Higher Apprenticeship Level 4 – Engineering Manufacture Technician

The broad purpose of the occupation is to provide specialist technical support for engineers, so that organisations can develop, produce or test new/existing products, processes, or procedures to meet a customer specification in terms of quality, cost and delivery, as efficiently and effectively as possible.  An Engineering Manufacture Technician will gather information and data from a range of sources and analyse the information/data. They will make decisions, solve problems and produce and/or update technical documentation, reports or specifications covering areas such as quality, reliability, production schedules/targets, costing or other technical documentation that informs others, either internally or externally what needs to be done such as how a product must be designed, manufactured, tested, modified, maintained, stored, transported, commissioned or decommissioned.

This occupation is found in large and small engineering and manufacturing organisations providing products and services throughout a wide range of sectors, such as Automotive, Aerospace/Airworthiness, Chemical Processing, Land Systems, Marine, Maritime Defence, Materials Manufacturers and their respective supply chains. Research indicates that the sector needs to recruit approximately 124,000 engineers and technicians every year.

Typical Engineering Manufacture Technician job titles Include, 

Manufacturing engineer quality, Manufacturing production engineer, Manufacturing procurement engineer, Quality engineer, Costing engineer, Test and commissioning engineer, Installation engineer, Process engineer, Production support engineer.

Occupational Profile

In their daily work, an employee in this occupation interacts with their line manager to confirm departmental programmes of work and to agree individual responsibilities. This in turn will align to an overarching organisational resource and delivery plan. Engineering Manufacturing  Technicians can be office based, manufacturing/plant based or more commonly combination of both, working with engineering and/or manufacturing teams at an operational level such as with production team leaders and/or management level working with specialist quality or design engineers. As well as liaising with internal colleagues, they may also be responsible for working directly with customers and/or suppliers or with representatives from appropriate regulatory bodies. Typically this would involve interaction with auditors to demonstrate compliance to specific organisational or regulatory requirements (such as Civil Aviation Authority).Their time will be spent between working in an office environment and working in the manufacturing environment or visiting customers or suppliers as and when required.

An employee in this occupation will be responsible for the quality, safety and delivery of the manufactured product or service, ensuring it is delivered to the customer on time at the agreed cost. They will typically report to an engineering or manufacturing manager as part of a cross functional team, the size of this team and responsibilities will vary depending on the size of the employer. Although working within defined quality processes and procedures, they are responsible for the delivery, quality and accuracy of the work they complete. They have the autonomy to use judgement when undertaking the occupational duties and applying their technical knowledge, skills and behaviours in a wide range of contexts and environments. They use a range of tools and techniques to support decision making and solve problems that are often complex and non-routine. They also have a responsibility to identify and contribute to making improvements such as business processes, procedures, ways and methods of working.

Occupational Duties

Occupation duties

Duty

KSBs

Duty 1 Ensure the safe and efficient performance of every production task in compliance with company procedures, approved engineering data and local Health and Safety requirements. Ensure Safe Systems of Work and risk assessments (assisting as necessary in the completion of risk assessments) are adhered to for engineering or manufacturing activities.K5 K7 K9 K10 K11 K13 K23

S8

B1 B5 B6 B7

Duty 2 Prepare product and process documentation by collecting, analysing, and summarising information and trends.K1 K6 K7 K9 K10 K11 K12 K14 K20 K21

S1 S3 S6 S7 S8 S9

B4 B6 B7

Duty 3 Manage internal and/or Supplier Quality Notifications, and liaison with the required stakeholders for resolution.K1 K2 K5 K7 K8 K9 K10 K11 K14

S1 S2 S3 S5 S6 S8

B1 B2 B3 B4 B5 B6 B7

Duty 4 Liaise with internal and external customers to implement programme initiatives, such as the application of lean analysis methods, processes and tools.K1 K2 K3 K4 K5 K6 K8 K9 K10 K11 K12 K14 K16 K17 K18 K19 K20 K23

S1 S2 S3 S4 S5 S6 S7 S8

B1 B2 B3 B4 B5 B6 B7

Duty 5 Carry out new product introduction and/or existing product modifications within engineering and/or manufacturing by contributing to activities such as facilitation of quality activities (including any testing and/or commissioning requirements), supplier approvals, gate reviews.K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K16 K17 K21 K22 K23

S1 S2 S3 S4 S5 S6 S7 S8 S10

B1 B2 B3 B4 B5 B6 B7

Duty 6 Deliver financial planning or costing analysis such as:- estimation of costs for manufacture, supplying drawings or specification for quotations, obtaining manufacture quotes, calculating costs associated with quality problem or  machine downtime.K2 K5 K6 K7 K9 K10 K11 K13 K14 K15 K19 K20 K21 K22 K23

S1 S2 S3 S4 S5 S6 S8 S9 S10

B1 B2 B3 B4 B5 B6

Duty 7 Develop new technology initiatives by contributing to activities such as, justifying capital investment equipment/system upgrades from purchase through to installation and commissioning.K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K19 K21 K23

S1 S2 S3 S4 S5 S6 S7 S8 S9

B1 B2 B3 B4 B5 B6 B7

Duty 8 Produce and maintain reports measuring Key Performance Indicators for data management activities.K2 K4 K5 K6 K8 K10 K13 K14 K15 K16 K17 K21 K22

S1 S2 S4 S5 S6 S7 S8 S9 S10

B1 B2 B6 B7

Duty 9 Ensure processes and current methods of engineering and manufacturing are as efficient and cost effective, such as:- utilising time and motion analysis, line balancing and flow to achieve the required level of production output.K1 K2 K3 K4 K5 K6 K9 K10 K11 K12 K15 K16 K17 K19 K20 K23

S1 S2 S3 S4 S5 S6 S8 S9 S10

B2 B3 B4 B5 B7

Duty 10 Liaise with appropriate internal and external stakeholders at all levels to ensure that engineering and manufacturing operations are completed in line with the agreed time scales. Examples of stakeholders could include production managers, production operatives, auditors, suppliers, customers.K1 K2 K3 K4 K6 K7 K8 K13 K14 K16 K17 K19

S1 S2 S3 S5

B1 B2 B4 B5 B6

Duty 11 Ensure work process and outcomes comply with any local, national and or international regulatory or compliance requirements. Such as :- maintain  compliance to Aerospace Regulatory bodies (CAA, EASA,MAA) as well as the wider regulations (such as Anti Bribery and Corruption, Export Control ).K5 K7 K9 K10 K11 K13 K14 K15 K16

S1 S3 S6

B1 B3 B4 B6 B7

Duty 12 Resolve identified engineering and/or manufacturing problems such as:- contributing to the route cause analysis exercise applying appropriate levels of containment and corrective action.K1 K2 K5 K6 K7 K8 K10 K14 K15 K16 K17 K20 K22

S1 S3 S5 S7

B2 B7

Duty 13 Produce engineering and/or manufacturing documentation (such as:- Build Manuals, Standard Operating Instructions/processes, Bill of Materials) to aid and ensure consistent, compliant and cost effective manufacturing processes.K7 K10 K14 K16 K17

S1 S5 S7

B2 B3

Duty 14 Review engineering or manufacturing methods to determine the most effective and economical method whilst meeting drawing/specification requirementsK2 K7 K14 K16 K17 K22 K23

S1 S7 S10

B2 B3 B6 B7

Knowledge | Skills | Behaviours

Knowledge

K1: Problem solving tools/techniques. Such as practical problem solving (PPS), root cause analysis (RCA) and process failure mode effects analysis (PFMEA).

K2: Effective communication techniques including listening, questioning and support of others.

K3: Use, benefits and applications of lean methods and tools used in manufacturing and engineering (such as Kaizen, Six Sigma and 8 wastes).

K4: How Industry 4.0 will impact organisations, including the integration of automation, digital systems and manufacturing engineering systems.

K5: Quality management systems used such as ISO9001, AS9100, ISO 14001 and TS16949, its purpose and internal governance arrangements to ensure compliance.

K6: Different manufacturing methods used, their applications, such as machining, joining, forming, assembling, shaping, processing, printing, moulding, extruding and casting)

K7: Principles of quality control and quality assurance in a manufacturing and engineering environment.

K8: Team integration techniques, including conflict resolution and managing difficult conversations (team working)

K9: Core engineering principles such as mathematics, science, mechanical and electrical/electronic applications relevant to manufacturing and engineering activity undertaken

K10: Importance for individuals to use and follow the organisations approved Standard Operating Procedures (SOP’s) and documentation recording systems and the potential implications on safety, quality and delivery if they are not adhered to.

K11: Statutory and organisation health and safety policies, procedures and regulations that must be adhered to in a manufacturing and engineering environment including the risk assessment process, procedures and documentation used within the work area.

K12: Project management techniques, such as Strengths, Weaknesses, Opportunities, Threats (SWOT), stakeholder matrices, risk mapping, radar chart and summary risk profiles.

K13: How human factors (organisational, environment and job factors) can influence and impact individual characteristics, performance and behaviours in the workplace.

K14: Engineering and manufacturing related documentation used such as job cards / build records, 2D & 3D drawing/models, Bill of Materials (BOM), Cost Analysis Reports, Compliance  Report, Standard Operating Instructions (SOI’s), Standard Process Instructions (POI’s), Engineering Query Notifications (EQN’s) and Drawing Query Notifications (DQN’s).

K15: Prioritisation of workload/time management techniques to ensure that personal and team objectives are achieved effectively.

K16: Engineering and manufacturing data collection systems used, their format and content.

K17: How organisations manage and monitor internal and or supplier performance to ensure that cost, quality, delivery and sustainability objectives are being delivered.

K18: Use and applications of common metallic and non – metallic materials used in manufacturing and engineering.

K19: Different production methods used and their applications such as single, batch, flow and mass.

K20: Different methods, tools and frequency used to check quality in manufacturing and engineering including measurements such as (dimensions, weight, signal, temperature, time,) and testing (such as non-destructive and destructive).

K21: Departmental process used to create, record and review financial data and information.

K22: The different applications and limitations of computer based software system/packages used such as Computer Aided Design (CAD), Data Analytics and Databases

K23: The impact of sustainability and environmental efficiency and how such matters influence manufacturing decisions.

Skills

S1 Read and extract relevant engineering and manufacturing related data and information (such as workplans/project plans ,schedules,  drawings, specifications, production data, quality reports, costing data, statistical information) drawing accurate conclusions and making informed decisions.

S2 Use project management tools, such as Strengths, Weaknesses, Opportunities, Threats (SWOT), stakeholder matrices, risk mapping, radar chart and summary risk profiles

S3 Use problem solving tools such as Root Cause Analysis (RCA) Process Failure Modes Effects Analysis (PFMEA), Fishbone, Practical Problem Solving (PPS) and Advanced Product Quality Planning (APQP).

S4 Analyse and interpret data and information in order to generate manufacturing engineering documentation such as Parts Per Million (PPM) quality adherence, cost analysis and test data.

S5 Communicate using the appropriate method for the audience such as, formal and informal presentations, written reports, verbal, electronic, social media and incorporating relevant and appropriate data and/or metrics.

S6 Use the approved process and quality compliance procedure to create or amend engineering and/or manufacturing documentation.

S7 Use lean tools and techniques, such as Six Sigma, 8 Wastes, Workplace organisation such as  5S’s (sort, set in order, shine, standardise and sustain), Kaizen and Poka-Yoke (Error proofing),

S8 Apply documentation control processes and procedures such as format, location, access, authorisation.

S9 Use financial planning, recording and review processes and documentation such as departmental budgets, estimating, cost control, cost forecasting, and investment appraisal

S10 Use computer based software system/packages such as Computer Aided Design (CAD), Data Analytics and Databases.

Behaviour

B1: Champions the importance of adherence to the organisation’s Environmental, Health and Safety management systems:- actively displays and promotes a safety first culture within the organisation.

B2: Operates in a systematic, proactive and transparent way.

B3: Actively promotes the case for the adoption of emerging and advanced engineering and manufacturing  technologies to optimise performance.

B4: Takes full responsibility for own professional development, seeking opportunities to enhance  knowledge, skills and experience. Keeping abreast of developments in engineering processes manufacturing and emerging technologies.

B5: Complies with statutory and organisational health & safety regulations and policies at all times. Accepts responsibility for their workload with a responsible approach to risk. Demonstrates a high level of motivation and resilience when facing challenge.

B6: Creates and maintains positive, professional, trusting and ethical  working relationships with their  team and the wider range of internal, external and connected stakeholders.

B7: Acts professionally with a positive and respectful attitude.

Qualifications

Mandatory Qualifications

All apprentices undertaking this apprenticeship (both those in the aerospace and non-aerospace sectors) must achieve:

Mandatory qualification: Higher National Certificate in Engineering or Level 4 Higher National Certificate in Manufacturing Operations

Ofqual regulated

Level of qualification: 4

English and maths qualifications

Apprentices without level 2 English and maths will need to achieve this level prior to taking the End-Point Assessment.  For those with an education, health and care plan or a legacy statement, the apprenticeship’s English and maths minimum requirement is Entry Level 3. A British Sign Language (BSL) qualification is an alternative to the English qualification for those whose primary language is BSL.

Professional recognition

IET / Eng Tech

IMechE / Eng Tech

Entry Requirements

Individual employers will set the selection criteria for their Apprenticeships. In order to optimise success candidates will typically have 5 GCSE’s at Grade C ( Grade 4/5 in the new numerical GCSE grading system) or above, including Mathematics, English and a Science, Technology or Engineering related subject, or 90+ credits in an Engineering BTEC at level 3. *(As further guidance, the level of Mathematics has an advisory GCSE level of grade B (Grade 5/6 in the new numerical GCSE grading system).

Attendance

In conjunction with assessment in the workplace, some college attendance at Colchester Institute will be required and this will be comfirmed post-application. Attendance and progress is closely monitored by the assessor towards the qualifications and your employer will be informed of any non-activity.

Assessment

This section sets out the requirements for end-point assessment (EPA) for the Engineering Manufacturing Technician apprenticeship standard. It is for end-point assessment organisations (EPAOs) who need to know how EPA for this apprenticeship must operate. It will
also be of interest to Engineering Manufacturing Technician apprentices, their employers and training providers.

Full time apprentices will typically spend 42 months on-programme (before the gateway) working towards the occupational standard, with a minimum of 20% off-the-job training. All apprentices must spend a minimum of 12 months on-programme.

The EPA period should only start, and the EPA be arranged, once the employer is satisfied that the apprentice is deemed to be consistently working at or above the level set out in the occupational standard, all of the pre-requisite gateway requirements for EPA have been met
and can be evidenced to an EPAO. Apprentices must prepare and submit a portfolio of evidence to support the EPA professional discussion.

As a gateway requirement, all apprentices must achieve the following qualification:

• Level 4 Higher National Certificate in Engineering or Level 4 Higher National Certificate
in Manufacturing Operations

End-point assessment (which will typically take three months)Assessment method 1:
Observation with questioningWith the following grades:
• fail
• passAssessment method 2:
Professional discussion supported by portfolio of evidence
With the following grades:
• fail
• pass
• distinction
Overall EPA/apprenticeship grade:
• fail
• pass
• distinction
Professional RecognitionAligns with recognition as Engineering Technician (EngTech)
by:
• Institute of Engineering and Technology (IET)
• Institute of Mechanical Engineers (IMechE)

Requirements in the Workplace

Students are required to be employed in a suitable work placement. Skilled and knowledgeable staff in the workplace will be necessary to support the apprentice.

How To Apply

To apply for an apprenticeship please read through the information below and then select the correct application button from the menu located further down the page.

If you are aged between 15 and 18 years old then please click the button ’15 – 18 Years – Apply Online’ and you will be taken to the next stage of the application process.

If you are aged 19 years or older please click the button ‘19+ Years – How to Apply‘, where you will be taken to the application options and information relevant to you.

Higher Apprenticeship Level 4 - Engineering Manufacture Technician
Course Outline: Designed to provide the manufacturing and engineering sector with high grade technicians and engineers

Starting employment as an apprentice can occur throughout the year however the start-date for attending college for training, where required, might vary depending on the type of apprenticeship and will be communicated post-employment and sign-up.

LevelLevel 4
LocationColchester
Duration42 months (this does not include EPA period)
CampusColchester Institute
Apprenticeship Funding Band (Levy paying employers)£21,000
Employer Contribution Fee (Non-levy paying employers)£1,050

Employer Information

Our Business Solutions team will work with you to recruit an Apprentice to your business, advertising the vacancy and managing applications, as well as providing a dedicated account manager and personal 1:1 advice and guidance on apprenticeships.

What will this cost my Business?

Non-levy paying employers will need to contribute 5% 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.

Apprenticeship Funding Bands

Apprenticeship Funding Bands
Employers with less than 50 employees who are recruiting an apprentice aged 16-18 years old will not be required to pay the contribution fee. Any associated cost to the individual will be made clear at the interview.

Disclaimer

All Fees and prices shown on this page are for courses starting in the 2020-21 academic year unless stated otherwise, and are correct at the time of entering/printing information, however these may be subject to change. The College cannot accept legal or financial liability as a result of any such changes.

The course information describes programmes offered by Colchester Institute. The College takes all reasonable steps to provide courses as described, but cannot guarantee provision. The information is for guidance and does not form any part of a contract.

The College reserves the right to update and amend information as and when necessary. Colchester Institute will do its best to provide the courses shown, but may have to modify or withdraw a course depending on customer demand and other factors.