Lean Manufacturing Operative Apprenticeship

Streamline efficiency and profits

Level 2 Lean Manufacturing Operative (LMO)

Enhance production through Lean Manufacturing training

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 organisations.

Adopting a Lean Manufacturing philosophy within an organisation will optimise performance and enhance production. Lean Manufacturing is a methodology that, while always focusing on the customer, reduces waste leading to improved & efficient processes that improve customer satisfaction and can also increase profits.

The role of a Lean Manufacturing Operative

A Lean Manufacturing Operative apprentice will carry out their work safely and meet the quality standards demanded in a fast paced and efficient processing environment throughout and following their training. They will develop into a multi-skilled operator through process ownership. A lean manufacturing operative may be required to carry out activities on multiple products with different specifications consecutively. For example, in automotive manufacturing the Lean Manufacturing Multi models manufacturing results in the manufacturing of different models of vehicle with different specification variants within a high volume environment.

More information about the areas of responsibility can be found in our brochure.

“The cutting-edge qualification for today’s modern manufacturing industries”

Core knowledge

Apprentices will learn the following core knowledge:

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

Apprentices will learn the following core skills:

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

Core behavior

Apprentices will demonstrate the following core 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

This apprenticeship will take 12-18 months.

More information about the Lean Manufacturing Standards, including entry requirements, can be found here.

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