Apprenticeship Lean Manufacturing Operative ST0420 Standard Level 2

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