Lean Manufacturing Operative Apprenticeship

The Lean Manufacturing Operative Apprenticeship course combines developing your practical and theoretical skills at College, together with experience gained in the workplace.

This course is designed to give you the relevant training and education required to become a successful employee within engineering manufacture. Learning through practical and theory sessions at the College is teamed with work-based experience and training in order to achieve a level 2 in a specific trade or technical field.

The Manufacturing Industry offers an exciting and varied career both in the UK and abroad providing a broad spectrum of opportunities for people to work in a technically advanced and innovative environment.

Businesses within the sector range from small family run manufacturing operations to large multi-national companies driving the countries growth & wealth.

The UK’s Manufacturing Industry is highly regarded worldwide for its innovation and manufacturing excellence and requires a high degree of skill and knowledge across all levels of their organisations.

Occupational Role Profile

A Lean Manufacturing Operative will be expected to carry out their work safely and meet the exacting quality standards demanded in a fast paced and efficient processing environment and develop into a multi-skilled operator through process ownership.  A lean manufacturing operative can be required to carry out manufacturing activities on multiple products with different specifications consecutively e.g. automotive manufacturing – Multi models manufacturing results in the manufacturing of different models of vehicle with different specification variants within a high volume environment.

They 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 & procedures. A Lean Manufacturing Operative will be responsible for maintaining Health and Safety requirements at all times e.g. wearing correct Personal Protective Equipment (P.P.E.) correct use of equipment and tooling, safe stopping and resetting of machinery, maintain an organised work area e.g. 5s (Sifting, Sorting, Sweeping, Spick & Span and Sustain) ensuring the safe disposal of waste in line with environmental systems and regulatory requirements (ISO 14001). They will 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 be responsible for carrying 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).

They will work closely with stakeholders and will have clear reporting lines to ensure appropriate escalation e.g. teamleader, line leader, process leader, supervisor etc. should problems occur within the process.

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; Manufacturing Process/Finishing Operative.

A Lean Manufacturing Operative must have the core requirements below and demonstrate the specialist requirements in ONE job specific role.

Core Knowledge and Skills

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

  • Health & Safety: Relevant statutory, organisational and health and safety regulations relating to lean manufacturing operations and safe practices
  • Environmental: Compliance procedures/systems in line with regulatory requirements e.g. ISO 14001 or other relevant environmental standards
  • Production: Their individual roles 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 the 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
  • Work Place Organisation: How to maintain a safe and efficient work site through work place organisation e.g. 5s and process ownership

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

  • Health & Safety: Work safely at all times, complying with health and safety legislation, regulations, and other relevant guidelines. Identifying risks within their processes and support/carry out countermeasure 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).
  • Environmental: 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 4R’s (Reduce, Re-use, Recycle, Recover) where possible.
  • Production: Demonstrate their ability to carry out their role effectively, efficiently and flexibly maintaining lean manufacturing principles to meet customer’s 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 completing 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 their 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. Identifying and eliminating 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
  • Work Place Organisation: Maintains and monitors the work site efficiently and effectively at all times using the elements of sifting, sorting, sweeping, spick & span (5’s) within the lean manufacturing environment
Course Units
Health and safety within a manufacturing environment-4 weeks
Communicating and working effectively within a manufacturing environment-4 weeks
Working relationships and individual rights and responsibilities within a manufacturing environment-4 weeks
Application of workplace organisation-5 weeks
Work related problem solving techniques-5 weeks
Preparing for manufacturing operations-3 weeks
Controlling manufacturing operations-3 weeks
Producing products by processing-2 weeks x 5 days blocks
Specialist Job Roles

Specialist job roles:

The advanced manufacturing sector has developed to include a wide range of new technologies and can involve the manufacturing of a number of different products with different specifications at any given time. This can result in lean manufacturing operatives being required to carry out manufacturing activities on multiple products with different specifications consecutively e.g. automotive manufacturing – Multi model manufacturing results in  the manufacturing of different models of vehicle with different specification variants within a high volume manufacturing environment.

In addition to the core knowledge and skills Lean Manufacturing Operatives must complete ONE of the following job roles options:

Job role option 1: Lean Manufacturing Operatives working within a Production/Assembly role will be able to meet the requirements of two different production/assembly processes or assignments:

Knowledge of:

  • The importance of following the specified assembly sequence and procedure at all times
  • How to check the quality of the assembly, against the required quality standards and what tools and equipment are used
  • The procedure for positioning, aligning and securing component parts during the assembly operations
  • Where to obtain the necessary job instructions, operating procedures and assembly specifications that are used, and how to interpret them
  • How to Identify and resolve current and potential production/assembly problems within the limits of their responsibility

Skills that will require them to:

  • Check components for damage and that they are in a usable condition
  • Correctly position, align and secure the components
  • Secure the components in position using the specified fastening device/method
  • Obtain and follow the correct Job instructions/Standard operating procedures production/assembly specifications in accordance with time constraints and the roles and responsibilities identified for the production/assembly activity
  • Produce components which comply with the specification and quality requirements
  • Carryout quality checks on component parts and completed assemblies and deal with quality concerns and defects in line with their responsibility

 Job role option 2: Manufacturing Operatives working within an Inspection/Quality assurance role will have:

Knowledge of:

  • The correct methods of handling and storing the samples
  • Where to obtain the necessary job instructions, inspection/quality procedures and product specifications that are used, and how to interpret them
  • How to identify which samples, products and materials do not meet the quality requirements
  • Procedures for the handling and segregation of defect components
  • Specific safe working practices and environmental regulations that need to be observed

Skills that will require them to:

  • Obtain and follow the correct Job instructions, inspection/quality procedures and product specifications in accordance with time constraints and the roles and responsibilities identified for the inspection/quality assurance activity
  • Collect production samples at the required frequency in accordance with inspection specification and operating procedures
  • Carryout inspection and testing activities using the specified methods and equipment
  • Prepare, Handle, transfer and store samples safely and correctly in accordance with quality control procedures
  • Accurately interpret the data/results gained from the inspection and testing procedures being used
  • Record and report inspection findings to relevant person

 Job role option 3: Manufacturing Operatives working within a Logistics/Material handling role will be required to:

Knowledge of:

  • The procedures and documentation required to allow the transfer of materials to take place
  • Where to obtain the necessary job instructions, specification details and specific transfer/handling procedures that are used, and how to interpret them
  • The procedures for the movement and transferring of materials to the correct location within given timelines
  • What tools and equipment are used for the material movement operations undertaken and how to check that they are in a safe and usable condition
  • The lifting and handling procedures, and load bearing capacities of the equipment being used

Skills that will require them to:

  • Safely move materials to the correct location using the relevant equipment
  • Obtain and follow the correct Job instructions, specification details and specific transfer/handling procedures in accordance with time constraints and the roles and responsibilities identified for the logistic/material handling activity
  • Move materials using the appropriate procedures, ensuring the materials are correct, safely loaded and secure.
  • Check materials selected to be moved are in line with job requirements
  • Carryout quality checks on materials that are to be moved and deal with quality concerns and damage in line with their responsibility
  • Return equipment to its correct location on completion of the activities and leave it in a safe and usable condition

Job role option 4: Manufacturing Operatives working within a Production processing/finishing role will have:

Knowledge of:

  • What tools and equipment are used for the processing/finishing operations undertaken and how to check that they are in a safe and usable condition
  • Where to obtain the necessary job instructions, processing/finishing procedures and equipment operating procedures that are used, and how to interpret them
  • Specific safe working practices, processing/finishing procedures and environmental regulations that need to be observed
  • The procedure for the recovery or restart of manufacturing due to quality or process concern
  • The importance of following the pre-determined sequence of events in the processing/finishing operation and the consequences of not following them

Skills that will require them to:

  • Perform one processing/finishing operation method e.g. hand processing, manually operated machine processing, fully automated machine processing, combined processing
  • Obtain and follow the correct Job instructions, processing/finishing procedures and equipment operating procedures in accordance with time constraints and the roles and responsibilities identified for the processing/finishing activity
  • Perform the processing/finishing operation according to instructions and safe operating procedures
  • Monitor and control the processing/finishing operation
  • Carryout quality checks on component parts and completed assemblies and deal with quality concerns and defects in line with their responsibility
  • Produce processed/finished products which comply with processing specification
Entry Requirements

The candidate should be suitably employed within the engineering industry, and be dedicated and committed to their study. Applicants will be required to attend an interview where they will also be required to sit a paper based trade test and basic skills assessments in literacy and numeracy. Candidates should also have 4 GCSEs (grades A*-E), or equivalent, including English , maths and science.

 

What Can I Do Next?

Possible progression to a Level 3 Improvement technician, Level 3 Machinist or Level 3 Metal Fabricator. Our Advanced Engineering Apprenticeships can be found here.

Career pathways may include progression within technical and craft support roles, in industries where engineering processes are used. The general nature of the Performing Manufacturing Operations Level 2 NVQ can also allow for apprentices to move between and across manufacturing sectors.

Information for Applicants

Qualifications

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.

Other qualifications (Title / Level)

Level 2 Diploma in Manufacturing (Knowledge & Skills)

How often do I have to attend college?

College attendance will be required over the duration of the course and will be determined post-application.

Information for Employers

How is my business going to benefit from an Apprentice?

All Lean Manufacture Operative apprentices are expected to perform the following Core Behaviours Requirements in the workplace:

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

  • Punctual, reliable and takes responsibility for their own actions.
  • Show respect for others, having regard for diversity and equality.
  • Respond positively to change in the working environment.
  • Integrates within the team and supports others.
  • Can work independently and effectively in challenging situations.
  • Maintains quality of work under pressure.
  • An open and honest communicator.
  • Listens to other people’s opinions.
  • A positive and respectful attitude.
  • Follows instructions and guidance and demonstrates attention to detail.
  • Seeks opportunities to develop and adapt to different situations, environments or technologies.

What will this cost my business?

The introduction of the Apprenticeship Levy in April 2017 has changed the way that government funds apprenticeships in England. All businesses operating within the UK with a wage bill of over £3million are required to contribute to the apprenticeship levy.

  • 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.
  • Levy payments will expire after 18 months.

Speak to an advisor at CI Business Solutions on 01206 712727 to make your levy payments work for you.

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.

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.

As the largest college provider of apprenticeships in Essex, we can provide expert advice and guidance on all areas of apprenticeship provision, including helping you find the right apprenticeship for your business, recruiting apprentices, quality delivery and assessment with on-going support and advice.

Does the apprentice have to attend college?

College attendance will be required over the duration of the course and will be determined post-application.

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?

Colchester Institute is the largest college provider of apprenticeships in Greater Essex. We are expert at connecting the right people, to the right training, to the right business and when it comes to Apprenticeships, our Apprenticeship Advisors can support your business every step of the way.

As part of our service we can support your business with:

  • Advertising the Apprenticeship vacancy
  • Manage the applications received in line with your individual requirements
  • Match prospective candidates already known to us
  • Conduct initial pre-screening for candidates
  • Carry out visits to your premises alongside regular reviews to support you, your staff and your apprentice
  • Advice on any grants or funding where available

Our team will provide:

  • A fee 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.
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.

Lean Manufacturing Operative Apprenticeship
Course Outline: Provides the relevant training and education required to become a successful employee within engineering manufacture.

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 2
LocationColchester
DurationAm minimum of 12 months (this does not include EPA period)
CampusColchester Institute
Apprenticeship Funding Band (Levy paying employers)£6,000
Employer Contribution Fee (Non-levy paying employers)£300

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.