Operating science industry manufacturing equipment.
The occupation is found in science process manufacturing industries.
Science process manufacturing is varied. It includes industries such as biotechnology, chemical, composites, petrochemical, polymer, and pharmaceutical.
Science process industries combine raw materials and apply a science based process or processes - biological, chemical, or physical - to create products. Products are made continuously or in batches.
Process manufacturing industries are highly regulated. The Health and Safety Executive and other industry regulators inspect employers. The Control of Major Accident Hazards (COMAH) Regulations apply to some process manufacturing companies. Employers must manage risks to the employee, product, environment, and sometimes the wider community.
The broad purpose of the occupation is to complete science-based manufacturing processes to produce materials and products following standard operating procedures. Products are varied and may include battery cells, composite wind turbine parts, drugs, plastic bottles, proteins, and solvents. This involves checking and preparing materials and using specialist science-based manufacturing process plant or equipment. They monitor the process and take action to resolve deviations. Maintaining the work area is part of the role. They contribute to quality control, continuous improvement, and problem solving activities. They also complete work records, which are important in regulated workplaces.
In their daily work, they interact with other science process manufacturing operatives and technicians, along with colleagues from other business functions. They typically report to a shift manager, team leader, or supervisor.
They are responsible for meeting work schedules. They must work to quality, health and safety, and environment regulations and procedures. This may include wearing personal protective equipment and complying with Control of Substances Hazardous to Health (COSHH).
They may work alone or as part of a team, under supervision.
They work in varied conditions. Some workplaces may be physically demanding. Some may require use of specialist safety equipment. They complete shift work. Sites often run 24 x 7, 365-days a year.
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 18 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 2 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 7 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.
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.
The occupation is found in science process manufacturing industries.
Science process manufacturing is varied. It includes industries such as biotechnology, chemical, composites, petrochemical, polymer, and pharmaceutical.
Science process industries combine raw materials and apply a science based process or processes - biological, chemical, or physical - to create products. Products are made continuously or in batches.
Process manufacturing industries are highly regulated. The Health and Safety Executive and other industry regulators inspect employers. The Control of Major Accident Hazards (COMAH) Regulations apply to some process manufacturing companies. Employers must manage risks to the employee, product, environment, and sometimes the wider community.
The broad purpose of the occupation is to complete science-based manufacturing processes to produce materials and products following standard operating procedures. Products are varied and may include battery cells, composite wind turbine parts, drugs, plastic bottles, proteins, and solvents. This involves checking and preparing materials and using specialist science-based manufacturing process plant or equipment. They monitor the process and take action to resolve deviations. Maintaining the work area is part of the role. They contribute to quality control, continuous improvement, and problem solving activities. They also complete work records, which are important in regulated workplaces.
In their daily work, they interact with other science process manufacturing operatives and technicians, along with colleagues from other business functions. They typically report to a shift manager, team leader, or supervisor.
They are responsible for meeting work schedules. They must work to quality, health and safety, and environment regulations and procedures. This may include wearing personal protective equipment and complying with Control of Substances Hazardous to Health (COSHH).
They may work alone or as part of a team, under supervision.
They work in varied conditions. Some workplaces may be physically demanding. Some may require use of specialist safety equipment. They complete shift work. Sites often run 24 x 7, 365-days a year.
| Duty | KSBs |
|---|---|
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Duty 1 Carry out process manufacturing operations using or operating plant or equipment in line with standard operating procedures. |
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Duty 2 Arrange and prepare materials for process activity. |
K1 K2 K3 K4 K5 K6 K9 K10 K11 K12 K13 K16 K18 K19 K20 K21 K22 K23 |
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Duty 3 Carry out pre-start checks of equipment and process before run or as part of handover responsibilities. |
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Duty 4 Monitor the process and resolve or escalate issues. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K18 K19 K20 K22 K23 |
|
Duty 5 Contribute to quality control: conduct quality checks and escalate concerns. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K12 K13 K14 K18 K19 K20 K22 K23 |
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Duty 6 Contribute to first-line maintenance, directly or through escalation. For example, equipment checks cleaning, and lubrication. |
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Duty 7 Contribute to continuous improvement and problem-solving activities. For example, work as part of an improvement team, identify issues, and put ideas forward. |
K1 K2 K3 K4 K5 K6 K7 K8 K10 K11 K13 K15 K18 K19 K20 K22 K23 |
|
Duty 8 Complete process work records - digital or paper, including traceability records. |
K2 K3 K4 K5 K6 K12 K13 K17 K18 K19 K20 K22 |
|
Duty 9 Contribute to maintaining own work area (housekeeping). |
K2 K3 K4 K5 K6 K12 K18 K20 K22 |
|
Duty 10 Conduct change over or clean down activities. |
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|
Duty 11 Carry out end of process activities. For example, finish, pack, discharge or move goods. |
K2 K3 K4 K5 K6 K10 K11 K12 K13 K18 K20 K22 |
K1: Process manufacturing definition. Types of process products across process industries. Types of employers. Types of customers.
Back to Duty
K2: Science manufacturing process operative role. Limits of responsibility.
Back to Duty
K3: Process industry safety: high-hazard sites and their potential impact, and The Control of Major Accident Hazards Regulations (COMAH).
Back to Duty
K4: 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.
Back to Duty
K5: Risk assessments and safe systems of work within process industries. Personal Protective Equipment (PPE). Isolation and emergency stop procedures.
Back to Duty
K6: 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.
Back to Duty
K7: Fundamentals of process chemistry: liquids, gases, and solids.
Back to Duty
K8: The effects of temperature, pressure, and flow on liquids, gases, and solids.
Back to Duty
K9: Awareness of process industry methods: measuring of raw ingredients and materials, blending, mixing, combining, melt processing, moulding, extrusion, and formulations.
Back to Duty
K10: 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.
Back to Duty
K11: Automation and digitalisation of manufacturing processes and its benefits.
Back to Duty
K12: Standard operating procedures (SOP). What they are and why they are important.
Back to Duty
K13: Process and product specifications. Continuous and batch manufacturing. Manufacturing environments.
Back to Duty
K14: Quality assurance requirements and monitoring processes.
Back to Duty
K15: Basic continuous improvement techniques: 5 Why’s, 5S, KAIZEN.
Back to Duty
K16: Stock requirements: control systems, and stock rotation.
Back to Duty
K17: Work record requirements and importance of records for traceability and audits. Management information systems.
Back to Duty
K18: Verbal communication techniques.
Back to Duty
K19: Written communication techniques.
Back to Duty
K20: Information technology: digital manufacturing management systems, virtual learning platforms, word processing, and email. General data protection regulation (GDPR). Cyber security.
Back to Duty
K21: Work organisation and time management techniques.
Back to Duty
K22: Principles of team working.
Back to Duty
K23: Equality, diversity, and inclusion.
Back to Duty
S1: Follow procedures in line with process industry health and safety regulations, standards, and guidance.
Back to Duty
S2: Follow procedures in line with process industry environmental and sustainability regulations, standards, and guidance.
Back to Duty
S3: Follow work instructions.
Back to Duty
S4: Follow process manufacturing standard operating procedures.
Back to Duty
S5: Conduct material preparation for example, measure, weigh, mix and load materials.
Back to Duty
S6: Check and set up science process industry tools, plant, or equipment.
Back to Duty
S7: Use science process industry tools, plant, or equipment required for task.
Back to Duty
S8: Monitor process manufacturing and take corrective actions to meet specification.
Back to Duty
S9: Apply product quality assurance procedures for example, take product samples, inspect products.
Back to Duty
S10: Conduct end of process procedures for example, finish, pack, label, discharge, move, and store batches.
Back to Duty
S11: Collect and interpret information.
Back to Duty
S12: Identify and resolve or report issues.
Back to Duty
S13: Store materials, monitor, and rotate stock.
Back to Duty
S14: Comply with housekeeping procedures for example, clean equipment and machinery, tidy work area.
Back to Duty
S15: Identify and segregate resources for reuse, recycling, and disposal.
Back to Duty
S16: Apply basic continuous improvement techniques for example, 5Why's, S5, and KAIZEN.
Back to Duty
S17: Perform simple calculations for example, raw material quantity and production calculations.
Back to Duty
S18: Record information (text and data) - paper based or electronic for example, quality control documentation, cleaning logs, handover notes, stock inventory systems.
Back to Duty
S19: Communicate with colleagues verbally.
Back to Duty
S20: Use information technology for example, digital manufacturing management systems, virtual learning platforms, word processing, and email. Comply with GDPR and cyber security procedures.
Back to Duty
S21: Apply team building principles.
Back to Duty
S22: Carry out and record learning and development.
Back to Duty
B1: Put health and safety first.
Back to Duty
B2: Consider the environment.
Back to Duty
B3: Take ownership for quality of given work.
Back to Duty
B4: Adapt to changing work requests.
Back to Duty
B5: Team focus to meet work goals for example, work collaboratively.
Back to Duty
B6: Seek learning and development opportunities.
Back to Duty
English and maths qualifications form a mandatory part of all apprenticeships and must be completed before an apprentice can pass through gateway. The requirements are detailed in the current version of the apprenticeship funding rules.
V1.1
This document explains the requirements for end-point assessment (EPA) for the science manufacturing process operative apprenticeship. End-point assessment organisations (EPAOs) must follow this when designing and delivering the EPA.
Science manufacturing process operative apprentices, their employers and training providers should read this document.
An approved EPAO must conduct the EPA for this apprenticeship. Employers must select an approved EPAO from the register of end-point assessment organisations (RoEPAO).
A full-time apprentice typically spends 18 months on-programme (this means in training before the gateway) working towards competence as a science manufacturing process operative. The apprentice must spend at least 12 months on-programme. The apprentice must complete the required amount of off-the-job training specified by the apprenticeship funding rules.
This EPA has 3 assessment methods.
The grades available for each assessment method are:
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 18 months
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The apprentice must complete training to develop the knowledge, skills and behaviours (KSBs) of the occupational standard. The apprentice must complete training towards English and maths qualifications in line with the apprenticeship funding rules. The apprentice must compile a portfolio of evidence. |
|---|---|
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End-point assessment gateway
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The employer must be content that the apprentice is working at or above the occupational standard. The apprentice’s employer must confirm that they think the apprentice:
The apprentice must have achieved English and maths qualifications in line with the apprenticeship funding rules. For the interview underpinned by a portfolio of evidence the apprentice must submit a portfolio of evidence. The apprentice must submit any policies and procedures as requested by the EPAO. |
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End-point assessment - typically 3 months
|
Grades available for each assessment method: Observation with questions
Interview underpinned by a portfolio of evidence
Multiple-choice test
Overall EPA and apprenticeship can be graded:
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Re-sits and re-takes
|
|
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 expectation is that the EPAO will confirm the gateway requirements have been met and the EPA starts as quickly as possible.
The apprentice’s employer must confirm that they think their apprentice is working at or above the occupational standard. The apprentice will then enter the gateway. The employer may take advice from the apprentice's training provider(s), but the employer must make the decision.
The apprentice must meet the gateway requirements before starting their EPA.
These are:
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.
The apprentice must submit any policies and procedures as 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. Simulation is not permitted. 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 an apprentice 2 weeks notice of the observation with questions.
The observation must take 2 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 during the working day.
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 following during the observation:
Activities may be completed in relation to the same process or different processes.
These activities provide the apprentice with the opportunity to demonstrate the KSBs mapped to this assessment method.
The independent assessor must ask questions. The purpose of the independent assessor's questions is to test the apprentice’s breadth and depth of underpinning knowledge against the grading descriptors.
Questioning can occur both during and after the observation. 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. Follow-up questions are allowed where clarification is required. 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.
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 observation and responses to questions must be assessed holistically by the independent assessor when they are 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 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 should maintain the security and confidentiality of EPA materials when consulting 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, training, and moderation.
In the interview, an independent assessor asks the apprentice questions. The apprentice can refer to and illustrate their answers with evidence from their portfolio of evidence. It gives the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method.
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 will be to cover 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 during the interview.
The apprentice can refer to and illustrate their answers with evidence from their portfolio of evidence however, it 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 7 questions. Follow-up questions are allowed where clarification is required. The independent assessor must use the questions from their EPAO’s question bank or create their own questions in-line with the EPAO’s training.
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 should maintain the security and confidentiality of EPA materials when consulting 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 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, training, and moderation.
A multiple-choice test is an assessment for asking 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:
This multiple-choice test must be appropriately structured to give the apprentice the opportunity to demonstrate the knowledge mapped to this assessment method to the highest available grade.
The multiple-choice test can be computer or paper based.
The multiple-choice test must consist of 40 multiple-choice questions.
Multiple-choice questions must have four options, with one correct answer.
The apprentice must be given at least 2 weeks notice of the date and time of the multiple-choice test.
The apprentice must have 60 minutes to complete the multiple-choice test.
The multiple-choice test is closed book which means that the apprentice cannot refer to reference books or materials whilst taking the test.
The multiple-choice test must be taken in the presence of an invigilator who is the responsibility of the EPAO. If the test can be taken on-line, specialised (proctor) software can be used to ensure the security of the test.
The EPAO must have an invigilation policy setting out how the multiple-choice 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 identity of the apprentice.
The EPAO is responsible for the security of the multiple-choice test including the arrangements for on-line testing. The EPAO must ensure that their security arrangements maintain the validity and reliability of the multiple-choice test.
The multiple-choice 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.
A correct answer gets 1 mark.
Any incorrect or missing answers get zero marks.
The EPAO is responsible for overseeing the marking of the multiple-choice test. The EPAO must ensure standardisation and moderation of written response test.
The apprentice must take the multiple-choice 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 multiple-choice test could take place remotely if the appropriate technology and systems are in place to prevent malpractice. The EPAO must verify the apprentice’s identity and ensure invigilation of the apprentice for example with, and not limited to, 360-degree cameras and screen sharing facilities.
The EPAO must write an assessment specification and question bank. It is recommended this is done in consultation with the employers of this occupation. The EPAO should maintain the security and confidentiality of EPA materials when consulting employers.
The specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must develop a purpose-built question bank and ensure that appropriate quality assurance procedures are in place for example, considering standardisation, training and moderation. 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 assessment specification and questions must be reviewed at least once a year to ensure they remain fit-for-purpose.
The EPAO must ensure that an apprentice has a different set of questions in the case of re-sits or re-takes.
The EPAO must produce the following material to support this assessment method:
Fail - does not meet pass criteria
|
Theme
KSBs
|
Pass
Apprentices must demonstrate all the pass descriptors
|
Distinction
Apprentices must demonstrate all the pass descriptors and all of the distinction descriptors
|
|---|---|---|
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Health and safety
K5 S1 S14 B1 |
Prioritises safe systems of work, following procedures in line with process industry health and safety regulations, standards and guidance and complies with housekeeping procedures to maintain a safe and tidy work area. Wears PPE correctly. Explains emergency stop procedures. (K5, S1, S14, B1) |
Explains why compliance with health and safety regulations and following safe systems of work is a priority within process industries. (K5, S1, B1) |
|
Work organisation
K21 S3 B3 |
Takes responsibility to complete allocated tasks within required timescales to the required quality, following work instructions. (K21, S3, B3) |
Implements and follows procedures without error, mitigating against potential issues, supporting a right first-time outcome with no back tracking. (K21, S3, B3) |
|
Process operations
K12 S4 S5 S6 S7 S8 |
Follows process manufacturing standard operating procedures (SOP). (K12, S4) Conducts material preparation in line with SOP. (S5) Checks and sets up process industry tools, plant, or equipment in line with SOP. (S6) Uses process industry tools, plant, or equipment in line with SOP. (S7) Monitors process and takes corrective action to meet specification in line with SOP. (S8) |
Identifies potential issues that could arise in process. Explains how they help prevent them occurring by following SOPs. (K12, S4, S8) |
|
Quality assurance
K14 S9 |
Applies quality assurance procedures. Identifies any specification deviation, taking action in line with quality assurance procedures. (K14, S9) |
Explains the importance of applying product quality assurance procedures and potential consequences of not doing do. (K14, S9) |
|
Communication
K18 S19 |
Communicates with others using verbal techniques that are suitable for the context and support task completion. (K18, S19) |
None |
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Documentation
K17 K19 S11 S18 |
Collects and interprets information. (S11) Records information - paper based or electronic - in line with work record requirements using written techniques that are suitable for the context and supports task completion. (K17, K19, S18) |
Explains the importance of completing documentation correctly and the potential impact of not doing so. (K17, S11, S18) |
Fail - does not meet pass criteria
|
Theme
KSBs
|
Pass
Apprentices must demonstrate all the pass descriptors
|
Distinction
Apprentices must demonstrate all the pass descriptors and all of the distinction descriptors
|
|---|---|---|
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Science manufacturing process operative’s role
K2 S12 S22 B6 |
Outlines their process operative role, describing how they identify and resolve or report issues in line with limits of responsibility. (K2, S12) Outlines learning and development they have completed to support competence in their role. (S22, B6)
|
Identifies how their role impacts on wider manufacturing process operations. (K2) |
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Stock control
K16 S13 |
Describes how they store materials, monitor, and rotate stock in line with stock requirements. (K16, S13) |
Describes the importance of accurate stock control and potential impact to the business of not following stock requirements. (K16, S13) |
|
End of process procedures
S10 |
Describes how they conduct end of process in line with procedures. (S10) |
None |
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Environment and sustainability
K6 S2 S15 B2 |
Outlines the potential impact that process industries have on the environment and how that is controlled through regulations. Describes how they follow procedures in line with environmental and sustainability regulations, standards, and guidance and how they consider the environment through the efficient use of resources. Describes how they identify and segregate resources for reuse, recycling, and disposal in line with waste reduction, waste streams, and recycling requirements. (K6, S2, S15, B2) |
Explains how their company’s or industry’s environmental and sustainability practice exceed regulatory requirements, or could be changed to better support, environmental and sustainability targets. (K6) |
|
Continuous improvement
K15 S16 |
Describes how they apply basic continuous improvement techniques. (K15, S16) |
Explains how the continuous improvement techniques they apply contribute to or have the potential to contribute to overall business effectiveness. (K15, S16) |
|
Information technology
K20 S20 |
Describes how they use IT in the workplace for example, digital manufacturing management systems, virtual learning platforms, word processing and email, and the importance of data protection and cyber security. (K20, S20) |
None |
|
Team working
K22 K23 S21 B4 B5 |
Describes how they meet their team's work goals and adapt to changing work requests, applying team working principles and taking account of individuals needs in relation to equality, diversity, and inclusion. (K22, K23, S21, B4, B5) |
Explains how their team focus supports wider teams to meet their goals. (K22, S21, B5) |
| Grade | Minimum marks required | Maximum marks required |
|---|---|---|
| Fail | 0 | 27 |
| Pass | 28 | 40 |
The assessment methods contribute equally to the overall EPA pass grade.
Performance in the EPA determines the apprenticeship grade of:
An independent assessor must individually grade the observation with questions and interview underpinned by a portfolio of evidence according to the requirements set out in this EPA plan.
The EPAO must combine the individual assessment method grades to determine the overall EPA grade.
If the apprentice fails one or more assessment methods, they will be awarded an overall EPA fail.
The apprentice must achieve at least a pass in all the assessment methods to get an overall pass. To achieve an overall EPA merit, the apprentice must achieve a distinction in one assessment method (the observation with questions or interview underpinned by a portfolio of evidence), and a pass in the other assessment methods. To achieve an overall EPA distinction, the apprentice must achieve a distinction in the observation with questions and 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 |
|---|---|---|---|
| Fail | Any grade | Any grade | Fail |
| Any grade | Fail | Any grade | Fail |
| Any grade | Any grade | Fail | Fail |
| Pass | Pass | Pass | Pass |
| Distinction | Pass | Pass | Merit |
| Pass | Distinction | Pass | Merit |
| Distinction | Distinction | Pass | Distinction |
If the apprentice fails one or more assessment methods 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 EPAO 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 pass for a re-sit or re-take, unless the EPAO determines there are exceptional circumstances.
| Roles | Responsibilities |
|---|---|
|
Apprentice |
As a minimum, the apprentice should:
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|
Employer |
As a minimum, the apprentice's employer must:
Post-gateway, the employer must:
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EPAO |
As a minimum, the EPAO must:
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Independent assessor |
As a minimum, an independent assessor must:
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Training provider |
As a minimum, the training provider must:
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Marker |
As a minimum, the marker must:
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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.
Internal quality assurance refers to how the EPAO ensures valid, consistent and reliable EPA decisions. The EPAO must adhere to the requirements within the roles and responsibilities section.
They must also:
Affordability of the EPA will be aided by using at least some of the following:
Professional body recognition is not relevant to this occupational apprenticeship.
| Knowledge | Assessment methods |
|---|---|
|
K1
Process manufacturing definition. Types of process products across process industries. Types of employers. Types of customers. Back to Grading |
Multiple-choice test |
|
K2
Science manufacturing process operative role. Limits of responsibility. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K3
Process industry safety: high-hazard sites and their potential impact, and The Control of Major Accident Hazards Regulations (COMAH). Back to Grading |
Multiple-choice test |
|
K4
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. Back to Grading |
Multiple-choice test |
|
K5
Risk assessments and safe systems of work within process industries. Personal Protective Equipment (PPE). Isolation and emergency stop procedures. Back to Grading |
Observation with questions |
|
K6
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. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K7
Fundamentals of process chemistry: liquids, gases, and solids. Back to Grading |
Multiple-choice test |
|
K8
The effects of temperature, pressure, and flow on liquids, gases, and solids. Back to Grading |
Multiple-choice test |
|
K9
Awareness of process industry methods: measuring of raw ingredients and materials, blending, mixing, combining, melt processing, moulding, extrusion, and formulations. Back to Grading |
Multiple-choice test |
|
K10
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. Back to Grading |
Multiple-choice test |
|
K11
Automation and digitalisation of manufacturing processes and its benefits. Back to Grading |
Multiple-choice test |
|
K12
Standard operating procedures (SOP). What they are and why they are important. Back to Grading |
Observation with questions |
|
K13
Process and product specifications. Continuous and batch manufacturing. Manufacturing environments. Back to Grading |
Multiple-choice test |
|
K14
Quality assurance requirements and monitoring processes. Back to Grading |
Observation with questions |
|
K15
Basic continuous improvement techniques: 5 Why’s, 5S, KAIZEN. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K16
Stock requirements: control systems, and stock rotation. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K17
Work record requirements and importance of records for traceability and audits. Management information systems. Back to Grading |
Observation with questions |
|
K18
Verbal communication techniques. Back to Grading |
Observation with questions |
|
K19
Written communication techniques. Back to Grading |
Observation with questions |
|
K20
Information technology: digital manufacturing management systems, virtual learning platforms, word processing, and email. General data protection regulation (GDPR). Cyber security. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K21
Work organisation and time management techniques. Back to Grading |
Observation with questions |
|
K22
Principles of team working. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K23
Equality, diversity, and inclusion. Back to Grading |
Interview underpinned by a portfolio of evidence |
| Skill | Assessment methods |
|---|---|
|
S1
Follow procedures in line with process industry health and safety regulations, standards, and guidance. Back to Grading |
Observation with questions |
|
S2
Follow procedures in line with process industry environmental and sustainability regulations, standards, and guidance. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S3
Follow work instructions. Back to Grading |
Observation with questions |
|
S4
Follow process manufacturing standard operating procedures. Back to Grading |
Observation with questions |
|
S5
Conduct material preparation for example, measure, weigh, mix and load materials. Back to Grading |
Observation with questions |
|
S6
Check and set up science process industry tools, plant, or equipment. Back to Grading |
Observation with questions |
|
S7
Use science process industry tools, plant, or equipment required for task. Back to Grading |
Observation with questions |
|
S8
Monitor process manufacturing and take corrective actions to meet specification. Back to Grading |
Observation with questions |
|
S9
Apply product quality assurance procedures for example, take product samples, inspect products. Back to Grading |
Observation with questions |
|
S10
Conduct end of process procedures for example, finish, pack, label, discharge, move, and store batches. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S11
Collect and interpret information. Back to Grading |
Observation with questions |
|
S12
Identify and resolve or report issues. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S13
Store materials, monitor, and rotate stock. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S14
Comply with housekeeping procedures for example, clean equipment and machinery, tidy work area. Back to Grading |
Observation with questions |
|
S15
Identify and segregate resources for reuse, recycling, and disposal. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S16
Apply basic continuous improvement techniques for example, 5Why's, S5, and KAIZEN. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S17
Perform simple calculations for example, raw material quantity and production calculations. Back to Grading |
Multiple-choice test |
|
S18
Record information (text and data) - paper based or electronic for example, quality control documentation, cleaning logs, handover notes, stock inventory systems. Back to Grading |
Observation with questions |
|
S19
Communicate with colleagues verbally. Back to Grading |
Observation with questions |
|
S20
Use information technology for example, digital manufacturing management systems, virtual learning platforms, word processing, and email. Comply with GDPR and cyber security procedures. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S21
Apply team building principles. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S22
Carry out and record learning and development. Back to Grading |
Interview underpinned by a portfolio of evidence |
| Behaviour | Assessment methods |
|---|---|
|
B1
Put health and safety first. Back to Grading |
Observation with questions |
|
B2
Consider the environment. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
B3
Take ownership for quality of given work. Back to Grading |
Observation with questions |
|
B4
Adapt to changing work requests. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
B5
Team focus to meet work goals for example, work collaboratively. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
B6
Seek learning and development opportunities. Back to Grading |
Interview underpinned by a portfolio of evidence |
| KSBS GROUPED BY THEME | Knowledge | Skills | Behaviour |
|---|---|---|---|
|
Health and safety
K5 S1 S14 B1 |
Risk assessments and safe systems of work within process industries. Personal Protective Equipment (PPE). Isolation and emergency stop procedures. (K5) |
Follow procedures in line with process industry health and safety regulations, standards, and guidance. (S1) Comply with housekeeping procedures for example, clean equipment and machinery, tidy work area. (S14) |
Put health and safety first. (B1) |
|
Work organisation
K21 S3 B3 |
Work organisation and time management techniques. (K21) |
Follow work instructions. (S3) |
Take ownership for quality of given work. (B3) |
|
Process operations
K12 S4 S5 S6 S7 S8 |
Standard operating procedures (SOP). What they are and why they are important. (K12) |
Follow process manufacturing standard operating procedures. (S4) Conduct material preparation for example, measure, weigh, mix and load materials. (S5) Check and set up science process industry tools, plant, or equipment. (S6) Use science process industry tools, plant, or equipment required for task. (S7) Monitor process manufacturing and take corrective actions to meet specification. (S8) |
None |
|
Quality assurance
K14 S9 |
Quality assurance requirements and monitoring processes. (K14) |
Apply product quality assurance procedures for example, take product samples, inspect products. (S9) |
None |
|
Communication
K18 S19 |
Verbal communication techniques. (K18) |
Communicate with colleagues verbally. (S19) |
None |
|
Documentation
K17 K19 S11 S18 |
Work record requirements and importance of records for traceability and audits. Management information systems. (K17) Written communication techniques. (K19) |
Collect and interpret information. (S11) Record information (text and data) - paper based or electronic for example, quality control documentation, cleaning logs, handover notes, stock inventory systems. (S18) |
None |
| KSBS GROUPED BY THEME | Knowledge | Skills | Behaviour |
|---|---|---|---|
|
Science manufacturing process operative’s role
K2 S12 S22 B6 |
Science manufacturing process operative role. Limits of responsibility. (K2) |
Identify and resolve or report issues. (S12) Carry out and record learning and development. (S22) |
Seek learning and development opportunities. (B6) |
|
Stock control
K16 S13 |
Stock requirements: control systems, and stock rotation. (K16) |
Store materials, monitor, and rotate stock. (S13) |
None |
|
End of process procedures
S10 |
None |
Conduct end of process procedures for example, finish, pack, label, discharge, move, and store batches. (S10) |
None |
|
Environment and sustainability
K6 S2 S15 B2 |
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. (K6) |
Follow procedures in line with process industry environmental and sustainability regulations, standards, and guidance. (S2) Identify and segregate resources for reuse, recycling, and disposal. (S15) |
Consider the environment. (B2) |
|
Continuous improvement
K15 S16 |
Basic continuous improvement techniques: 5 Why’s, 5S, KAIZEN. (K15) |
Apply basic continuous improvement techniques for example, 5Why's, S5, and KAIZEN. (S16) |
None |
|
Information technology
K20 S20 |
Information technology: digital manufacturing management systems, virtual learning platforms, word processing, and email. General data protection regulation (GDPR). Cyber security. (K20) |
Use information technology for example, digital manufacturing management systems, virtual learning platforms, word processing, and email. Comply with GDPR and cyber security procedures. (S20) |
None |
|
Team working
K22 K23 S21 B4 B5 |
Principles of team working. (K22) Equality, diversity, and inclusion. (K23) |
Apply team building principles. (S21) |
Adapt to changing work requests. (B4) Team focus to meet work goals for example, work collaboratively. (B5) |
Contact us about this apprenticeship
| Version | Change detail | Earliest start date | Latest start date | Latest end date |
|---|---|---|---|---|
| 1.1 | Standard and end-point assessment plan revised | 22/08/2022 | Not set | Not set |
| 1.0 | Approved for delivery | 27/02/2018 | 21/08/2022 | Not set |
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