Role Profile

Product Design & Development Technicians primarily work on all stages of product creation and modification. They support activities ranging from early concept feasibility, design and development stages right through to final preparation for launch and customers. This includes working in concept studios, rapid prototyping, assembly, testing, validating and analysing performance. Typically they
work closely with engineers in bring new concepts to life or supporting redesigns of existing products.

Specific Specialist Knowledge and Skills

Specific Specialist Knowledge:

• understand mathematical techniques, formula and calculations in a product design and development environment
• understand material applications and methods of testing (destructive and non- destructive)
• understand Computer Aided Design (CAD) methods and applications
• understand material joining applications and systems
• understand mechanical, electrical, electronic and process control systems
• understand measurement, monitoring, testing and diagnostic methods and techniques

Specific Specialist Skills:

• read and interpret relevant data and documentation used in the design and development of components, assemblies and systems
• produce components and prototypes using a wide range of hand fitting techniques
• produce assemblies and rigs using a range of materials and techniques
• use mechanical, electrical and electronic testing devices and equipment
• produce components and prototypes using a wide range of hand fitting techniques
• prepare and using lathes, milling machines, as well as other general or specialist high technology equipment such as 3D printing/additive manufacturing techniques
  produce assemblies and rigs using a range of materials and techniques
• use a range of mechanical, electrical and electronic testing devices and equipment
• apply mechanical principles and joining techniques to develop products, devices and equipment
• apply electrical and electronic principles to develop products devices and equipment
• identify, diagnose and rectify design problems through the whole creation process including design studio, workshops, test environments or under laboratory conditions
• contribute to the business by identifying possible opportunities for improving working practices, processes and/or procedures

Mandatory Qualifications

After a period of foundation skills and technical knowledge development all apprentices will be required to achieve the following qualifications:

• Level 2 Diploma in Advanced Manufacturing Engineering (Foundation Competence)
• Level 2 Award for Foundation Phase Gateway Assessment

After a further period of skills and technical knowledge development all apprentices will be required to achieve the following qualifications:

• Level 3 Diploma in Advanced Manufacturing Engineering (Development Competence) – Product  Design and Development

Plus one of the following

• Level 3 Diploma in Engineering Technology (QCF) – for starts up to June 2017 only
• Level 3 Extended Diploma in Engineering Technologies (QCF) – for starts up to June 2017 only
• Level 3 Diploma or Extended Diploma in Advanced Manufacturing Engineering (Development Knowledge) – for all starts from 1st July 2017

Role Profile

Toolmakers and Tool & Die Maintenance Technicians are predominantly involved in the highly skilled, complex and specialist detailed work of manufacturing and maintaining the engineering tooling used to produce components, products and assemblies. These products, assemblies and systems affect all of our daily lives, whether it be for travel such as (cars, planes, boats and rail) energy, defence, food, clothing, packaging and health including medical equipment, devices and implants such as joint replacements. This requires the application of a broad range of activities including the interpretation of Engineering drawings and technical instructions and the use of hand, machine and automated computer controlled machine tools and measuring equipment.
Technicians must comply with applicable legislation and organisational safety requirements and be expected to work both individually and as part of a manufacturing team, working with minimum supervision, taking responsibility for the quality and accuracy of the work they undertake. They will be proactive in finding solutions to problems and identifying ways to improve the business
They will be expected to test and adjust the systems they have built or maintained ensuring tooling, jigs, fixtures and assemblies meet the required specification. This requires the application of a broad range of skills, knowledge and occupational behaviours across a range of engineering disciplines.

Specific Specialist Knowledge and Skills

Specific Specialist Knowledge:

• understand mathematical techniques, formula and calculations in a Toolmaking environment
• understand the structure, properties and characteristics of common materials used for the manufacture and repair of tooling, Moulds, Dies and jigs and fixtures
• understand the safe operation, correct selection and the application of a range of hand tools used for toolmaking and die maintenance, including grinders, drills, stones etc.
• understand the safe operation and operating principles of a range of complex and often state of the art workshop machinery (such as CNC lathes, milling, grinding and erosion machining centres, drilling and welding equipment)
• understand how to set up and operate the machinery/equipment efficiently and effectively
• understand the principles of how the relevant tools, dies, jigs and fixtures being manufactured/maintained function, the operating sequences, the purpose of individual components/systems and how they interact
• Understand the application of pneumatics, hydraulics, electrical and electronic systems as applied to various moulding, injection, pressing and similar associated
  machinery.

Specific Specialist Skills:

• read and interpret relevant data and documentation used to produce and/or maintain tool and die components, assemblies and systems
• apply methods and techniques to produce, assemble, disassemble repair and/or maintain tools, dies, jigs and fixtures as applicable to the employer requirements
• manufacture components (such as tooling, dies, jigs and fixtures)
• undertake testing to confirm correct operation, and of the effectiveness of repairs and maintenance activities carried out.
• undertake equipment/asset care and/or Preventative Planned Maintenance processes and procedures
• Carry out complex fault diagnosis and repair activities covering the following technologies as applicable to the tool, die, jig and fixture environment:
  • Maintaining mechanical equipment
  • Maintaining fluid & pneumatic power equipment
  • Maintaining electrical & electronic equipment
  • Maintaining process control equipment

• contribute to the business by identifying possible opportunities for improving working practices, processes and/or procedures

Mandatory Qualifications

After a period of foundation skills and technical knowledge development all apprentices will be required to achieve the following qualifications:

• Level 2 Diploma in Advanced Manufacturing Engineering (Foundation Competence)

After a further period of skills and technical knowledge development all apprentices will be required to achieve the following qualifications:

• Level 3 Diploma in Advanced Manufacturing Engineering (Development Competence) – Toolmaker, Tool and Die Maintenance

Plus one of the following

• Level 3 Diploma in Engineering Technology (QCF) – for starts up to June 2017 only
• Level 3 Extended Diploma in Engineering Technologies (QCF) – for starts up to June 2017 only
• Level 3 Diploma or Extended Diploma in Advanced Manufacturing Engineering (Development Knowledge) – for all starts from 1st July 2017

Role Profile

Technical Support Technicians, work as part of a team to provide technical support and expertise for all areas of the Engineering and Manufacturing function including communications software, test, analysis tools, measurement, off line programming, process control, performance and continuous improvement solutions, capacity planning, production scheduling/planning, product technical applications and capability, technical sales and marketing support, product development and innovation, engineering drawing, purchasing and/or supply of goods or services for engineering activities, quality control, inspection and e-commerce technologies as required. The requirements are designed to offer stretch and progression. They will be able to work with minimum supervision, taking responsibility for the quality, accuracy and timely delivery of the work they undertake. They will be proactive in finding solutions to problems and identifying areas for improving the business.

Specific Specialist Knowledge and Skills

Specific Specialist Knowledge:

• understand mathematical techniques, formula and calculations used in a technical support environment
• understand the methods and techniques used to evaluate technical data and documentation
• understand how to identify that the data and documentation being used is current and up to date
• understand the procedure to be used for making changes to issued documentation
• understand where and how to source other areas of technical expertise/information to help solve technical problems
• understand the requirements of the customer (internal/external) and support using the appropriate tools, equipment and processes

Specific Specialist Skills:

• produce technical documentation that contains all the relevant and necessary data
  and information required for the technical support activity being carried out
• present the technical documentation in the required format
  ensure that codes, symbols and other references used in the technical
  documentation follows agreed uk/international conventions
• save and store technical documentation in the correct format, location in accordance with organisational and/or customer requirements
• make any changes/amendments to the technical documentation using agreed quality
• assurance control procedures
• develop effective business and/or customer relationships
• provide technical advice and guidance to others
• contribute to the business by identifying possible opportunities for improving working practices, processes and/or procedures

Plus one of the following:

• produce engineering/manufacturing production plans
• obtain resources for engineering/manufacturing activities
• obtain and control materials used in engineering/manufacturing environments
  implement quality control/assurance systems and procedures in an engineering/manufacturing environment
• provide technical support services on products or services to internal and/or external customers
• produce documentation to supply or procure goods or services
• produce off line programs for computer numerical controlled machines
• produce programs for scanning/digitizing or co-ordinate measuring machines
• produce programs for programmable logic control equipment
• produce programs for industrial robot applications
• produce engineering software tools/programs for analysis, quality, configuration management, safety assessments, system security applications
• produce engineering drawings/models using computer aided design techniques
  (such as mechanical, electrical, fabrication, fluid power, integrated systems or services)
• undertake complex fault diagnostic and/or condition monitoring activities on equipment, plant or services
• carry out inspection activities on equipment/components/systems (such as mechanical, electrical, electronic, welded and fabricated.
• check and calibrate control and test equipment used in an engineering and/or manufacturing environment

Mandatory Qualifications

After a period of foundation skills and technical knowledge development all apprentices will be required to achieve the following qualifications:

• Level 2 Diploma in Advanced Manufacturing Engineering (Foundation Competence)

After a further period of skills and technical knowledge development all apprentices will be required to achieve the following qualifications:

• Level 3 Diploma in Advanced Manufacturing Engineering (Development Competence) – Technical Support
• Level 3 Diploma or Extended Diploma in Advanced Manufacturing Engineering (Development Knowledge) – for all starts from 1st July 2017

Pathway – Mechatronics Maintenance Technician

Role Profile

Mechatronics Maintenance Technicians ensure that plant and equipment perform to the required standard to facilitate production targets regarding Safety, Quality, Delivery and Cost within High Value Manufacturing environments. Typically the work would cover a broad range of activities include installation, testing, fault finding and the on-going planned maintenance of complex automated equipment. This requires the application of a complex blend of skills, knowledge and occupational behaviours across the electrical, electronic, mechanical, fluid power and control systems disciplines.

Specific Specialist Knowledge and Skills

Specific Specialist Knowledge:

• understand mathematical techniques, formula and calculations in a mechatronics maintenance environment and the type of equipment being maintained
• understand mechanical, electrical, electronic, fluid power and process control principles in a mechatronics maintenance environment
• understand how equipment being maintained functions and operating parameters in individual components and how they interact
• understand fault diagnostic methods, techniques and equipment used when maintaining equipment and systems
• understand condition monitoring methods and equipment used and understand how the information gained supports the planning of maintenance activities
• understand how to minimise machinery downtime by implementing planned preventative maintenance programmes

Specific Specialist Skills:

• read and interpret relevant data and documentation used to maintain components, equipment and systems
• carry out condition monitoring of plant and equipment
• carry out planned maintenance activities on plant and equipment
• carrying out complex fault diagnosis and repair activities on high technology engineered systems such as:
  • Maintaining mechanical equipment
  • Maintaining fluid & pneumatic power equipment
  • Maintaining electrical & electronic equipment
  • Maintaining process control equipment
• carrying out confirmation testing and subsequent smooth hand over of equipment & plant support the installation, testing and commissioning of equipment (where applicable).
• contribute to the business by identifying possible opportunities for improving working practices, processes and/or procedures

Mandatory Qualifications

After a period of foundation skills and technical knowledge development all apprentices will be required to achieve the following qualifications

• Level 2 Diploma in Advanced Manufacturing Engineering (Foundation Competence)
• Level 2 Award for Foundation Phase Gateway Assessment

After a further period of skills and technical knowledge development all apprentices will be required to achieve the following qualifications:

• Level 3 Diploma in Advanced Manufacturing Engineering (Development Competence) – Mechatronics Maintenance Technician

Plus one of the following

• Level 3 Diploma in Engineering Technology (QCF) – for starts up to June 2017 only
• Level 3 Extended Diploma in Engineering Technologies (QCF) – for starts up to June 2017 only
• Level 3 Diploma or Extended Diploma in Advanced Manufacturing Engineering (Development Knowledge) – for all starts from 1st July 2017

Braintree: Level 2 competency duration and times: Full time attendance, 5 days a week for 18 weeks, 09.00-17.00

Level 2 competency units delivered and covered are:

• Complying with statutory regulations and organisational safety requirements
• Working efficiently and effectively in an engineering environment
• Using and communicating technical information
• Conducting business improvement activities
• Producing components using hand fitting techniques
• Preparing and using lathes for turning operations
• Preparing and using milling machines
• Wiring and testing electrical equipment and circuits
• Electronics, Control & Instrumentation
• Producing mechanical engineering drawings using a CAD system

Colchester: Level 2 competency duration and times: 2 days a week for 36 weeks, 09.00-17.00

Level 2 competency units covered are:

• Complying with statutory regulations and organisational safety requirements
• Working efficiently and effectively in an engineering environment
• Using and communicating technical information
• Conducting business improvement activities
• Producing components using hand fitting techniques
• Preparing and using lathes for turning operations
• Preparing and using milling machines
• Wiring and testing electrical equipment and circuits
• Preparing and using MIG/MAG equipment
• Producing mechanical engineering drawings using a CAD system

All learners will have to undertake a Level 2 gateway assessment which may require a 1 week block assessment.  Following this, learners shall attend at Colchester to study the modular delivery that occurs in each semester.

Colchester: Level 3 knowledge duration and times: 1 day a week, 36 weeks, 3 years, 09.00-17.00

Student will study the Level 3 Knowledge qualification, which is delivered for 1 day a week for 3 years and the Level 3 competency, which will be assessed in the work place.  Level 3 competency qualification units will be discussed and agreed with the employer.  A selection of the Level 3 knowledge qualification units taught include:

• Engineering and environmental health and safety
• Communication for engineering
• Engineering mathematics
• Projecting
• Mechanical principles
• Engineering materials
• Computer aided design (CAD)
• Organisational efficiency and improvement
• Engineering primary forming processes
• Engineering secondary and finishing techniques
• Fabrication processes and technology
• Electrical technology
• Electrical and electronic principles
• Features and applications of electrical machines
• Manufacturing planning
• Business operations in engineering

What knowledge and skills are covered?

• understanding the importance of complying with statutory, quality, organisational and health and safety regulations
• understanding of general engineering/manufacturing mathematical and scientific principles, methods, techniques, graphical expressions, symbols formulae and calculations used by engineering technicians
• understanding the structure, properties and characteristics of common materials used in the sector
• understanding the typical problems that may arise within their normal work activities/environment
• understanding approved diagnostic methods and techniques used to help solve engineering/manufacturing problems
• understanding the importance of only using current approved processes, procedures, documentation and the potential implications for the organisation if this is not adhered to
• understanding and interpreting relevant engineering/manufacturing data and documentation in order to complete their job role
• understanding the different roles and functions in the organisation and how they interact.
• understanding why it is important for an organisation to continually review their processes and procedures
• obtaining, checking and using the appropriate documentation (such as job instructions, drawings, quality control documentation)
• working safely at all times, complying with health, safety and environmental legislation, regulations and organisational requirements
• planning and where applicable obtaining all the resources required to undertake the work activity
• undertaking the work activity using the correct processes, procedures and equipment
• carrying out the required checks (such as quality, compliance or testing) using the correct procedures, processes and/or equipment
• dealing promptly and effectively with engineering/manufacturing problems within the limits of their responsibility using approved diagnostic methods and techniques and report those which cannot be resolved to the appropriate personnel
• completing any required documentation using the defined recording systems at the appropriate stages of the work activity
• restoring the work area on completion of the activity and where applicable return any resources and consumables to the appropriate location

What are the entry requirements?

Individual employers will set the selection criteria, but candidates will typically have 4 GCSEs at Grade C (4) or equivalent, including Mathematics, English and a Science subject

How often do I have to attend college?

College attendance of 2 day per week will be required for year one, with one day per week in years 2/3/4. This will be in conjunction with further assessment in the workplace. Our well-equipped workshops will allow apprentices to carry out practical work in a safe environment.

How will I be assessed?

College based assignments/examinations and accredited qualifications, work placed assessment in competency.

What can I do next?

Completion of the Apprenticeship is designed to be recognised by relevant Professional Engineering Institutions at the appropriate level of professional registration (EngTech). In the case of the Military specific pathway in the Aircraft Maintenance Fitter/Technician Standard, professional competence will be recognised by the Military Independent Assessment Authority (MIAA).

Possible progression into further training as a Higher Apprentice Level 4/5 or a Degree Apprenticeship level 6 with the support of a suitable employer.

How can I fit this apprentice into my business?

How is my business going to benefit from an Engineering Technician Apprentice?

Having an Apprentice employee that can demonstrate the following behaviours:

1. Personal responsibility, resilience and ethics. Comply with health and safety guidance and procedures, be disciplined and have a responsible approach to risk, work diligently at all times, accept responsibility for managing time and workload and stay motivated and committed when facing challenges. Comply with any organisational policies/codes of conduct in relation to ethical compliance
2. Work effectively in teams. Integrate with the team, support other people, consider implications of their actions on other people and the business
3. Effective communication and interpersonal skills. open and honest communicator, communicating clearly using appropriate methods, listening to others and have a positive and respectful attitude
4. Focus on quality and problem solving. Follow instructions and guidance, demonstrates attention to detail, follow a logical approach to problem solving and seek opportunities to improve quality, speed and efficiency
5. Continuous personal development. Reflect on skills, knowledge and behaviours and seeks opportunities to develop, adapt to different situations, environments or technologies and have a positive attitude to feedback and advice

What will this cost my business?

From April 2017 the way that government funds apprenticeships in England will be changing. All businesses operating within the UK with a wage bill of over £3 million will be required to contribute to the apprenticeship levy monthly via HMRC.

• If the levy applies to your business you will be required to pay 0.5% of your entire wage bill into the levy. This will be offset against a levy allowance worth £15,000 for each tax year
• You will only be able to use your levy payment for government backed apprenticeships through providers who are registered on the Register of Apprenticeship Training Providers
• Levy payments will expire after 18 months.

From April 2017 all existing apprenticeship frameworks and new apprenticeship standards (often referred to as trailblazer standards) will be allocated to Government funding bands.

Funding bands determine the maximum amount of money that Government will contribute for the training delivery and end-point assessment of each apprenticeship. All approved apprenticeship standards have already been allocated to funding bandings with maximum funding caps.

If you take on an apprentice who is between 16 and 18 years old at the start of their apprenticeship, you will receive a payment to help meet the extra costs of employing them. This will be paid to you through the training provider in two £500 instalments at 3 months and 12 months if the apprentice continues in learning beyond this point.

Non-levy paying employers will need to contribute 10% of the maximum funding band as published by the Skills Funding Agency for the delivery of training and assessment for their apprenticeship. Levy paying employers will pay the full cost of the agreed funding band using their Digital Apprenticeship account. Where there are no longer funds in this digital account the Government will co-invest 90% of the funding with the levy paying employer being the asked to contribute the remaining 10% on a monthly basis.

Levy paying employers can estimate their funding contributions through the use of the free Funding Apprenticeship Systems calculating tool.

The agreed funds will be taken from the employer’s digital account to pay the training provider, up to a maximum amount of funding allocated by Government to that particular apprenticeship.

For non-levy paying employers the Digital Apprenticeship Service will not be available until at least 2018. They will need to discuss and agree a price with their training provider.

Does the apprentice have to attend college?

College attendance of 2 day per week will be required for year one, with one day per week in years 2/3/4. This will be in conjunction with further assessment in the workplace. Our well-equipped workshops will allow apprentices to carry out practical work in a safe environment.

How is the apprentice assessed?

College based assignments/examinations and accredited qualifications, work placed assessment in competency.

What about support in the workplace?

Skilled and knowledgeable staff must be available to support the apprentice as they complete work- based tasks

Why should I choose Colchester Institute to support my recruitment and retention?

Our team will provide:

• A free recruitment service.
• Personal 1:1 Apprenticeship Levy advice and guidance.
• A dedicated Account Manager.
• Industry experienced, professional, technical tutors.
• Bespoke programmes available upon request.
• An Essex priority skills focus.
• Free employer events.