Level 2 Lean Manufacturing Operative

A 12-month programme

Programme Overview:

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 vehicles, with different specifications 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 and procedures. A Lean Manufacturing Operative 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) ensuring the safe disposal of waste in line with environmental systems and regulatory requirements (ISO 14001). The Lean Manufacturing Operative will be required to contribute, develop and support improvement in the manufacturing operations 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., Team Leader, Line Leader, Process Leader, Supervisor etc. should problems occur within the process.

The type of job roles across the manufacturing sector would include Team Member Production, Manufacturing Production Operative, Manufacturing Assembly Operative, Manufacturing Inspection/Quality Assurance Operative, Manufacturing Logistics Operative, Manufacturing Material Handling Operative, and Manufacturing Process/Finishing Operative.

Core Knowledge:

A Lean Manufacturing Operative will gain 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 Operative – Manufacturing standard operations 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 reports, 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 environments e.g., oral, written, electronic, information boards, and visual displays.
Work Plan 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 skills and understanding to:

Health and 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 countermeasures activities to improve safe working. Manage tooling, equipment and materials daily in-line with supplier standards e.g., COSSH (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 4Rs (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 the customer’s demand e.g., JIT.
Lean Manufacturing Operations – Demonstrate their skill and knowledge following SOPs and building their versality across a number of processes and process areas. Select and use appropriate tools, equipment and materials to carry out the manufacturing operations.
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 a lean manufacturing environment using effective problem solving 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 (5s) within the lean manufacturing environment.

Core Behaviours Requirements:

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

Punctual, reliable and takes responsibility for their own actions.
Shows 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.

Specialist job roles:

In addition to the core knowledge and skills Lean Manufacturing Operative 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 procedures 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 instruction/standard operating procedures production/assembly specification in accordance with time constraints and the roles and responsibilities identified for the production/assembly activity.
Produce components which comply with specification and quality requirements.
Carry out 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 samples.
Where to obtain the necessary job instructions, inspection/quality procedures and product specification 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 instruction, inspection/quality procedure 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.
Carry out 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.

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

Knowledge of:

The procedure 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 materials movement’s 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 material are correctly, safely loaded and secure.
Check materials selected to be moved are in line with job requirements.
Carry out 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 procedures 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.
Carry out 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 specifications.

How will it be assessed?

Full time work-based learners will typically spend 12/14 months on-programme working towards the apprenticeship standard, with a minimum of 20% off this time being off-the-job training.

Learners without English and Maths at a Level 2 must achieve Level 2 prior to taking their End Point Assessment (EPA).

The EPA should only start once the employer is satisfied that the gateway requirements for EPA have been met and that the learner is consistently working at or above the level set out in the standard.

Through the journey to the gateway with GEM Partnership you will complete a set of mini gateways ensuring that you are ready to take the EPA.

The EPA consists of three distinct assessment methods:

Assessment method 1 – observation with question and answer.
Assessment method 2 – professional discussion.

Performance in the EPA will determine the learner grade of fail, pass, merit or distinction.