Apprenticeship training course

Science manufacturing process operative (level 2)

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Information about Science manufacturing process operative (level 2)

Operating science industry manufacturing equipment.

• Knowledge, skills and behaviours:
  View knowledge, skills and behaviours

  Knowledge

  • Process manufacturing definition. Types of process products across process industries. Types of employers. Types of customers.
  • Science manufacturing process operative role. Limits of responsibility.
  • Process industry safety: high-hazard sites and their potential impact, and The Control of Major Accident Hazards Regulations (COMAH).
  • Awareness of health and safety regulations and requirements and impact on role. Health and Safety at Work Act. Control of Substances Hazardous to Health (COSHH). Manual handling. Slips, trips, and falls. Situational awareness. Safety equipment: guards, signage, fire extinguishers.
  • Risk assessments and safe systems of work within process industries. Personal Protective Equipment (PPE). Isolation and emergency stop procedures.
  • Environment and sustainability regulations and role of the Environmental Agency. Types of pollution and control measures: noise, smells, spills, and waste. Efficient use of resources. Recycling. Waste reduction and waste streams.
  • Fundamentals of process chemistry: liquids, gases, and solids.
  • The effects of temperature, pressure, and flow on liquids, gases, and solids.
  • Awareness of process industry methods: measuring of raw ingredients and materials, blending, mixing, combining, melt processing, moulding, extrusion, and formulations.
  • Common science manufacturing industry plant, equipment, and tools: pumps, valves, temperature gauges, filtration equipment, tanks, vessels and production and processing machinery, and control systems; what they are and what they do. The importance of operational checks.
  • Automation and digitalisation of manufacturing processes and its benefits.
  • Standard operating procedures (SOP). What they are and why they are important.
  • Process and product specifications. Continuous and batch manufacturing. Manufacturing environments.
  • Quality assurance requirements and monitoring processes.
  • Basic continuous improvement techniques: 5 Why’s, 5S, KAIZEN.
  • Stock requirements: control systems, and stock rotation.
  • Work record requirements and importance of records for traceability and audits. Management information systems.
  • Verbal communication techniques.
  • Written communication techniques.
  • Information technology: digital manufacturing management systems, virtual learning platforms, word processing, and email. General data protection regulation (GDPR). Cyber security.
  • Work organisation and time management techniques.
  • Principles of team working.
  • Equality, diversity, and inclusion.

  Skills

  • Follow procedures in line with process industry health and safety regulations, standards, and guidance.
  • Follow procedures in line with process industry environmental and sustainability regulations, standards, and guidance.
  • Follow work instructions.
  • Follow process manufacturing standard operating procedures.
  • Conduct material preparation for example, measure, weigh, mix and load materials.
  • Check and set up science process industry tools, plant, or equipment.
  • Use science process industry tools, plant, or equipment required for task.
  • Monitor process manufacturing and take corrective actions to meet specification.
  • Apply product quality assurance procedures for example, take product samples, inspect products.
  • Conduct end of process procedures for example, finish, pack, label, discharge, move, and store batches.
  • Collect and interpret information.
  • Identify and resolve or report issues.
  • Store materials, monitor, and rotate stock.
  • Comply with housekeeping procedures for example, clean equipment and machinery, tidy work area.
  • Identify and segregate resources for reuse, recycling, and disposal.
  • Apply basic continuous improvement techniques for example, 5Why's, S5, and KAIZEN.
  • Perform simple calculations for example, raw material quantity and production calculations.
  • Record information (text and data) - paper based or electronic for example, quality control documentation, cleaning logs, handover notes, stock inventory systems.
  • Communicate with colleagues verbally.
  • Use information technology for example, digital manufacturing management systems, virtual learning platforms, word processing, and email. Comply with GDPR and cyber security procedures.
  • Apply team building principles.
  • Carry out and record learning and development.

  Behaviours

  • Put health and safety first.
  • Consider the environment.
  • Take ownership for quality of given work.
  • Adapt to changing work requests.
  • Team focus to meet work goals for example, work collaboratively.
  • Seek learning and development opportunities.
• Apprenticeship category (sector): Engineering and manufacturing
• Qualification level: 2; Equal to GCSE
• Course duration: 18 months
• Maximum funding: £6,000 ; Maximum government funding for ; apprenticeship training and assessment costs.
• Job titles include:
  • Applications operator
  • Aseptic operation process operator
  • Batch maker
  • Chemical plant process operator
  • Manufacturing process operator
  • Powder handling operative
  • Primary process operator
  • Process operator
  • Process support operator
  • Production process operator
  • Sterile operations process operator

View more information about Science manufacturing process operative (level 2) from the Institute for Apprenticeships and Technical Education.