The UK’s Manufacturing Industry is highly regarded worldwide for its innovation and manufacturing excellence and requires a high degree of skill & knowledge across all levels of their organisations.
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. team leader, 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 Production
- Manufacturing 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.
All learners will complete both on and off the job training elements for this standard and at the end of their programme will not only complete their Lean Manufacturing Operative Level 2 Apprenticeship but will also gain qualifications at Level 2 Diploma in Manufacturing (Knowledge & Skills). Dependent upon prior qualifications learners may also need to complete functional skills in Maths and English to a minimum of Level 1 and have taken the tests for Level 2.
- Off the Job Training Subjects Include:
- Health & Safety within a Manufacturing Environment
- Communicating and Working effectively within a Manufacturing Environment
- Working Relationships and Individual Rights & Responsibilities within a Manufacturing Environment
- Application of Workplace Organisation
- Work Related Problem Solving Techniques
For the On the Job training learners have the following subjects to select from subject to their individual requirements, qualification requirements and correlation to their job role:
- Preparing, Controlling or Concluding Manufacturing Operations
- Transferring or Receiving & Checking Materials for Manufacturing Operations
- Producing Products by Assembly or Processing Operations
- Finishing Operations
- Analysing the Results of Inspection and Confirming Quality of Production
- Carrying Out Inspection and Testing Activities
- Recording & Reporting Inspection and Test Results
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
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
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.