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Lean Manufacturing Operative Level 2

Who is this course for?

This course is for any eligible candidates, who wish to earn a wage while developing their skills and knowledge needed to be able to pursue a career in the manufacturing sector.

As a Lean Manufacturing Operative, you will be expected to carry out your 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.  You could 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.

You will be required to prepare, control, contribute to and complete manufacturing operations, and follow manufacturing processes and standard operating procedures whilst adhering to specific safe working policies & procedures. You would work closely with stakeholders and will have clear reporting lines to ensure appropriate escalation.

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, which include:

  • Production/Assembly role
  • Inspection/Quality assurance role
  • Logistics/Material handling role 
  • Production processing/finishing role

Entry Requirements

Must be a UK citizen, or have the right of abode in the UK, or is a citizen of a country that is within the EEA and have been ordinarily resident in the UK, the EU or the EEA continuously for the previous three years before the start of learning.

Candidates will have achieved a minimum of GCSE Grade 2 (E) or equivalent Level 1 in English and Mathematics.  We also offer Functional Skills English and maths at Level 1 and Level 2 for those needing to gain these qualifications prior to enrolment.

Apprentices must be employed, normally for a minimum of 30 hours, in a role that suits the skills requirements of this apprenticeship. If you are not already employed, in this type of job role, you could search our apprenticeship vacancy page at:

New applicants will be contacted by a vocational delivery tutor to determine suitability/ eligibility prior, give information and advice on the next steps.

Shortlisted applicants will be sent to the employer, to then follow their recruitment procedure. Unsuitable applicants will be signed posted to other areas of our service to develop transferable/ employability skills, with a view to ensuring they are suitable for other apprenticeship positions in the future.

What is the curriculum intent of this apprenticeship?

The structure and delivery of the course curriculum will enable you to develop the skills, knowledge and behaviours to reflect the needs of local and regional employers, gain qualifications and be successful in this area.

The curriculum is planned and sequenced to enable learners with previous knowledge and experience to develop the new skills needed to progress to the next stage of their career, training, education or employment.

The curriculum is flexible and responsive to learner demands and can be tailored to suit individual needs, arising from any current and dynamic issues affecting their role, which can be addressed during workshop sessions.

As an apprentice you will need to be able to demonstrate knowledge and practical skills at the end of your apprenticeship training programme and understand how this reflects the needs of the local, regional and national economy.

What will the apprenticeship cover?

The Lean Manufacturing Operative Level 2 Apprenticeship will

Develop the 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.
  • Production: Their individual roles and responsibilities within the organisation and the flexibility required to deliver products to meet customers costs/delivery targets/requirements.
  • 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.
  • 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

Please note additional knowledge units will be worked towards, specific to the manufacturing route taken

Develop the skills in:

  • Health & Safety: Work safely always, 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.
  • Environmental: Comply with environmental procedures and systems and contribute to the achievement of specific standards.
  • Production: Demonstrate their ability to carry out their role effectively, efficiently, and flexibly maintaining lean manufacturing principles to meet customer’s demands.
  • Lean Manufacturing Operations: Demonstrate their skill and knowledge following SOPs and building their versatility across several 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.
  • 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.
  • Workplace 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.

Please note additional skills units will be worked towards, specific to the manufacturing route taken

Develop and demonstrate the following behaviours:

  • 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..

On completion of the on-programme element of the apprenticeship you will enter gateway to the End Point Assessment, which is the final assessment. This will be conducted by an independent end point assessor who will grade the assessment.

End Point Assessment methods

To trigger the End Point Assessment, you must:

  • Have proof of English & maths GCSE minimum grade 2/ E or equivalent level 1 qualification.
  • Have completed or have certified proof of Level 2 Diploma in Manufacturing.
  • Completed a showcase portfolio, demonstrating how you have met the knowledge, skills and behaviours.

The End Point Assessment consists of:

  • Observation of Practice – 120 mins observed in the workplace (this includes Q&A).
  • Professional discussion – 40 mins (underpinned with a portfolio of evidence).

This standard will be graded as Distinction, Pass or Fail.

What could I do when I finish my apprenticeship?

You may gain employment with your employer and / or work towards the Team Leader Level 3 Apprenticeship, depending on job role.

You will also be given information and guidance to continue onto other courses.

Where and when will I learn?

During the course you will be expected to, normally, attend work a minimum of 30 hours per week where you will learn the skills and knowledge required to continue through your qualification. This may include shift working, bank holiday working and weekend working. You will be supported in the workplace through regular visits with your tutor and you will also be expected to come into the training centre (Coleridge Centre, DL1 5AJ) for support sessions. These sessions will allow you to complete coursework, receive instant feedback and ensure you are ready for the End Point Assessment

This on-programme taught element will typically take 15 months, but this is based on a vocational initial assessment to determine prior learning in this area and may be reduced. The course duration is based on the apprentice working 30 hours per week but will be extended if the apprentice works less hours. The End Point Assessment will be completed within 3 months of completing the on-programme taught element.

How much will the apprenticeship cost?

There are no costs to the apprentice for this course

What do I do next?

If you are already employed in this area and wish to join the course, or have identified an employer wishing to start you as an apprentice in this area contact us on 01325 405601

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