Apply a process or processes to create products to a specification.
Process industry technicians are found in process manufacturing industries.
They run processes involving high hazard inputs to produce products that meet specifications. This may include chemical-based products, stabilised crude, ethane, butane, methane, and hydrogen. The working environment is highly controlled due to the use of high hazard chemicals. Technicians must follow high-level safety systems. Typically, production is on a large scale using a continuous process. This usually means operations are 24 hours per day, seven days per week. Technicians may be required to work shifts.
Technicians run and maintain the process or processes in line with operational parameters. They conduct quality assurance, resolving or escalating any issues, and complete records. Maintaining workplace safety by following health, safety and environmental risk and management systems is a vital part of the role. Preparing equipment for maintenance and bringing equipment back on line is also part of the role. They also support risk assessment, improvement activities, and audits.
On a daily basis, they work with other members of the process team. They also have contact with people in other teams for example, laboratory, maintenance, process engineering, supply chain, and warehouse. They may also have contact with external people such as, customers, service providers, and regulators.
They must ensure that the process and products meet quality specifications and are produced to schedule. They must work to external manufacturing regulations to protect the process, product, plant and equipment, company employees, and the environment. They must also consider sustainability. They may need to wear specialist PPE to protect the product or themselves. This may include, safety glasses, chemical resistant gloves, suits, and footwear, and breathing apparatus. They may work alone or part of a team. They work with minimal supervision, taking responsibility for the quality and accuracy of their work.
Oil and gas process technician
Petrochemical process technician
Plant technician
Process industry technician
Process manufacturing technician
Process technician
Production technician
This is a summary of the key things that you – the apprentice and your employer need to know about your end-point assessment (EPA). You and your employer should read the EPA plan for the full details. It has information on assessment method requirements, roles and responsibilities, and re-sits and re-takes.
An EPA is an assessment at the end of your apprenticeship. It will assess you against the knowledge, skills, and behaviours (KSBs) in the occupational standard. Your training will cover the KSBs. The EPA is your opportunity to show an independent assessor how well you can carry out the occupation you have been trained for.
Your employer will choose an end-point assessment organisation (EPAO) to deliver the EPA. Your employer and training provider should tell you what to expect and how to prepare for your EPA.
The length of the training for this apprenticeship is typically 36 months. The EPA period is typically 3 months.
The overall grades available for this apprenticeship are:
When you pass the EPA, you will be awarded your apprenticeship certificate.
The EPA gateway is when the EPAO checks and confirms that you have met any requirements required before you start the EPA. You will only enter the gateway when your employer says you are ready.
The gateway requirements for your EPA are:
Observation with questions
You will be observed by an independent assessor completing your work. It will last at least 3 hours. They will ask you at least 5 questions.
Interview underpinned by a portfolio of evidence
You will have an interview with an independent assessor. It will last at least 60 minutes. They will ask you at least 8 questions. The questions will be about certain aspects of your occupation. You need to compile a portfolio of evidence before the EPA gateway. You can use it to help answer the questions.
Multiple-choice test
You will complete a multiple-choice test. It will be closed book, meaning you will not have access to any books or reference materials.
In the test you can have:
The test will have 40 multiple-choice questions. You will have 60 minutes to complete it.
The EPAO will confirm where and when each assessment method will take place.
You should speak to your employer if you have a query that relates to your job.
You should speak to your training provider if you have any questions about your training or EPA before it starts.
You should receive detailed information and support from the EPAO before the EPA starts. You should speak to them if you have any questions about your EPA once it has started.
If you have a disability, a physical or mental health condition or other special considerations, you may be able to have a reasonable adjustment that takes this into account. You should speak to your employer, training provider and EPAO and ask them what support you can get. The EPAO will decide if an adjustment is appropriate.
This apprenticeship aligns with The Institution of Chemical Engineers (IChemE) for Engineering Technician (EngTech). Upon successful completion of the apprenticeship and receipt of the apprenticeship certificate, individuals are eligible to apply for EngTech through a shortened application route. It will need to confirm that the EngTech requirements have been met. Individuals also need to be a member of a professional body licensed by the Engineering Council to be awarded this status. Further information is on the IChemE’s website.
Process industry technicians are found in process manufacturing industries.
They run processes involving high hazard inputs to produce products that meet specifications. This may include chemical-based products, stabilised crude, ethane, butane, methane, and hydrogen. The working environment is highly controlled due to the use of high hazard chemicals. Technicians must follow high-level safety systems. Typically, production is on a large scale using a continuous process. This usually means operations are 24 hours per day, seven days per week. Technicians may be required to work shifts.
Technicians run and maintain the process or processes in line with operational parameters. They conduct quality assurance, resolving or escalating any issues, and complete records. Maintaining workplace safety by following health, safety and environmental risk and management systems is a vital part of the role. Preparing equipment for maintenance and bringing equipment back on line is also part of the role. They also support risk assessment, improvement activities, and audits.
On a daily basis, they work with other members of the process team. They also have contact with people in other teams for example, laboratory, maintenance, process engineering, supply chain, and warehouse. They may also have contact with external people such as, customers, service providers, and regulators.
They must ensure that the process and products meet quality specifications and are produced to schedule. They must work to external manufacturing regulations to protect the process, product, plant and equipment, company employees, and the environment. They must also consider sustainability. They may need to wear specialist PPE to protect the product or themselves. This may include, safety glasses, chemical resistant gloves, suits, and footwear, and breathing apparatus. They may work alone or part of a team. They work with minimal supervision, taking responsibility for the quality and accuracy of their work.
Oil and gas process technician
Petrochemical process technician
Plant technician
Process industry technician
Process manufacturing technician
Process technician
Production technician
Employers will set their own entry requirements. Typically, they require applicants to have GCSE science grade C or 4. An employer may require applicants to have a health screening to ensure suitability for working in some work environments.
| Duty | KSBs |
|---|---|
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Duty 1 Run and maintain process industry plant and equipment in line with operational parameters. For example, pressures, flows, temperatures, levels, production targets, and specification. |
K4 K13 K14 K16 K22 K25 K26 K27 K28 K29 K30 K31 K32 K33 K34 K35 K36 K37 K39 |
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Duty 2 Maintain the work area following health, safety, environmental and risk management systems. |
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Duty 3 Resolve and report, or escalate, process, quality, health and safety, environment, and operating environment issues when operating out of normal parameters. For example, out of specification parameter. |
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Duty 4 Undertake quality assurance processes. |
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Duty 5 Conduct dispatch of intermediate product or final processed product. |
K4 K13 K14 K16 K22 K25 K26 K27 K28 K29 K30 K31 K32 K33 K34 K36 K37 K39 |
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Duty 6 Conduct handover responsibilities - receiving information from or providing information to other shifts or maintenance teams. |
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Duty 7 Complete process documentation - digital or paper based. For example, process and production records, traceability records, and quality assurance records. |
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Duty 8 Conduct first line routine maintenance and testing of process and plant equipment. |
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Duty 9 Prepare plant for shutdown for example, for maintenance, overall, and decommissioning. |
K4 K13 K14 K22 K23 K25 K26 K27 K28 K29 K30 K31 K32 K33 K34 K36 K37 K39 |
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Duty 10 Bring process industry equipment back on-line. |
K4 K13 K14 K22 K24 K25 K26 K27 K28 K29 K30 K31 K32 K33 K34 K36 K37 K39 |
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Duty 11 Participate in risk assessment activities. |
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Duty 12 Participate in continuous improvement activities. |
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Duty 13 Support audits - internal or external. For example, supply information. |
K1: Science process manufacturing sector awareness: range of products, manufacturing environments, types of customers.
Back to Duty
K2: Role and limits of responsibility. Escalation procedures. Impact of operators’ competence on product quality. Change control requirement.
Back to Duty
K3: Health and safety regulations, standards, and guidance: Control of Substances Hazardous to Health (COSHH), Dangerous Substances and Explosive Atmospheres Regulations (DSEAR), Electrical safety and compliance, Fire safety, Health and Safety at Work Act – responsibilities, incident and near miss reporting and investigation, Lifting Operations and Lifting Equipment Regulations (LOLER), Legionella, Lone working, Management of health and safety at work, Manual handling, Noise regulation, Permits to work, Provision and Use of Work Equipment Regulations (PUWER), Safety signage and purpose, Slips trips and falls, The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR), Working in confined spaces, and Working at height.
Back to Duty
K4: Control of Major Accident Hazards (COMAH) regulation and impact on workplaces.
Back to Duty
K5: Science process manufacturing safety hazards – risks they pose and their management: temperature, pressure, and vapours. Risk assessment and safe systems of work. Personal Protective Equipment (PPE) requirements.
Back to Duty
K6: Emergency procedures.
Back to Duty
K7: Health and safety management systems; key performance indicators (KPIs) and learning from incidents.
Back to Duty
K8: Environmental hazards that can arise from process. Hierarchy of control.
Back to Duty
K9: Environmental management systems standard. Environmental Protection Act. Environmental signage and notices.
Back to Duty
K10: Principles of sustainability and circular economy. Resource (energy, water, and waste) efficiency and reuse of materials. Principles of control and management of emissions and waste.
Back to Duty
K11: Planning, prioritising, and time management techniques.
Back to Duty
K12: Continuous and batch techniques. Production requirements: product specification, processing specification, rate of production. Material safety data sheet, product labelling and product codes; the importance of identifying non-conforming materials and products. Overall Equipment Effectiveness (OEE). Stock control. Current Good Manufacturing Practice (cGMP).
Back to Duty
K13: Standard operating procedures (SOP) - what they are and why they are important.
Back to Duty
K14: Standard operating conditions (SOC) - what they are and why they are important.
Back to Duty
K15: Documentation requirements: documentation control, auditable records.
Back to Duty
K16: Main factors influencing quality assurance in industrial process industries. Quality standards.
Back to Duty
K17: Principles of laboratory quality procedures: calibration requirements for quality control, representative sampling, and common methods of analysis.
Back to Duty
K18: How customer feedback can be used to assess quality performance. Purpose of audits. Non-conformance reports (NCR). Corrective Action Preventive Action (CAPA).
Back to Duty
K19: Common faults and causes in processing: flow, blockages, instrumentation failures, seals and human factors.
Back to Duty
K20: Problem solving and fault-finding techniques: root cause analysis, 5-Whys.
Back to Duty
K21: Continuous improvement (CI) systems and techniques.
Back to Duty
K22: Different types of maintenance activities: preventative and reactive.
Back to Duty
K23: Requirements for shutting down and preparing for maintenance.
Back to Duty
K24: Requirements for bringing equipment back from maintenance.
Back to Duty
K25: Purpose and operation of process industry equipment.
Back to Duty
K26: Process control systems and their constituent components.
Back to Duty
K27: Uses of water in and around the plant. Types of water: raw, treated, demineralized; uses, differences, and composition. Water purification requirements and methods.
Back to Duty
K28: Common process manufacturing principles: distillation, phase separation, crystallisation, and drying.
Back to Duty
K29: The thermal and flow properties of solids, liquids, and gases.
Back to Duty
K30: The structure of atoms, elements, and compounds - chemical symbols that represent them.
Back to Duty
K31: Fundamental scientific laws to the construction and use of balanced chemical equations.
Back to Duty
K32: Solutions, solubility, and solubility curves.
Back to Duty
K33: The application and importance of electrochemical principles.
Back to Duty
K34: The structure, classification, and properties of carbon compounds and polymers.
Back to Duty
K35: The structure and properties of elements, mixtures, compounds, crystals, and alloys.
Back to Duty
K36: The importance of chemical equilibrium and energy changes in reactions involved in manufacturing processes.
Back to Duty
K37: Electrochemical principles - electrolysis and galvanic corrosion, their applications and importance.
Back to Duty
K38: Numerical approximations and unit conversion tables. Areas, volumes, and pressure and flow rates calculations. Statistical data.
Back to Duty
K39: Conventions for drawings and graphical information.
Back to Duty
K40: Information and digital technology to support process industry operations. Cyber security requirements.
Back to Duty
K41: General data protection regulation (GDPR).
Back to Duty
K42: Written communication techniques. Technical report writing techniques.
Back to Duty
K43: Verbal communication techniques.
Back to Duty
K44: Principles of team working. Principles of equality, diversity, and inclusion in the workplace.
Back to Duty
S1: Review instructions or information to understand the task.
Back to Duty
S2: Plan tasks. Identify and organise resources with consideration for safety, environmental impact, quality, and cost.
Back to Duty
S3: Identify hazards and risks in the workplace and personal safety and mitigation measures.
Back to Duty
S4: Apply health, safety, and environmental procedures in compliance with regulations, standards, and guidance.
Back to Duty
S5: Follow environment emergency procedures. For example, make area safe, evacuate.
Back to Duty
S6: Apply sustainability principles for example, minimising waste.
Back to Duty
S7: Apply standard operating procedures (SOPs).
Back to Duty
S8: Check equipment.
Back to Duty
S9: Select, check, and prepare raw materials for process for example, weighing, measuring, control and blending, conditioning, dissolving, and sanitisation.
Back to Duty
S10: Set and adjust processing parameters such as temperature, pressure, speed or time, distance.
Back to Duty
S11: Monitor process for example, take readings and conduct walk-arounds.
Back to Duty
S12: Conduct the control of product streams to maintain specifics.
Back to Duty
S13: Apply quality assurance procedures. For example, density checks, contaminant check, and take samples for laboratory testing.
Back to Duty
S14: Apply intermediate or post-manufacturing procedure for example, labelling, packing, storage, visual inspection, discharge.
Back to Duty
S15: Manage waste streams.
Back to Duty
S16: Clean equipment for example, boil-outs, steam-outs, bake-outs, steam in place SIP, clean in place (CIP).
Back to Duty
S17: Conduct calculations for example, conversations, tare weight, charge weights, yield calculations.
Back to Duty
S18: Store tools and equipment.
Back to Duty
S19: Identify equipment for handover.
Back to Duty
S20: Apply signage and access restriction measures.
Back to Duty
S21: Shut down the process and equipment.
Back to Duty
S22: Isolate process and systems.
Back to Duty
S23: Complete isolation checks.
Back to Duty
S24: Empty equipment for example, drain, purge, vent, and de-pressure.
Back to Duty
S25: Purge, fill, pressurise and leak test.
Back to Duty
S26: Complete post maintenance equipment checks.
Back to Duty
S27: Line-up equipment.
Back to Duty
S28: Connect service connections such as water, electrical, pneumatic, hydraulic for chemical or petrochemical processing.
Back to Duty
S29: De-isolate process, mechanical and electrical systems.
Back to Duty
S30: Complete pre-start up checks.
Back to Duty
S31: Start-up plant and equipment.
Back to Duty
S32: Re-start process.
Back to Duty
S33: Record or enter information - paper based or electronic.
Back to Duty
S34: Interpret data for example, process data, quality control and test procedure data.
Back to Duty
S35: Interpret drawings and graphs.
Back to Duty
S36: Identify issues for example, defects, deviations, process variance, and maintenance requirements.
Back to Duty
S37: Escalate issues outside limits of responsibility.
Back to Duty
S38: Apply problem solving and fault-finding techniques.
Back to Duty
S39: Apply continuous improvement techniques. Make a suggestion for improvement.
Back to Duty
S40: Use information and digital technology for example, management information systems, human machine interfaces, word processing, spreadsheet, email, virtual learning platforms, document sharing platforms. Comply with cyber security requirements.
Back to Duty
S41: Produce written documents for example, handover notes or emails, non-conformances, design change requests.
Back to Duty
S42: Communicate with others verbally for example, colleagues and stakeholders.
Back to Duty
S43: Apply team working principles.
Back to Duty
S44: Plan how to meet personal development needs. Carry out and record planned and unplanned learning and development (CPD) activities.
Back to Duty
B1: Prioritise health, safety, and environment.
Back to Duty
B2: Consider sustainability when using resources and carrying out processes.
Back to Duty
B3: Team-focus to meet work goals including support for equality, diversity and inclusion.
Back to Duty
B4: Take responsibility for the quality of their own work.
Back to Duty
B5: Respond and adapt to work demands.
Back to Duty
B6: Committed to continued professional development.
Back to Duty
Apprentices without level 2 English and maths will need to achieve this level prior to taking the End-Point Assessment. For those with an education, health and care plan or a legacy statement, the apprenticeship’s English and maths minimum requirement is Entry Level 3. A British Sign Language (BSL) qualification is an alternative to the English qualification for those whose primary language is BSL.
This standard aligns with the following professional recognition:
V1.0
This document explains the requirements for end-point assessment (EPA) for the process industry manufacturing technician apprenticeship. End-point assessment organisations (EPAOs) must follow this when designing and delivering the EPA.
Process industry manufacturing technician apprentices, their employers and training providers should read this document.
A full-time process industry manufacturing technician apprentice typically spends 36 months on-programme. The apprentice must spend at least 12 months on-programme and complete the required amount of off-the-job training in line with the apprenticeship funding rules.
The EPA should be completed within an EPA period lasting typically 3 months.
The apprentice must complete their training and meet the gateway requirements before starting their EPA. The EPA will assess occupational competence.
An approved EPAO must conduct the EPA for this apprenticeship. Employers must select an approved EPAO from the apprenticeship provider and assessment register (APAR).
This EPA has 3 assessment methods.
The grades available for each assessment method are below.
Assessment method 1 - observation with questions:
Assessment method 2 - interview underpinned by a portfolio of evidence:
Assessment method 3 - multiple-choice test:
The result from each assessment method is combined to decide the overall apprenticeship grade. The following grades are available for the apprenticeship:
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On-programme - typically 36 months
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The apprentice must:
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End-point assessment gateway
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The apprentice’s employer must be content that the apprentice is occupationally competent. The apprentice must:
For the interview underpinned by a portfolio of evidence, the apprentice must submit a portfolio of evidence.
Gateway evidence must be submitted to the EPAO, along with any organisation specific policies and procedures requested by the EPAO. |
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End-point assessment - typically 3 months
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The grades available for each assessment method are below
Observation with questions:
Interview underpinned by a portfolio of evidence:
Multiple-choice test:
Overall EPA and apprenticeship can be graded:
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Professional recognition
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This apprenticeship aligns with:
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Re-sits and re-takes
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The EPA is taken in the EPA period. The EPA period starts when the EPAO confirms the gateway requirements have been met and is typically 3 months.
The EPAO should confirm the gateway requirements have been met and start the EPA as quickly as possible.
The apprentice’s employer must be content that the apprentice is occupationally competent. That is, they are deemed to be working at or above the level set out in the apprenticeship standard and ready to undertake the EPA. The employer may take advice from the apprentice's training provider, but the employer must make the decision. The apprentice will then enter the gateway.
The apprentice must meet the gateway requirements before starting their EPA.
They must:
Portfolio of evidence requirements:
The apprentice must compile a portfolio of evidence during the on-programme period of the apprenticeship. It should only contain evidence related to the KSBs that will be assessed by this assessment method. It will typically contain 10 discrete pieces of evidence. Evidence must be mapped against the KSBs. Evidence may be used to demonstrate more than one KSB; a qualitative as opposed to quantitative approach is suggested.
Evidence sources may include:
This is not a definitive list; other evidence sources can be included.
The portfolio of evidence should not include reflective accounts or any methods of self-assessment. Any employer contributions should focus on direct observation of performance for example, witness statements rather than opinions. The evidence provided should be valid and attributable to the apprentice; the portfolio of evidence should contain a statement from the employer and apprentice confirming this.
The EPAO should not assess the portfolio of evidence directly as it underpins the interview. The independent assessor should review the portfolio of evidence to prepare questions for the interview. They are not required to provide feedback after this review.
Gateway evidence must be submitted to the EPAO, along with any organisation specific policies and procedures requested by the EPAO.
The assessment methods can be delivered in any order.
The result of one assessment method does not need to be known before starting the next.
In the observation with questions, an independent assessor observes the apprentice in their workplace and asks questions. The apprentice completes their day-to-day duties under normal working conditions. It gives the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method.
This assessment method is being used because:
The observation with questions must be structured to give the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method to the highest available grade.
An independent assessor must conduct and assess the observation with questions.
The independent assessor must only observe one apprentice at a time to ensure quality and rigour. They must be as unobtrusive as possible.
The EPAO must give the apprentice 2 weeks' notice of the observation with questions.
The observation must take 3 hours.
The independent assessor can increase the time of the observation with questions by up to 10%. This time is to allow the apprentice to complete a task or respond to a question if necessary.
The observation may be split into discrete sections held on the same working day.
The EPAO must manage invigilation of the apprentice during the assessment, to maintain security of the EPA, in line with their malpractice policy. This includes breaks and moving between locations.
The independent assessor must explain to the apprentice the format and timescales of the observation with questions before it starts. This does not count towards the assessment time.
The independent assessor should observe the apprentice conducting the following during the observation:
The following KSBs may be assessed using simulation if they do not occur naturally:
The EPAO must make arrangements for this with the employer if required.
These activities provide the apprentice with the opportunity to demonstrate the KSBs mapped to this assessment method.
The independent assessor must ask questions. Questioning can occur both during and after the observation.
The purpose of the questions is to assess the level of competence against the grading descriptors.
The time for questioning is included in the overall assessment time. The independent assessor must ask at least 5 questions. To remain as unobtrusive as possible, the independent assessor should ask questions during natural stops between tasks and after completion of work rather than disrupting the apprentice’s flow. The independent assessor must use the questions from the EPAO’s question bank or create their own questions in line with the EPAO’s training. Follow-up questions are allowed where clarification is required.
The independent assessor must ask questions about KSBs that were not observed to gather assessment evidence. These questions are in addition to the above set number of questions for the observation with questions and should be kept to a minimum.
The independent assessor must make the grading decision. The independent assessor must assess the observation and responses to questions holistically when deciding the grade.
The independent assessor must keep accurate records of the assessment. They must record:
The observation with questions must take place in the apprentice’s normal place of work for example, their employer’s premises or a customer’s premises. Equipment and resources needed for the observation must be provided by the employer and be in good and safe working condition.
Questioning that occurs after the observation should take place in a suitable environment, for example a quiet room, free from distractions and influence.
The EPAO must develop a purpose-built assessment specification and question bank. It is recommended this is done in consultation with employers of this occupation. The EPAO must maintain the security and confidentiality of EPA materials when consulting with employers. The assessment specification and question bank must be reviewed at least once a year to ensure they remain fit-for-purpose.
The assessment specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this.
The EPAO must produce the following materials to support the observation with questions:
The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation and moderation.
In the interview, an independent assessor asks the apprentice questions. It gives the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method.
The apprentice can refer to and illustrate their answers with evidence from their portfolio of evidence.
This assessment method is being used because:
The interview must be structured to give the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method to the highest available grade.
An independent assessor must conduct and assess the interview.
The purpose of the independent assessor's questions is to assess the apprentice against the following themes:
The EPAO must give an apprentice 2 weeks' notice of the interview.
The independent assessor must have at least 2 weeks to review the supporting documentation.
The apprentice must have access to their portfolio of evidence during the interview.
The apprentice can refer to and illustrate their answers with evidence from their portfolio of evidence however, the portfolio of evidence is not directly assessed.
The interview must last for 60 minutes. The independent assessor can increase the time of the interview by up to 10%. This time is to allow the apprentice to respond to a question if necessary.
The independent assessor must ask at least 8 questions. The independent assessor must use the questions from the EPAO’s question bank or create their own questions in line with the EPAO’s training. Follow-up questions are allowed where clarification is required.
The independent assessor must make the grading decision.
The independent assessor must keep accurate records of the assessment. They must record:
The interview must take place in a suitable venue selected by the EPAO for example, the EPAO’s or employer’s premises.
The interview can be conducted by video conferencing. The EPAO must have processes in place to verify the identity of the apprentice and ensure the apprentice is not being aided.
The interview should take place in a quiet room, free from distractions and influence.
The EPAO must develop a purpose-built assessment specification and question bank. It is recommended this is done in consultation with employers of this occupation. The EPAO must maintain the security and confidentiality of EPA materials when consulting with employers. The assessment specification and question bank must be reviewed at least once a year to ensure they remain fit-for-purpose.
The assessment specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this.
The EPAO must ensure that the apprentice has a different set of questions in the case of re-sits or re-takes.
The EPAO must produce the following materials to support the interview underpinned by a portfolio of evidence:
The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation and moderation.
In the multiple-choice test, the apprentice answers questions in a controlled and invigilated environment. It gives the apprentice the opportunity to demonstrate the knowledge mapped to this assessment method.
This assessment method is being used because:
The multiple-choice test must be structured to give the apprentice the opportunity to demonstrate the knowledge mapped to this assessment method to the highest available grade.
The test can be computer or paper based.
The test will consist of 40 multiple-choice questions.
Multiple-choice questions must have four options, including one correct answer.
The apprentice must be given at least 2 weeks’ notice of the date and time of the test.
The apprentice must have 60 minutes to complete the test.
The test is closed book which means that the apprentice cannot refer to reference books or materials whilst taking the test.
The following equipment is allowed to be used during the test:
The test must be taken in the presence of an invigilator who is the responsibility of the EPAO. The EPAO must have an invigilation policy setting out how the test must be conducted. It must state the ratio of apprentices to invigilators for the setting and allow the test to take place in a secure way.
The EPAO must verify the apprentice’s identity and ensure invigilation of the apprentice for example, with 360-degree cameras and screen sharing facilities.
The EPAO is responsible for the security of the test including the arrangements for on-line testing. The EPAO must ensure that their security arrangements maintain the validity and reliability of the test.
The test must be marked by an independent assessor or marker employed by the EPAO. They must follow a marking scheme produced by the EPAO. Marking by computer is allowed where question types support this.
A correct answer gets 1 mark.
Any incorrect or missing answers get zero marks.
The EPAO is responsible for overseeing the marking of the test.
The apprentice must take the test in a suitably controlled and invigilated environment that is a quiet room, free from distractions and influence. The EPAO must check the venue is suitable.
The test could take place remotely if the appropriate technology and systems are in place to prevent malpractice.
The EPAO must develop a purpose-built assessment specification and question bank. It is recommended this is done in consultation with employers of this occupation. The EPAO should maintain the security and confidentiality of EPA materials when consulting with employers. The assessment specification and question bank must be reviewed at least once a year to ensure they remain fit-for-purpose.
The assessment specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this.
The EPAO must ensure that the apprentice has a different set of questions in the case of re-sits or re-takes.
The EPAO must produce the following materials to support the test:
The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation and moderation.
Fail - does not meet pass criteria
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Theme
KSBs
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Pass
The apprentice must demonstrate all of the pass descriptors for the core and their option
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Distinction
The apprentice must demonstrate all of the pass and distinction descriptors for the core and their option
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Organise work
K11 S1 S2 |
Reviews instructions or information to understand the task's requirements. (S1) Plans tasks and identifies and organises resources required to complete it using planning, prioritising, and time management techniques with consideration for safety, environmental impact, quality, and cost. (K11, S2) |
The balance of safety, environmental impact, quality, and cost factors in their planning decisions is justified. (K11, S2) |
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Maintain the work area
K5 K8 S3 S4 S18 B1 |
Identifies health and safety and environmental hazards and risks in the workplace, and personal safety and mitigation measures with consideration of hierarchy of control. Prioritises and applies health, safety, and environmental procedures in compliance with regulations, standards and guidance mitigating against risks including use of personal protective equipment. Stores tools and equipment safety in line with company procedures. (K5, K8, S3, S4, S18, B1) |
Explains the importance of applying health, safety and environmental procedures in their work. (K5, K8, S4) |
|
Run and maintain process
K14 K25 K26 S8 S10 S11 S20 |
Checks equipment in line with company procedures. Monitors process or processes and sets and adjusts processing parameters on process industry equipment, using process control system and its constituent components, to meet standard operating conditions in line with standard operating procedures. (K14, K25, K26, S8, S10, S11) Applies signage and access restriction measures in line with task requirements and company procedures. (S20) |
Justifies their approach for monitoring and setting and adjusting process parameters in terms of effectiveness or efficiencies of practice and the impact of their actions on others. (S10, S11)
|
|
Conduct process industry quality assurance
K16 S13 B4 |
Takes responsibility for the quality of their own work by applying quality assurance procedures in line with quality standards that take account of the main factors influencing quality assurance in industrial process industries. (K16, S13, B4) |
Explains the importance of applying quality assurance procedures to support quality standards. (K16, S13) |
|
Complete process documentation
K15 S33 |
Records or enters data for work tasks - paper based or electronic - in line with company procedures for documentation control and auditable records. (K15, S33) |
None |
|
Communicate with others
K43 S42 |
Uses verbal communication techniques suitable for the context. (K43, S42) |
None |
Fail - does not meet pass criteria
|
Theme
KSBs
|
Pass
The apprentice must demonstrate all of the pass descriptors for the core and their option
|
Distinction
The apprentice must demonstrate all of the pass and distinction descriptors for the core and their option
|
|---|---|---|
|
Role and responsibilities
K2 S37 B5 |
Describes their role as a science process manufacturing technician including their limits of responsibility, how they escalate issues, and how they respond and adapt to work demands in line with organisational requirements. Outlines the impact of an operator’s competence on product quality. Outlines change control requirements and why they are important. (K2, S37, B5) |
None |
|
Emergency procedures
K6 S5 |
Describes what they would do in an environmental emergency situation in line with company procedures. (K6, S5) |
None |
|
Sustainability
K10 S6 B2 |
Describes how they consider and apply the principles of sustainability and the circular economy when using resources and carrying out processes including resource efficiency, reuse of materials, and recycling and control of emissions and waste. (K10, S6, B2) |
Explains how they have supported the development or implementation of sustainability practice in the workplace beyond their role for example, through promoting good practice to others, identifying improvement to practice. (S6, B2) |
|
Process industry operations
K13 S7 S9 S12 S14 S15 S16 |
Describes how they select, check, and prepare raw materials for process in line with task requirements and SOPs. Describes how they conduct the control of product streams to maintain specifics in line with task requirements and SOPs. Describes how they manage waste streams in line with SOPs. Describes how they clean equipment in line with SOPs. Describes how they apply intermediate or post-manufacturing procedures in line with task requirements. (K13, S7, S9, S12, S14, S15, S16) |
Evaluates the impact of non-conformity in applying SOPs within role and wider organisation. (K13, S7) |
|
Shutting down for maintenance
K23 S19 S21 S22 S23 S24 |
Describes how they prepare for shutting down for maintenance in line with their company's procedures, including:
(K23, S19, S21, S22, S23, S24) |
None |
|
Bringing back from maintenance
K24 S25 S26 S27 S28 S29 S30 S31 S32 |
Describes how they bring equipment back from maintenance in line with their company's procedures including:
(K24, S25, S26, S27, S28, S29, S30, S31, S32) |
None |
|
Problem solving and fault finding
K19 K20 S36 S38 |
Describes how they identify issues and apply problem solving and fault-finding techniques to establish the root cause of common faults in processing including flow, blockages, instrumentation failures, seals, and human factors. (K19, K20, S36, S38) |
Assesses the value of specific fault-finding and problem solving techniques for different issues. (K19, K20, S36, S38) |
|
Continuous improvement
K21 S39 |
Describes how they have applied continuous improvement (CI) techniques and a made a viable suggestion for improvement in their work to support CI systems. (K21, S39) |
Justifies the potential impact of the improvement suggestion with consideration to benefits and any potential risks. (K21, S39) |
|
Written communication
K42 S41 |
Describes how they apply written communication and report writing techniques to produce communications in their work suitable for context. (K42, S41) |
None |
|
Information and digital technology
K40 S40 |
Describes how they use information and digital technology in work tasks in compliance with cyber security requirements. (K40, S40) |
None |
|
Teamwork
K44 S43 B3 |
Describes how they apply team working principles to meet work goals in line with their company's policy on equality, diversity, and inclusion. (K44, S43, B3) |
Justifies how their team focus approach helped to achieve a positive outcome in a team activity. (K44, S43, B3) |
|
Continued professional development
S44 B6 |
Describes the planned and unplanned learning and development (CPD) activities they have carried out and recorded to meet personal development needs, showing a commitment to future CPD. (S44, B6) |
None |
| Grade | Minimum marks required | Maximum marks required |
|---|---|---|
| Fail | 0 | 27 |
| Pass | 28 | 40 |
Performance in the EPA determines the overall grade of:
An independent assessor must individually grade the observation with questions and interview underpinned by a portfolio of evidence in line with this EPA plan.
The EPAO must combine the individual assessment method grades to determine the overall EPA grade.
If the apprentice fails one assessment method or more, they will be awarded an overall fail.
To achieve an overall pass, the apprentice must achieve at least a pass in all the assessment methods. To achieve an overall EPA merit, the apprentice must achieve a distinction in one assessment method (observation with questions, or interview underpinned by a portfolio of evidence), and a pass in the other two assessment methods. To achieve an overall EPA distinction, the apprentice must achieve a distinction in the observation with questions, a distinction in the interview underpinned by a portfolio of evidence, and a pass in the multiple-choice test.
Grades from individual assessment methods must be combined in the following way to determine the grade of the EPA overall.
| Observation with questions | Interview underpinned by a portfolio of evidence | Multiple-choice test | Overall Grading |
|---|---|---|---|
| Any grade | Any grade | Fail | Fail |
| Any grade | Fail | Any grade | Fail |
| Fail | Any grade | Any grade | Fail |
| Pass | Pass | Pass | Pass |
| Distinction | Pass | Pass | Merit |
| Pass | Distinction | Pass | Merit |
| Distinction | Distinction | Pass | Distinction |
If the apprentice fails one assessment method or more, they can take a re-sit or a re-take at their employer’s discretion. The apprentice’s employer needs to agree that a re-sit or re-take is appropriate. A re-sit does not need further learning, whereas a re-take does. The apprentice should have a supportive action plan to prepare for a re-sit or a re-take.
The employer and the EPAO should agree the timescale for a re-sit or re-take. A re-sit is typically taken within 2 months of the EPA outcome notification. The timescale for a re-take is dependent on how much re-training is required and is typically taken within 4 months of the EPA outcome notification.
Failed assessment methods must be re-sat or re-taken within a 6-month period from the EPA outcome notification, otherwise the entire EPA will need to be re-sat or re-taken in full.
Re-sits and re-takes are not offered to an apprentice wishing to move from pass to a higher grade.
The apprentice will get a maximum EPA grade of if pass they need to re-sit or re-take one or more assessment methods, unless the EPAO determines there are exceptional circumstances.
| Roles | Responsibilities |
|---|---|
|
Apprentice |
As a minimum, the apprentice should:
|
|
Employer |
As a minimum, the apprentice's employer must:
|
|
EPAO |
As a minimum, the EPAO must:
|
|
Independent assessor |
As a minimum, an independent assessor must:
|
|
Training provider |
As a minimum, the training provider must:
|
|
Marker |
As a minimum, the marker must:
|
|
Invigilator |
As a minimum, the invigilator must:
|
The EPAO must have reasonable adjustments arrangements for the EPA.
This should include:
Adjustments must maintain the validity, reliability and integrity of the EPA as outlined in this EPA plan.
Special considerations
The EPAO must have special consideration arrangements for the EPA.
This should include:
Special considerations must maintain the validity, reliability and integrity of the EPA as outlined in this EPA plan.
Internal quality assurance refers to the strategies, policies and procedures that an EPAO must have in place to ensure valid, consistent and reliable EPA decisions.
EPAOs for this EPA must adhere to the requirements within the roles and responsibilities table.
They must also appoint independent assessors who:
Affordability of the EPA will be aided by using at least some of the following:
This apprenticeship aligns with:
| Knowledge | Assessment methods |
|---|---|
|
K1
Science process manufacturing sector awareness: range of products, manufacturing environments, types of customers. Back to Grading |
Multiple-choice test |
|
K2
Role and limits of responsibility. Escalation procedures. Impact of operators’ competence on product quality. Change control requirement. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K3
Health and safety regulations, standards, and guidance: Control of Substances Hazardous to Health (COSHH), Dangerous Substances and Explosive Atmospheres Regulations (DSEAR), Electrical safety and compliance, Fire safety, Health and Safety at Work Act – responsibilities, incident and near miss reporting and investigation, Lifting Operations and Lifting Equipment Regulations (LOLER), Legionella, Lone working, Management of health and safety at work, Manual handling, Noise regulation, Permits to work, Provision and Use of Work Equipment Regulations (PUWER), Safety signage and purpose, Slips trips and falls, The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR), Working in confined spaces, and Working at height. Back to Grading |
Multiple-choice test |
|
K4
Control of Major Accident Hazards (COMAH) regulation and impact on workplaces. Back to Grading |
Multiple-choice test |
|
K5
Science process manufacturing safety hazards – risks they pose and their management: temperature, pressure, and vapours. Risk assessment and safe systems of work. Personal Protective Equipment (PPE) requirements. Back to Grading |
Observation with questions |
|
K6
Emergency procedures. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K7
Health and safety management systems; key performance indicators (KPIs) and learning from incidents. Back to Grading |
Multiple-choice test |
|
K8
Environmental hazards that can arise from process. Hierarchy of control. Back to Grading |
Observation with questions |
|
K9
Environmental management systems standard. Environmental Protection Act. Environmental signage and notices. Back to Grading |
Multiple-choice test |
|
K10
Principles of sustainability and circular economy. Resource (energy, water, and waste) efficiency and reuse of materials. Principles of control and management of emissions and waste. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K11
Planning, prioritising, and time management techniques. Back to Grading |
Observation with questions |
|
K12
Continuous and batch techniques. Production requirements: product specification, processing specification, rate of production. Material safety data sheet, product labelling and product codes; the importance of identifying non-conforming materials and products. Overall Equipment Effectiveness (OEE). Stock control. Current Good Manufacturing Practice (cGMP). Back to Grading |
Multiple-choice test |
|
K13
Standard operating procedures (SOP) - what they are and why they are important. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K14
Standard operating conditions (SOC) - what they are and why they are important. Back to Grading |
Observation with questions |
|
K15
Documentation requirements: documentation control, auditable records. Back to Grading |
Observation with questions |
|
K16
Main factors influencing quality assurance in industrial process industries. Quality standards. Back to Grading |
Observation with questions |
|
K17
Principles of laboratory quality procedures: calibration requirements for quality control, representative sampling, and common methods of analysis. Back to Grading |
Multiple-choice test |
|
K18
How customer feedback can be used to assess quality performance. Purpose of audits. Non-conformance reports (NCR). Corrective Action Preventive Action (CAPA). Back to Grading |
Multiple-choice test |
|
K19
Common faults and causes in processing: flow, blockages, instrumentation failures, seals and human factors. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K20
Problem solving and fault-finding techniques: root cause analysis, 5-Whys. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K21
Continuous improvement (CI) systems and techniques. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K22
Different types of maintenance activities: preventative and reactive. Back to Grading |
Multiple-choice test |
|
K23
Requirements for shutting down and preparing for maintenance. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K24
Requirements for bringing equipment back from maintenance. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K25
Purpose and operation of process industry equipment. Back to Grading |
Observation with questions |
|
K26
Process control systems and their constituent components. Back to Grading |
Observation with questions |
|
K27
Uses of water in and around the plant. Types of water: raw, treated, demineralized; uses, differences, and composition. Water purification requirements and methods. Back to Grading |
Multiple-choice test |
|
K28
Common process manufacturing principles: distillation, phase separation, crystallisation, and drying. Back to Grading |
Multiple-choice test |
|
K29
The thermal and flow properties of solids, liquids, and gases. Back to Grading |
Multiple-choice test |
|
K30
The structure of atoms, elements, and compounds - chemical symbols that represent them. Back to Grading |
Multiple-choice test |
|
K31
Fundamental scientific laws to the construction and use of balanced chemical equations. Back to Grading |
Multiple-choice test |
|
K32
Solutions, solubility, and solubility curves. Back to Grading |
Multiple-choice test |
|
K33
The application and importance of electrochemical principles. Back to Grading |
Multiple-choice test |
|
K34
The structure, classification, and properties of carbon compounds and polymers. Back to Grading |
Multiple-choice test |
|
K35
The structure and properties of elements, mixtures, compounds, crystals, and alloys. Back to Grading |
Multiple-choice test |
|
K36
The importance of chemical equilibrium and energy changes in reactions involved in manufacturing processes. Back to Grading |
Multiple-choice test |
|
K37
Electrochemical principles - electrolysis and galvanic corrosion, their applications and importance. Back to Grading |
Multiple-choice test |
|
K38
Numerical approximations and unit conversion tables. Areas, volumes, and pressure and flow rates calculations. Statistical data. Back to Grading |
Multiple-choice test |
|
K39
Conventions for drawings and graphical information. Back to Grading |
Multiple-choice test |
|
K40
Information and digital technology to support process industry operations. Cyber security requirements. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K41
General data protection regulation (GDPR). Back to Grading |
Multiple-choice test |
|
K42
Written communication techniques. Technical report writing techniques. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K43
Verbal communication techniques. Back to Grading |
Observation with questions |
|
K44
Principles of team working. Principles of equality, diversity, and inclusion in the workplace. Back to Grading |
Interview underpinned by a portfolio of evidence |
| Skill | Assessment methods |
|---|---|
|
S1
Review instructions or information to understand the task. Back to Grading |
Observation with questions |
|
S2
Plan tasks. Identify and organise resources with consideration for safety, environmental impact, quality, and cost. Back to Grading |
Observation with questions |
|
S3
Identify hazards and risks in the workplace and personal safety and mitigation measures. Back to Grading |
Observation with questions |
|
S4
Apply health, safety, and environmental procedures in compliance with regulations, standards, and guidance. Back to Grading |
Observation with questions |
|
S5
Follow environment emergency procedures. For example, make area safe, evacuate. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S6
Apply sustainability principles for example, minimising waste. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S7
Apply standard operating procedures (SOPs). Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S8
Check equipment. Back to Grading |
Observation with questions |
|
S9
Select, check, and prepare raw materials for process for example, weighing, measuring, control and blending, conditioning, dissolving, and sanitisation. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S10
Set and adjust processing parameters such as temperature, pressure, speed or time, distance. Back to Grading |
Observation with questions |
|
S11
Monitor process for example, take readings and conduct walk-arounds. Back to Grading |
Observation with questions |
|
S12
Conduct the control of product streams to maintain specifics. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S13
Apply quality assurance procedures. For example, density checks, contaminant check, and take samples for laboratory testing. Back to Grading |
Observation with questions |
|
S14
Apply intermediate or post-manufacturing procedure for example, labelling, packing, storage, visual inspection, discharge. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S15
Manage waste streams. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S16
Clean equipment for example, boil-outs, steam-outs, bake-outs, steam in place SIP, clean in place (CIP). Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S17
Conduct calculations for example, conversations, tare weight, charge weights, yield calculations. Back to Grading |
Multiple-choice test |
|
S18
Store tools and equipment. Back to Grading |
Observation with questions |
|
S19
Identify equipment for handover. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S20
Apply signage and access restriction measures. Back to Grading |
Observation with questions |
|
S21
Shut down the process and equipment. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S22
Isolate process and systems. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S23
Complete isolation checks. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S24
Empty equipment for example, drain, purge, vent, and de-pressure. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S25
Purge, fill, pressurise and leak test. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S26
Complete post maintenance equipment checks. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S27
Line-up equipment. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S28
Connect service connections such as water, electrical, pneumatic, hydraulic for chemical or petrochemical processing. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S29
De-isolate process, mechanical and electrical systems. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S30
Complete pre-start up checks. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S31
Start-up plant and equipment. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S32
Re-start process. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S33
Record or enter information - paper based or electronic. Back to Grading |
Observation with questions |
|
S34
Interpret data for example, process data, quality control and test procedure data. Back to Grading |
Multiple-choice test |
|
S35
Interpret drawings and graphs. Back to Grading |
Multiple-choice test |
|
S36
Identify issues for example, defects, deviations, process variance, and maintenance requirements. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S37
Escalate issues outside limits of responsibility. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S38
Apply problem solving and fault-finding techniques. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S39
Apply continuous improvement techniques. Make a suggestion for improvement. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S40
Use information and digital technology for example, management information systems, human machine interfaces, word processing, spreadsheet, email, virtual learning platforms, document sharing platforms. Comply with cyber security requirements. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S41
Produce written documents for example, handover notes or emails, non-conformances, design change requests. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S42
Communicate with others verbally for example, colleagues and stakeholders. Back to Grading |
Observation with questions |
|
S43
Apply team working principles. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S44
Plan how to meet personal development needs. Carry out and record planned and unplanned learning and development (CPD) activities. Back to Grading |
Interview underpinned by a portfolio of evidence |
| Behaviour | Assessment methods |
|---|---|
|
B1
Prioritise health, safety, and environment. Back to Grading |
Observation with questions |
|
B2
Consider sustainability when using resources and carrying out processes. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
B3
Team-focus to meet work goals including support for equality, diversity and inclusion. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
B4
Take responsibility for the quality of their own work. Back to Grading |
Observation with questions |
|
B5
Respond and adapt to work demands. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
B6
Committed to continued professional development. Back to Grading |
Interview underpinned by a portfolio of evidence |
| KSBS GROUPED BY THEME | Knowledge | Skills | Behaviour |
|---|---|---|---|
|
Organise work
K11 S1 S2 |
Planning, prioritising, and time management techniques. (K11) |
Review instructions or information to understand the task. (S1) Plan tasks. Identify and organise resources with consideration for safety, environmental impact, quality, and cost. (S2) |
None |
|
Maintain the work area
K5 K8 S3 S4 S18 B1 |
Science process manufacturing safety hazards – risks they pose and their management: temperature, pressure, and vapours. Risk assessment and safe systems of work. Personal Protective Equipment (PPE) requirements. (K5) Environmental hazards that can arise from process. Hierarchy of control. (K8) |
Identify hazards and risks in the workplace and personal safety and mitigation measures. (S3) Apply health, safety, and environmental procedures in compliance with regulations, standards, and guidance. (S4) Store tools and equipment. (S18) |
Prioritise health, safety, and environment. (B1) |
|
Run and maintain process
K14 K25 K26 S8 S10 S11 S20 |
Standard operating conditions (SOC) - what they are and why they are important. (K14) Purpose and operation of process industry equipment. (K25) Process control systems and their constituent components. (K26) |
Check equipment. (S8) Set and adjust processing parameters such as temperature, pressure, speed or time, distance. (S10) Monitor process for example, take readings and conduct walk-arounds. (S11) Apply signage and access restriction measures. (S20) |
None |
|
Conduct process industry quality assurance
K16 S13 B4 |
Main factors influencing quality assurance in industrial process industries. Quality standards. (K16) |
Apply quality assurance procedures. For example, density checks, contaminant check, and take samples for laboratory testing. (S13) |
Take responsibility for the quality of their own work. (B4) |
|
Complete process documentation
K15 S33 |
Documentation requirements: documentation control, auditable records. (K15) |
Record or enter information - paper based or electronic. (S33) |
None |
|
Communicate with others
K43 S42 |
Verbal communication techniques. (K43) |
Communicate with others verbally for example, colleagues and stakeholders. (S42) |
None |
| KSBS GROUPED BY THEME | Knowledge | Skills | Behaviour |
|---|---|---|---|
|
Role and responsibilities
K2 S37 B5 |
Role and limits of responsibility. Escalation procedures. Impact of operators’ competence on product quality. Change control requirement. (K2) |
Escalate issues outside limits of responsibility. (S37) |
Respond and adapt to work demands. (B5) |
|
Emergency procedures
K6 S5 |
Emergency procedures. (K6) |
Follow environment emergency procedures. For example, make area safe, evacuate. (S5) |
None |
|
Sustainability
K10 S6 B2 |
Principles of sustainability and circular economy. Resource (energy, water, and waste) efficiency and reuse of materials. Principles of control and management of emissions and waste. (K10) |
Apply sustainability principles for example, minimising waste. (S6) |
Consider sustainability when using resources and carrying out processes. (B2) |
|
Process industry operations
K13 S7 S9 S12 S14 S15 S16 |
Standard operating procedures (SOP) - what they are and why they are important. (K13) |
Apply standard operating procedures (SOPs). (S7) Select, check, and prepare raw materials for process for example, weighing, measuring, control and blending, conditioning, dissolving, and sanitisation. (S9) Conduct the control of product streams to maintain specifics. (S12) Apply intermediate or post-manufacturing procedure for example, labelling, packing, storage, visual inspection, discharge. (S14) Manage waste streams. (S15) Clean equipment for example, boil-outs, steam-outs, bake-outs, steam in place SIP, clean in place (CIP). (S16) |
None |
|
Shutting down for maintenance
K23 S19 S21 S22 S23 S24 |
Requirements for shutting down and preparing for maintenance. (K23) |
Identify equipment for handover. (S19) Shut down the process and equipment. (S21) Isolate process and systems. (S22) Complete isolation checks. (S23) Empty equipment for example, drain, purge, vent, and de-pressure. (S24) |
None |
|
Bringing back from maintenance
K24 S25 S26 S27 S28 S29 S30 S31 S32 |
Requirements for bringing equipment back from maintenance. (K24) |
Purge, fill, pressurise and leak test. (S25) Complete post maintenance equipment checks. (S26) Line-up equipment. (S27) Connect service connections such as water, electrical, pneumatic, hydraulic for chemical or petrochemical processing. (S28) De-isolate process, mechanical and electrical systems. (S29) Complete pre-start up checks. (S30) Start-up plant and equipment. (S31) Re-start process. (S32) |
None |
|
Problem solving and fault finding
K19 K20 S36 S38 |
Common faults and causes in processing: flow, blockages, instrumentation failures, seals and human factors. (K19) Problem solving and fault-finding techniques: root cause analysis, 5-Whys. (K20) |
Identify issues for example, defects, deviations, process variance, and maintenance requirements. (S36) Apply problem solving and fault-finding techniques. (S38) |
None |
|
Continuous improvement
K21 S39 |
Continuous improvement (CI) systems and techniques. (K21) |
Apply continuous improvement techniques. Make a suggestion for improvement. (S39) |
None |
|
Written communication
K42 S41 |
Written communication techniques. Technical report writing techniques. (K42) |
Produce written documents for example, handover notes or emails, non-conformances, design change requests. (S41) |
None |
|
Information and digital technology
K40 S40 |
Information and digital technology to support process industry operations. Cyber security requirements. (K40) |
Use information and digital technology for example, management information systems, human machine interfaces, word processing, spreadsheet, email, virtual learning platforms, document sharing platforms. Comply with cyber security requirements. (S40) |
None |
|
Teamwork
K44 S43 B3 |
Principles of team working. Principles of equality, diversity, and inclusion in the workplace. (K44) |
Apply team working principles. (S43) |
Team-focus to meet work goals including support for equality, diversity and inclusion. (B3) |
|
Continued professional development
S44 B6 |
None |
Plan how to meet personal development needs. Carry out and record planned and unplanned learning and development (CPD) activities. (S44) |
Committed to continued professional development. (B6) |
Contact us about this apprenticeship
| Version | Change detail | Earliest start date | Latest start date | Latest end date |
|---|---|---|---|---|
| 1.0 | Approved for delivery | 30/11/2023 | Not set | Not set |
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