: Comply with environmental procedures and systems and contribute to the achievement of specific standards e.g. ISO 14001 or other relevant environmental standards and use the 4Rs (Reduce, Re-use, Recycle, Recover) where possible
  • Production: Demonstrate the ability to carry out their role effectively, efficiently and flexibly, maintaining lean manufacturing principles to meet customers’ demands e.g. JIT
  • Lean Manufacturing Operations: Demonstrate their skill and knowledge following SOPs and building their versatility across a number of processes and process areas. Select and use appropriate tools, equipment and materials to carry out the manufacturing operation
  • Quality Control: Demonstrate appropriate process documentation control. Accurately complete check sheets, monitoring process and equipment data efficiently and legibly using the correct terminology required to meet the quality standard e.g. ISO 9002
  • Problem Solving: Demonstrate the ability to identify and resolve problems within the lean manufacturing environment using effective problem solving tools and techniques. Manage problems that may occur during the manufacturing process within the limits of their responsibility and escalate as appropriate
  • Continuous Improvement: Generate ideas and contribute to process improvement activities individually or as part of a team through fact finding and analysis to improve the safety, environment, quality, cost or production process. Identify and eliminate the 7 wastes (defects, over production, transportation, waiting, inventory, motion and processing)
  • Communication: Demonstrate communication skills which include oral, written, electronic (PC), information boards or visual displays to effectively share information
  • Workplace Organisation: Maintain and monitor the work site efficiently and effectively at all times using the elements of sifting, sorting, sweeping, spick and span (5s) within the lean manufacturing environment

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.

The apprenticeship will be delivered in the workplace.

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 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.

  • Level 2 Diploma in Manufacturing (Knowledge and Skills)
  • For Level 2 apprenticeships, apprentices without English and mathematics at Level 2 must achieve Level 1 English and mathematics and take the tests for Level 2 prior to taking their EPA
  • Portfolio of evidence

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.

Your EPA

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

• fail

• pass

Assessment method 2: Professional discussion

• fail

• pass

• distinction

Performance in the EPA will determine the overall apprenticeship standard grade of:

• fail

• pass

• distinction

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.

For more information contact Derby College on 0800 0280289 or enquiries@derby-college.ac.uk

Course Information for Employers

This Intermediate Apprenticeship for Lean Manufacturing is designed as a 12-month programme. It will equip apprentices with skills and knowledge to work safely and to high quality standards in a fast-paced and efficient processing environment. It will also allow them to develop to become a multi-skilled operator.

The apprentice 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, they 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).

They 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. They 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 the 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.

Individual employers will set the selection criteria for their apprenticeships. In order to optimise success, candidates will typically have three GCSEs at grade C, or equivalent, including Mathematics and English (grade 4 or above).

Employers who recruit candidates without English or Maths at grade C/4 or above must ensure that the candidate achieves this standard prior to the completion of the apprenticeship.

Your apprentice will need access to work that covers a broad range of activities depending on the requisite role defined. These elements will be discussed and defined during an assessor skill scan with yourself and the apprentice. 

You will also nominate a mentor to support the apprentice with the on-the-job training.

Core Behaviours Requirements

A Lean Manufacturing Operative requires the behaviours that will ensure they:

  • Are punctual, reliable and can take responsibility for their own actions
  • Show respect for others, having regard for diversity and equality
  • Respond positively to change in the working environment
  • Integrate within the team and support others
  • Can work independently and effectively in challenging situations.
  • Maintain quality of work under pressure
  • Are an open and honest communicator
  • Listen to other people’s opinions
  • Adopt a positive and respectful attitude
  • Follow instructions and guidance and demonstrate attention to detail
  • Seek opportunities to develop and adapt to different situations, environments or technologies.

They will receive an apprenticeship certificate on completion.

There are three elements that will be assessed throughout the apprenticeship: Knowledge, Skills and Behaviours.

Technical knowledge and coaching on-role and off-role (20% off-the-job) will need to be supported by you or your designated workplace mentor and your assessor. Pre-assessments will be undertaken to determine the apprentice’s competence in these areas as they progress through the apprenticeship, for which feedback will be reviewed and advised by you or your designated workplace mentor, your assessor and your apprentice. 

An apprentice must complete the approved qualification mandated in the lean manufacturing occupational standard and the below requisites in order to be entered for EPA.

  • Level 2 Diploma in Manufacturing (Knowledge and Skills).
  • For Level 2 apprenticeships, apprentices without English and mathematics at Level 2 must achieve Level 1 English and mathematics and take the tests for Level 2 prior to taking their EPA
  • Portfolio of evidence

The End Point Assessment 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. You or your designated workplace mentor must be satisfied (provide endorsement) that the apprentice is consistently working at or above the level set out in the occupational standard.

EPA

This must be completed within a typical period of 12 weeks after the apprentice has met the EPA gateway requirements.The EPA will be conducted by an external organisation approved to offer services against this apprenticeship standard, to be authorised by you as the employer.

The EPA will consist of two distinct assessment methods. 

The individual assessment methods will have the following grades: 

Assessment method 1: Observation with question and answers

• fail

• pass 

Assessment method 2: Professional discussion

• fail

• pass

• distinction 

Performance in the EPA will determine the overall apprenticeship standard grade of:

• fail

• pass

• distinction

The apprenticeship programme takes place entirely in the workplace.

Adequate workplace PPE will need to be provided by you. Your assessor will be able to confirm whether adequate PPE is in place and will support you with any questions about PPE provisioning.

There are numerous further professional qualifications they can take to advance their career. 

Examples of the job titles from across the manufacturing sector that would be covered within this standard are: 

Team Member – ProductionManufacturing Production Operative; Manufacturing Assembly Operative; Manufacturing Inspection/Quality Assurance Operative; Manufacturing Logistics Operative; Manufacturing Material Handling Operative; and Manufacturing Process/Finishing Operative.

You may already have someone in your organisation or someone has come to you direct asking for an apprenticeship, but if you don’t we have a free recruitment service to help you hire the best candidate for your organisation from our talent pool and external advertising through social media and the national apprenticeship services website

If you are an employer and you would like to know more, please email businessenquiries@derby-college.ac.uk or call 01332 387421

Career Information

This course could lead to one of these careers...

Production Managers and Directors in Manufacturing

£40466

Production Managers and Directors in Manufacturing

Quality Control and Planning Engineers

£34073

Quality Control and Planning Engineers

Production and Process Engineers

£40755

Production and Process Engineers

Engineering Professionals n.e.c.

£45110

Engineering Professionals n.e.c.

Plant and Machine Operatives n.e.c.

£33772

Plant and Machine Operatives n.e.c.

More Careers Information at: https://www.derby-college.ac.uk/career-pathways
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Course Information Last Updated On: November 4, 2021 11:06 am