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Composites technician

This is not the latest approved version of this apprenticeship. View the latest version

This apprenticeship is in revision

Key information

  1. Status: In development
  2. Ticked Proposal approved
    Ticked Occupational standard approved
    Ticked End-point assessment plan approved
  3. Reference: ST0094
  4. Level: 3
  5. Typical duration to gateway: 36 months
  6. Typical EPA period: 3 months
  7. Route: Engineering and manufacturing
  8. Date updated: 22/09/2022
  9. Lars code: 160
  10. EQA provider: Ofqual
Print occupational standard

Details of the occupational standard

Occupation summary

Composite technicians work in the process manufacturing sector.

Composite components are used in the aerospace, automotive, construction, furniture, marine, medical, motorsport, oil and gas, rail, and renewables industries and many more. Composite products include doors, prosthetic limbs, shower trays, and tennis rackets.

Composites combine polymeric resins (plastics) and a reinforcing material such as carbon fibre, glass fibre, or Kevlar to produce a material with improved properties. For example, increased strength or stiffness without significantly increasing the weight.

Composite technicians produce polymer matrix composite (thermoset and thermoplastics) components or final products to a specification. They may combine the composite elements or use a pre-prepared material to produce the product using a variety of moulding processes. The processes require manual dexterity and skills. Production tends to be in batches and conducted in small-scale production facilities. Quality and process control is part of the role. They conduct quality assurance processes, check equipment and tooling for future usability, complete documentation, and participate in improvement activities. 

They work with other members of the manufacturing team. They also have contact with other functions for example, process engineers, maintenance engineers, laboratory staff, supply chain staff, and warehouse staff. They may also have contact with external people such as customers, service providers, suppliers, and regulators.

They must ensure that the process and products meet quality specifications and are produced to schedule. They must comply with health and safety, regulations and procedures including wearing personal protection equipment (PPE). They also need to meet environmental and sustainability regulations and procedures – minimising waste and recycling materials. They may work alone or as part of a team with minimal supervision. They are responsible for the quality and accuracy of their own work

Typical job titles include:

Composites laminator Green leaf Composites materials technician Green leaf Composites technician Green leaf Composites tooling technician Green leaf

Occupation duties

Duty

KSBs

Duty 1 Complete composite pre-processing activities. For example, organise and prepare mould tools and materials.

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K18 K19 K20 K21 K22 K26 K37

S1 S2 S4 S5 S6 S7 S8 S9 S12 S18 S24

B1 B2 B3 B4 B5 B6

Duty 2 Conduct composite processing activities following technical instructions.

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K22 K23 K25 K26 K37

S1 S2 S4 S5 S6 S9 S11 S12 S13 S14 S15 S18 S24

B1 B2 B3 B4 B5 B6

Duty 3 Complete quality assurance processes. For example, conduct grading parameters checks (size, appearance, weight), and take samples for laboratory testing.

K1 K2 K3 K4 K5 K6 K8 K11 K12 K13 K16 K18 K20 K24 K26 K27 K28 K30 K33 K37

S1 S2 S4 S5 S6 S12 S16 S17 S18 S20 S21 S22 S24

B1 B2 B3 B4 B5 B6

Duty 4 Check the composite processing equipment and tooling for future usability; make repairs or escalate.

K1 K2 K3 K4 K5 K6 K16 K18 K21 K22 K26 K33 K37

S1 S4 S5 S6 S8 S18 S20 S22 S24 S25

B1 B2 B3 B4 B5 B6

Duty 5 Complete process manufacturing documentation - digital or paper based. For example, process and production records, traceability records, quality assurance records.

K1 K2 K3 K4 K5 K6 K26 K29 K33 K34 K35

S1 S4 S5 S20 S26 S27

B1 B2 B3 B4 B5 B6

Duty 6 Conduct handover responsibilities - providing information to or receiving information from other shifts or maintenance teams.

K2 K3 K4 K5 K6 K26 K33 K34 K35 K36 K37

S1 S4 S5 S18 S20 S24 S25 S26 S27

B1 B2 B3 B4 B5 B6

Duty 7 Maintain the work area (housekeeping) following safety, environmental and risk management systems. Ensure waste is separated, segregated, and disposed of in accordance with environmental standards.

K2 K3 K4 K5 K6 K24 K26

S1 S2 S3 S4 S5 S6 S10 S18 S19

B1 B2 B3 B4 B5 B6

Duty 8 Participate in continuous improvement activities. For example, ways to contribute to achieving Net Carbon zero by focussing on reduction of unnecessary energy use and waste.

K2 K3 K4 K5 K6 K19 K20 K24 K27 K31 K32 K33 K34 K35 K36

S1 S2 S4 S5 S6 S18 S20 S22 S23 S24 S25 S26 S27 S28

B1 B2 B3 B4 B5 B6 B7

Duty 9 Participate in risk assessment activities.

K2 K3 K4 K5 K6 K34 K35 K36

S1 S3 S4 S5 S18 S20 S24 S25 S26 S27

B1 B2 B3 B4 B5 B6


KSBs

Knowledge

K1: Composite industry awareness. Range of composite products. Manufacturing environments. Types of customers. Back to Duty

K2: Composite technician’s role. Limits of responsibility. Escalation procedures. Back to Duty

K3: Health and safety regulations and standards awareness. Control of Substances Hazardous to Health (COSHH). Display Screen Equipment. Electrical safety and compliance. Fire safety. Hand arm vibration (HAVS). Health and Safety at Work Act – responsibilities. Human factors, ergonomics. Legionella. Lifting Operations and Lifting Equipment Regulations (LOLER). Lone working. Manual handling. Noise regulation. Provision and Use of Work Equipment Regulations (PUWER). Slips trips and falls. The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR). Working at Height. Working in Confined Spaces. Back to Duty

K4: Health and safety practice. Risk assessment and risk mitigation in composites process manufacturing environment. Personal protective equipment (PPE) requirements: selection, inspection, operation, wearing, and disposal. Back to Duty

K5: Environmental and sustainability regulations and guidance. Environmental hazards that can arise from composite operations. Environmental management systems standard. Environmental Protection Act. Environmental signage and notices. Back to Duty

K6: Principles of sustainability and circular economy. Energy efficiency and reuse of materials. Recycling procedures. Principles of control and management of emissions and waste. Back to Duty

K7: Definition of a composite. Interaction between resin and fibre. Types of core. Benefits of adding core. Advantages and disadvantages of composites. Back to Duty

K8: The characteristics of finished composite products and their various applications. Back to Duty

K9: The difference between thermoset and thermoplastics: mechanical and thermal benefits, processing requirements, and re-cycling potential. Back to Duty

K10: Types of reinforcement materials: aramid, carbon, glass, natural fibres, and thermoplastic fibres; processing, cost, performance, benefits, and limitations. Back to Duty

K11: Types of matrix materials: bismaleimide, cyanate ester, epoxy, phenolic, polyester, vinylester, and bio-derived: processing, cost, performance, benefits, and limitations. Back to Duty

K12: The manufacture of materials: chopped strand mat, non-crimp fabrics, pre-impregnated, preforms, unidirectional, and woven reinforcements. Different weave styles: plain, satin and twill; impact on drape and mechanical properties. Back to Duty

K13: Composite process materials and consumables: peel plies, release agents, release films, sealant tapes, and vacuum bag; application and benefits of use. Back to Duty

K14: Hand lay-up techniques: open moulding, spray lay-up, and pre-impregnated. Resin infusion, resin transfer moulding, and closed moulding using vacuum techniques. Back to Duty

K15: Awareness of automated lay-up: automated fibre placement, automated tape layup, braiding, and filament winding. Back to Duty

K16: Plant, equipment, machinery, and hand tools used within composites manufacture: application and operation. Back to Duty

K17: The curing cycle. Glass transition temperature (Tg). The science of pressure and vacuum. Back to Duty

K18: Principles of process control and instrument control methodology. Back to Duty

K19: Awareness of application of digital systems to support manufacture: CAD (computer-aided design), CAM (computer-aided manufacturing), CMM (coordinate measuring machine), and additive manufacture. Back to Duty

K20: Composite tooling and product design process awareness. Back to Duty

K21: Composite mould tool manufacture methods, techniques, and considerations. Back to Duty

K22: Composite mould tool preparation and operation. Back to Duty

K23: Composite manufacture processes and principles: moulding, laminating, and curing. Back to Duty

K24: Process risk in composite manufacture and mitigation. Defect types and causes. Back to Duty

K25: Composite repair techniques: step, scarf, gel, resin injection, and riveting. Back to Duty

K26: Standard operating procedures, drawings, and work instructions: what are they, why they are important. Back to Duty

K27: Quality, cost, and delivery (QCD) standards and their importance in the workplace. Back to Duty

K28: Quality assurance, testing and inspection methods. Back to Duty

K29: Documentation requirements. Back to Duty

K30: Awareness of audits and their purpose. Back to Duty

K31: Problem solving: root cause analysis, 5-Whys. Back to Duty

K32: Continuous improvement (CI) techniques: lean, 6-sigma, KAIZEN, and 5S. Back to Duty

K33: Information technology. Management information systems, word processing, spreadsheet, email, virtual learning platforms, document sharing platforms. General data protection regulation (GDPR). Cyber security. Back to Duty

K34: Verbal communication techniques. Composite industry terminology. Back to Duty

K35: Written communication techniques. Back to Duty

K36: Principles of team working. Equality, diversity and inclusion. Back to Duty

K37: Planning, prioritising, and time management techniques. Back to Duty

Skills

S1: Review drawings, instructions, or information to understand task. Back to Duty

S2: Plan work. Identify and organise resources. Back to Duty

S3: Identify hazards and risks in the workplace. Back to Duty

S4: Apply health and safety procedures in compliance with regulations and standards. Back to Duty

S5: Apply environmental and sustainability procedures in compliance with regulations and standards. Back to Duty

S6: Apply sustainability principles for example, in choice of materials, minimising waste. Back to Duty

S7: Prepare and use mould tools. Back to Duty

S8: Select and check hand tools, equipment and machinery including calibration record. Back to Duty

S9: Use or operate hand tools, equipment, and machinery. Back to Duty

S10: Store mould tools, hand tools, and equipment. Back to Duty

S11: Select, check, and prepare materials for example, weigh resins, cut reinforcement. Back to Duty

S12: Follow quality control processes during manufacture for example, check for contaminants, record batch numbers or expiry dates. Back to Duty

S13: Apply laminate to mould for example, cut, add darts, corner definition, orientation, position, and order. Back to Duty

S14: Complete preparation for and start curing process for example, select and apply consumables for example vacuum bag, infuse with resin, add heat or pressure. Back to Duty

S15: Extract product from mould (break out). Back to Duty

S16: Conduct final product quality assurance procedure. For example, conduct grading parameters checks (size, appearance, weight), and take samples for laboratory testing. Back to Duty

S17: Identify issues for example, de-laminations, inclusions, surface defects, surface imperfections, and maintenance requirements. Back to Duty

S18: Escalate issues outside limits of responsibility. Back to Duty

S19: Segregate resources for reuse, recycling, and disposal. Back to Duty

S20: Record or enter data - paper based or electronic. For example, process and production records, traceability records, and quality assurance records. Back to Duty

S21: Interpret data for example, defect data and geometrical measurements. Use data to validate suggestions. Back to Duty

S22: Investigate a problem to identify the underlying cause. Identify a solution to the problem. Back to Duty

S23: Apply continuous improvement techniques. Devise suggestions for improvement. For example, improving the energy consumption or waste profile of processes and procedures to improve the sustainability or carbon footprint of a product, process, or task. Back to Duty

S24: Apply team working principles. Back to Duty

S25: Communicate with others verbally for example, colleagues and stakeholders. Back to Duty

S26: Communicate in written form in the workplace for example, handover notes or emails, non-conformances, design change requests. Back to Duty

S27: Use information technology for work tasks. Comply with GDPR and cyber security regulations and policies. Back to Duty

S28: Plan how to meet personal development needs. Carry out and record planned and unplanned continued professional development (CPD) activities. Evaluate CPD against plans made. Back to Duty

Behaviours

B1: Prioritise health and safety. Back to Duty

B2: Consider the environment and sustainability. Back to Duty

B3: Demonstrate professional integrity. Back to Duty

B4: Take responsibility for the quality of work. Back to Duty

B5: Team-focus with commitment to inclusivity. Back to Duty

B6: Respond and adapt to work demands or situations. Back to Duty

B7: Committed to continued professional development. Back to Duty


Qualifications

English and Maths

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.

Professional recognition

This standard aligns with the following professional recognition:

  • The Institute of Materials, Minerals and Mining for Engineering Technician (EngTech)
Print EPA plan

End-point assessment plan

1.1

Introduction and overview

This document explains the requirements for end-point assessment (EPA) for the composites technician apprenticeship. End-point assessment organisations (EPAOs) must follow this when designing and delivering the EPA.

Composites technician 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 Education and Skills Funding Agency’s Register of end-point assessment organisations (RoEPAO).

A full-time apprentice typically spends 36 months on-programme (this means in training before the gateway) working towards competence as a composites technician. 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:

EPA summary table

On-programme (typically 36 months)

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. This includes those with an education, health and care plan or a legacy statement. British sign language (BSL) qualifications are an alternative to English qualifications for those who have BSL as their primary language.

The apprentice must compile a portfolio of evidence.

End-point assessment gateway

The apprentice's 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:

  • is working at or above the occupational standard as a composites technician
  • has the evidence required to pass the gateway and is ready to take the EPA

The apprentice must have achieved English and mathematics qualifications (including those with an education, health and care plan or a legacy statement) as specified by the apprenticeship funding rules. British Sign Language (BSL) qualifications are an alternative to English qualifications for those who have BSL as their primary language.

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.

End-point assessment (typically 3 months)

Grades available for each assessment method:

Observation with questions

  • fail
  • pass
  • distinction

Interview underpinned by a portfolio of evidence

  • fail
  • pass
  • distinction

Multiple-choice test

  • fail
  • pass

Overall EPA and apprenticeship can be graded:

    • fail
    • pass
    • merit
    • distinction

Professional recognition

This apprenticeship aligns with The Institute of Materials, Minerals and Mining for Engineering Technician (EngTech).







Re-sits and re-takes



  • Re-take and re-sit grade cap: pass
  • Re-sit timeframe: typically 2 months
  • Re-take timeframe: typically 4 months

Duration of end-point assessment period

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 the EPA should start as quickly as possible.

EPA gateway

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 they must make the decision.

The apprentice must meet the gateway requirements before starting their EPA.

These are:

  • achieved English and mathematics (including those with an education, health and care plan or a legacy statement) as specified by the apprenticeship funding rules. British Sign Language (BSL) qualifications are an alternative to English qualifications for those who have BSL as their primary language

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:

  • workplace documentation and records
  • workplace policies and procedures
  • witness statements
  • annotated photographs
  • video clips (maximum total duration 10 minutes); the apprentice must be in view and identifiable

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.

Assessment methods

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.

Observation with questions

Overview

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.

Rationale

This assessment method is being used because:

Delivery

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 4 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 relate to the to the same or different products.

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 assess the level of competence 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 5questions. 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 KSBs observed
  • the apprentice’s answers to questions
  • the KSBs demonstrated in answers to questions
  • the grade achieved 

Assessment location

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.

In exceptional circumstances, the venue could be a simulated environment selected by the EPAO (for example the EPAO’s or employer’s premises).

EPAOs must ensure suitable and familiar tools, equipment, machinery, resources, and materials are available within the simulated environment that replicate workplace and industry standards. The EPAO can liaise with the employer to provide these.

Simulated environments may only be used where apprentices are prevented from being observed in the workplace and remote observation is not a suitable alternative. For this occupation, a barrier could be that the presence of a third party for example the independent assessor, in a specific apprentice's workplace area is prohibited for verifiable security reasons.

The EPAO must retain evidence for the need to use a simulated environment for a particular employer or timeframe. This evidence will include a request and rationale from the employer contracting them for the EPA in scope.

The simulated environment must:

Question and resource development

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:

  • independent assessor assessment materials which include:
    • training materials
    • administration materials
    • moderation and standardisation materials
    • guidance materials
    • grading guidance
    • question bank
  • EPA guidance for the apprentice and the employer

The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation, training, and moderation.

Interview underpinned by a portfolio of evidence

Overview

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 evidenct gives the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method.

Rationale

This assessment method is being used because:

Delivery

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 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 is however, it is not directly assessed.

The interview must last for 90 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 9 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 apprentice’s answers to questions
  • the KSBs demonstrated in answers to questions
  • the grade achieved 

Assessment location

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.

Question and resource development

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:

  • independent assessor assessment materials which include:
  • training materials
  • administration materials
  • moderation and standardisation materials
  • guidance materials
  • grading guidance
  • question bank
  • EPA guidance for the apprentice and the employer

The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation, training, and moderation.

Multiple-choice test

Overview

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.

Rationale

This assessment method is being used because:

Delivery

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 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.

Test administration

The apprentice must have 60 minutes to complete the 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 under the responsibility of the EPAO.

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 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.

Marking

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 the multiple-choice test.

Assessment location

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 may take place remotely if the appropriate technology and systems are in place to prevent malpractice. The EPAO must ensure invigilation of the apprentice for example with, and not limited to, 360-degree cameras and screen sharing facilities.

Question and resource development

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 multiple-choice test:

  • independent assessor assessment materials which include:
    • training materials
    • administration materials
    • moderation and standardisation materials
    • guidance materials
    • grading guidance
    • test specification
    • sample test and mark schemes
    • live tests and mark schemes
    • question bank
  • EPA guidance for the apprentice and the employer

The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation, training, and moderation.

Grading

Observation with questions

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

Planning
K37 S2

Plans work and identifies and organises resources required to complete tasks using planning, prioritising, and time management techniques. (K37, S2)

None

Work environment: health and safety, environment
K4 S3 S4 S5 S19 B1

Identifies and documents hazards and risks in the workplace. Applies health and safety procedures in compliance with regulations and standards mitigating against risks including correct selection, inspection, operation, wearing, and disposal of personal protective equipment. Prioritises health and safety over other factors. (K4, S3, S4, B1)

Applies environmental and sustainability procedures in compliance with regulations and standards including segregating resources for reuse, recycling, and disposal. (S5, S19)

Justifies their choice to comply with and prioritise health and safety legislation in their composites work. (K4, S4, B1)

Tools and equipment
K16 S8 S9 S10

Selects and checks hand tools, equipment, and machinery for the task including checking calibration records if relevant. (S8)

Uses or operates hand tools, equipment, and machinery in line with their employer’s and manufacturers’ instructions. (K16, S9)

Stores hand tools and equipment after use in line with employer’s guidelines. (S10)

None

Materials
S11

Selects, checks, and prepares materials in line with manufacturing specification. (S11)

None

Composite processing
K22 K23 K26 S1 S7 S13 S14 S15

Performs the composite manufacturing processes of moulding, laminating, and curing and extracts product from the mould in line with drawings, instructions, and information for the task.

Identifies the principles behind the curing process used.

(K22, K23, K26, S1, S7, S13, S14, S15)

Produces a consistent high-quality output, mitigating against potential issues for example, attention to detail, right first time, minimises scrap rate, minimises defects. 

Explains how they can change the curing process to influence the quality of the final laminate.

(K22, K23, K26, S1, S7, S13, S14, S15)

Quality assurance
K28 S12 S16 B4

Applies quality control processes during manufacture and conducts final product quality assurance procedure in line with task requirements, taking responsibility for outcomes. (K28, S12, S16, B4)

Justifies the use of quality control and assurance methods for composite manufacturing. (K28, S12, S16, B4)

Communication
K34 S25

Uses verbal communication techniques suitable for the context, adapting style and use of terminology to suit the audience. (K34, S25)

None

Documentation
K29 S20

Records or enters data to complete work records required for tasks correctly and in full - paper based or electronic. (K29, S20)

None

Interview underpinned by a portfolio of evidence

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

Composite technician's role
K2 K27 S18 B3

Explains how they conduct their role in line with limits of responsibility and escalate issues outside their remit in line with company procedures. (K2, S18)

Explains how they adhere to organisational quality, cost, and delivery (QCD) standards and company professional integrity standards. (S18, B3)

None

Sustainability
K6 S6 B2

Describes how they consider and apply the principles of environmental sustainability in their work in line with organisational procedures, regulations and standards on energy efficiency, material reuse, recycling, and management of emissions and waste. (K6, S6, B2)

Supports the development of environmental and sustainability practice in the workplace for example, through promoting good practice to others, identifying improvement to practice. (K6, S6, B2)

Design and manufacture - tools and processes
K19 K20 K21

Explains composite mould tool manufacture methods, techniques and considerations, showing awareness of the application of digital systems to support manufacture: CAD (computer-aided design), CAM (computer-aided manufacturing), CMM (coordinate measuring machine), and additive manufacture and composite tooling and product design process with reference to their company's practices. (K19, K20, K21)

None

Composite process risk and repairs
K24 K25

Explains process risk in composite manufacture and mitigation, defect types and causes, and repair techniques: step, scarf, gel, resin injection, and riveting with reference to their company's practice. (K24, K25)

None

Problem solving and continuous improvement
K31 K32 S17 S21 S22 S23

Explains how they have identified an issue with a composite and applied either root cause analysis or 5-Whys method to investigate, identifying the cause and finding a solution. (K31, S17, S22)

Explains how they have applied either the lean, 6-sigma, KAIZEN, or 5S continuous improvement technique to provide a solution to a composite related issue or process in their own work. (K32, S23)

Explains how they have interpreted data and used it to validate suggestions related to composite product or process improvement. (S21)

Evaluates how the improvement suggestion has the potential to improve the work of the wider team, workplace, or system. (K32, S23)

Written communication
K35 S26

Describes how they have communicated in written form in the workplace using techniques suitable for context. (K35, S26)

None

Information technology
K33 S27

Describes how they have applied information technology in work tasks in compliance with GDPR and organisational cyber security regulations and policies. (K33, S27)

None

Team working
K36 S24 B5 B6

Describes how they have applied team working principles in line with the organisational policy on equality, diversity, and inclusion within their own team. Describes how they have responded and adapted to work demands or situations to support their own team’s work goals. (K36, S24, B5, B6)

Explains how their team focus and commitment to inclusivity extends to wider teams or stakeholders. (K36, S24, B5, B6)

Continued professional development
S28 B7

Describes the planned and unplanned continued professional development (CPD) activities they have carried out and recorded to meet personal and organisation development needs, showing a commitment to future CPD. Evaluates what the impact of their CPD has been and how it has benefited the business. (S28, B7)

None

Multiple-choice test

Grade Minimum marks required Maximum marks required
Fail 0 27
Pass 28 40

Overall EPA grading

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 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 or more assessment methods, they will be awarded an overall EPA fail. 

To achieve an overall pass, the apprentice should 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 multiple-choice test. 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 should 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

Re-sits and re-takes

An apprentice who fails one or more assessment method(s) can take a re-sit or a re-take at the 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 apprentice's 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 EPA 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 and responsibilities

Roles Responsibilities

Apprentice

As a minimum, the apprentice should:

  • participate in and complete on-programme training to meet the KSBs as outlined in the occupational standard for a minimum of 12 months
  • complete the required amount of off-the-job training specified by the apprenticeship funding rules and as arranged by the employer and training provider
  • understand the purpose and importance of EPA
  • meet the gateway requirements 
  • undertake the EPA  

 

Employer

As a minimum, the apprentice's employer must:

  • select the EPAO and training provider 
  • work with the training provider (where applicable) to support the apprentice in the workplace and to provide the opportunities for the apprentice to develop the KSBs
  • arrange and support off-the-job training to be undertaken by the apprentice 
  • decide when the apprentice is working at or above the occupational standard and is ready for EPA 
  • ensure that supporting evidence required at the gateway is submitted in line with this EPA plan 
  • liaise with the training provider and EPAO to ensure the EPA is booked in a timely manner

Post-gateway, the employer must: 

  • confirm arrangements with the EPAO for the EPA (who, when, where) in a timely manner (including providing access to any employer-specific documentation as required, for example company policies)
  • ensure that the EPA is scheduled with the EPAO for a date and time which allows the opportunity for the apprentice to be assessed against the KSBs 
  • remain independent from the delivery of the EPA
  • ensure the apprentice is given sufficient time away from regular duties to prepare for, and complete all post-gateway elements of the EPA, and that any required supervision during this time (as stated within this EPA plan) is in place
  • where the apprentice is assessed in the workplace, ensure that the apprentice has access to the resources used on a regular basis 
  • pass the certificate to the apprentice upon receipt from the EPAO

EPAO

As a minimum, the EPAO must:  

  • conform to the requirements of this EPA plan and deliver its requirements in a timely manner 
  • conform to the requirements of the register of end-point assessment organisations (RoEPAO) 
  • conform to the requirements of the external quality assurance provider (EQAP) for this apprenticeship 
  • understand the occupational standard 
  • make the EPA contractual arrangements, including agreeing the price of the EPA 
  • develop and produce assessment materials as detailed for each assessment method in this EPA plan 
  • appoint qualified and competent independent assessors in line with the requirements of this EPA plan to conduct assessments and oversee their working 
  • appoint administrators (and invigilators where required) to administer the EPA  
  • provide training for independent assessors in terms of good assessment practice, operating the assessment tools and grading 
  • provide information, advice, guidance and documentation to enable apprentices, employers and training providers to prepare for the EPA 
  • confirm all gateway requirements have been met as quickly as possible 
  • arrange for the EPA to take place, in consultation with the employer 
  • ensure that the apprentice has access to the required resources and liaise with the employer to agree this if necessary, where the apprentice is not assessed in the workplace 
  • develop and provide assessment recording documentation to ensure a clear and auditable process is in place for providing assessment decisions and feedback to stakeholders 
  • have no direct connection with the apprentice, their employer or training provider in all instances; there must be no conflict of interest 
  • have policies and procedures for internal quality assurance (IQA), and maintain records of IQA activity and moderation for external quality assurance (EQA) purposes 
  • deliver induction training for independent assessors, and for invigilators and markers (where used) 
  • undertake standardisation activity on this apprenticeship for an independent assessor before they conduct an EPA for the first time, if the EPA is updated and periodically (a minimum of annually) 
  • manage invigilation of the apprentice to maintain security of the assessment in line with the EPAO’s malpractice policy 
  • verify the identity of the apprentice  
  • use language in the development and delivery of the EPA that is appropriate to the level of the occupational standard 

Independent assessor

As a minimum, an independent assessor must: 

  • have the competence to assess the apprentice at the level of this apprenticeship and hold any required qualifications and experience in line with the requirements of the independent assessor as detailed in the IQA section of this EPA plan 
  • understand the occupational standard and the requirements of this EPA 
  • have, maintain and be able to evidence, up-to-date knowledge and expertise of the occupation 
  • deliver the end-point assessment in-line with this EPA plan 
  • comply with the IQA requirements of the EPAO 
  • have no direct connection or conflict of interest with the apprentice, their employer or training provider; in all instances; there must be no conflict of interest 
  • attend induction training 
  • attend standardisation events when they start working for the EPAO, before they conduct an EPA for the first time and a minimum of annually for this apprenticeship  
  • assess each assessment method, as determined by the EPA plan  
  • assess the KSBs assigned to each assessment method, as shown in the mapping of KSBs to assessment methods in this EPA plan  
  • make the grading decisions 
  • record and report assessment outcome decisions, for each apprentice, following instructions and using assessment recording documentation provided by the EPAO, in a timely manner 
  • use language in the development and delivery of the EPA that is appropriate to the level of the occupational standard 
  • mark open (constructed) test answers accurately according to the EPAO’s mark scheme and procedures 

Training provider

As a minimum, the training provider must: 

  • work with the employer and support the apprentice during the off-the-job training to provide the opportunities to develop the KSBs as listed in the occupational standard 
  • conduct training covering the KSBs agreed as part of the Commitment Statement or the Individual Learning Plan 
  • monitor the apprentice’s progress during any training provider led on-programme learning 
  • advise the employer, upon request, on the apprentice’s readiness for EPA 
  • remain independent from the delivery of the EPA 

Marker

As a minimum, the marker must:

  • attend induction training as directed by the EPAO 
  • have no direct connection or conflict of interest with the apprentice, their employer or training provider in all instances 
  • mark test answers in line with the EPAO’s mark scheme and procedures 

Invigilator

As a minimum, the invigilator must: 

  • attend induction training as directed by the EPAO 
  • have no direct connection or conflict of interest with the apprentice, their employer or training provider in all instances 
  • invigilate and supervise apprentices during tests and in breaks during assessment methods to prevent malpractice in accordance with the EPAO’s invigilation procedures 

Reasonable adjustments

The EPAO must have reasonable adjustments arrangements for the EPA.

This should include:

  • how an apprentice qualifies for reasonable adjustment
  • what reasonable adjustments may be made

Adjustments must maintain the validity, reliability and integrity of the EPA as outlined in this EPA plan.

Internal quality assurance (IQA)

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.

The EPAO must also:

  • have quality assurance systems and procedures that ensure fair, reliable and consistent EPA regardless of employer, place, time or independent assessor
  • appoint independent assessors who are competent to deliver the EPA and who:
    • have recent relevant experience of the occupation or sector to at least occupational level 3 gained in the last 3 years or significant experience of the occupation or sector
  • operate induction training for anyone involved in the delivery or assessment of the EPA
  • provide training for independent assessors in good assessment practice, operating the assessment tools and making grading decisions
  • provide ongoing training for markers and invigilators
  • provide standardisation activity for this apprenticeship standard for all independent assessors:
    • before they conduct an EPA for the first time
    • if the EPA is updated
    • periodically as appropriate (a minimum of annually)
  • conduct effective moderation of EPA decisions and grades
  • conduct appeals where required, according to the EPAO’s appeals procedure, reviewing and making final decisions on EPA decisions and grades
  • have no direct connection with the apprentice, their employer or training provider

Professional recognition

Mapping of KSBs to assessment methods

Knowledge Assessment methods
K1

Composite industry awareness. Range of composite products. Manufacturing environments. Types of customers.

Back to Grading
Multiple-choice test
K2

Composite technician’s role. Limits of responsibility. Escalation procedures.

Back to Grading
Interview underpinned by a portfolio of evidence
K3

Health and safety regulations and standards awareness. Control of Substances Hazardous to Health (COSHH). Display Screen Equipment. Electrical safety and compliance. Fire safety. Hand arm vibration (HAVS). Health and Safety at Work Act – responsibilities. Human factors, ergonomics. Legionella. Lifting Operations and Lifting Equipment Regulations (LOLER). Lone working. Manual handling. Noise regulation. Provision and Use of Work Equipment Regulations (PUWER). Slips trips and falls. The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR). Working at Height. Working in Confined Spaces.

Back to Grading
Multiple-choice test
K4

Health and safety practice. Risk assessment and risk mitigation in composites process manufacturing environment. Personal protective equipment (PPE) requirements: selection, inspection, operation, wearing, and disposal.

Back to Grading
Observation with questions
K5

Environmental and sustainability regulations and guidance. Environmental hazards that can arise from composite operations. Environmental management systems standard. Environmental Protection Act. Environmental signage and notices.

Back to Grading
Multiple-choice test
K6

Principles of sustainability and circular economy. Energy efficiency and reuse of materials. Recycling procedures. Principles of control and management of emissions and waste.

Back to Grading
Interview underpinned by a portfolio of evidence
K7

Definition of a composite. Interaction between resin and fibre. Types of core. Benefits of adding core. Advantages and disadvantages of composites.

Back to Grading
Multiple-choice test
K8

The characteristics of finished composite products and their various applications.

Back to Grading
Multiple-choice test
K9

The difference between thermoset and thermoplastics: mechanical and thermal benefits, processing requirements, and re-cycling potential.

Back to Grading
Multiple-choice test
K10

Types of reinforcement materials: aramid, carbon, glass, natural fibres, and thermoplastic fibres; processing, cost, performance, benefits, and limitations.

Back to Grading
Multiple-choice test
K11

Types of matrix materials: bismaleimide, cyanate ester, epoxy, phenolic, polyester, vinylester, and bio-derived: processing, cost, performance, benefits, and limitations.

Back to Grading
Multiple-choice test
K12

The manufacture of materials: chopped strand mat, non-crimp fabrics, pre-impregnated, preforms, unidirectional, and woven reinforcements. Different weave styles: plain, satin and twill; impact on drape and mechanical properties.

Back to Grading
Multiple-choice test
K13

Composite process materials and consumables: peel plies, release agents, release films, sealant tapes, and vacuum bag; application and benefits of use.

Back to Grading
Multiple-choice test
K14

Hand lay-up techniques: open moulding, spray lay-up, and pre-impregnated. Resin infusion, resin transfer moulding, and closed moulding using vacuum techniques.

Back to Grading
Multiple-choice test
K15

Awareness of automated lay-up: automated fibre placement, automated tape layup, braiding, and filament winding.

Back to Grading
Multiple-choice test
K16

Plant, equipment, machinery, and hand tools used within composites manufacture: application and operation.

Back to Grading
Observation with questions
K17

The curing cycle. Glass transition temperature (Tg). The science of pressure and vacuum.

Back to Grading
Multiple-choice test
K18

Principles of process control and instrument control methodology.

Back to Grading
Multiple-choice test
K19

Awareness of application of digital systems to support manufacture: CAD (computer-aided design), CAM (computer-aided manufacturing), CMM (coordinate measuring machine), and additive manufacture.

Back to Grading
Interview underpinned by a portfolio of evidence
K20

Composite tooling and product design process awareness.

Back to Grading
Interview underpinned by a portfolio of evidence
K21

Composite mould tool manufacture methods, techniques, and considerations.

Back to Grading
Interview underpinned by a portfolio of evidence
K22

Composite mould tool preparation and operation.

Back to Grading
Observation with questions
K23

Composite manufacture processes and principles: moulding, laminating, and curing.

Back to Grading
Observation with questions
K24

Process risk in composite manufacture and mitigation. Defect types and causes.

Back to Grading
Interview underpinned by a portfolio of evidence
K25

Composite repair techniques: step, scarf, gel, resin injection, and riveting.

Back to Grading
Interview underpinned by a portfolio of evidence
K26

Standard operating procedures, drawings, and work instructions: what are they, why they are important.

Back to Grading
Observation with questions
K27

Quality, cost, and delivery (QCD) standards and their importance in the workplace.

Back to Grading
Interview underpinned by a portfolio of evidence
K28

Quality assurance, testing and inspection methods.

Back to Grading
Observation with questions
K29

Documentation requirements.

Back to Grading
Observation with questions
K30

Awareness of audits and their purpose.

Back to Grading
Multiple-choice test
K31

Problem solving: root cause analysis, 5-Whys.

Back to Grading
Interview underpinned by a portfolio of evidence
K32

Continuous improvement (CI) techniques: lean, 6-sigma, KAIZEN, and 5S.

Back to Grading
Interview underpinned by a portfolio of evidence
K33

Information technology. Management information systems, word processing, spreadsheet, email, virtual learning platforms, document sharing platforms. General data protection regulation (GDPR). Cyber security.

Back to Grading
Interview underpinned by a portfolio of evidence
K34

Verbal communication techniques. Composite industry terminology.

Back to Grading
Observation with questions
K35

Written communication techniques.

Back to Grading
Interview underpinned by a portfolio of evidence
K36

Principles of team working. Equality, diversity and inclusion.

Back to Grading
Interview underpinned by a portfolio of evidence
K37

Planning, prioritising, and time management techniques.

Back to Grading
Observation with questions
Skill Assessment methods
S1

Review drawings, instructions, or information to understand task.

Back to Grading
Observation with questions
S2

Plan work. Identify and organise resources.

Back to Grading
Observation with questions
S3

Identify hazards and risks in the workplace.

Back to Grading
Observation with questions
S4

Apply health and safety procedures in compliance with regulations and standards.

Back to Grading
Observation with questions
S5

Apply environmental and sustainability procedures in compliance with regulations and standards.

Back to Grading
Observation with questions
S6

Apply sustainability principles for example, in choice of materials, minimising waste.

Back to Grading
Interview underpinned by a portfolio of evidence
S7

Prepare and use mould tools.

Back to Grading
Observation with questions
S8

Select and check hand tools, equipment and machinery including calibration record.

Back to Grading
Observation with questions
S9

Use or operate hand tools, equipment, and machinery.

Back to Grading
Observation with questions
S10

Store mould tools, hand tools, and equipment.

Back to Grading
Observation with questions
S11

Select, check, and prepare materials for example, weigh resins, cut reinforcement.

Back to Grading
Observation with questions
S12

Follow quality control processes during manufacture for example, check for contaminants, record batch numbers or expiry dates.

Back to Grading
Observation with questions
S13

Apply laminate to mould for example, cut, add darts, corner definition, orientation, position, and order.

Back to Grading
Observation with questions
S14

Complete preparation for and start curing process for example, select and apply consumables for example vacuum bag, infuse with resin, add heat or pressure.

Back to Grading
Observation with questions
S15

Extract product from mould (break out).

Back to Grading
Observation with questions
S16

Conduct final product quality assurance procedure. For example, conduct grading parameters checks (size, appearance, weight), and take samples for laboratory testing.

Back to Grading
Observation with questions
S17

Identify issues for example, de-laminations, inclusions, surface defects, surface imperfections, and maintenance requirements.

Back to Grading
Interview underpinned by a portfolio of evidence
S18

Escalate issues outside limits of responsibility.

Back to Grading
Interview underpinned by a portfolio of evidence
S19

Segregate resources for reuse, recycling, and disposal.

Back to Grading
Observation with questions
S20

Record or enter data - paper based or electronic. For example, process and production records, traceability records, and quality assurance records.

Back to Grading
Observation with questions
S21

Interpret data for example, defect data and geometrical measurements. Use data to validate suggestions.

Back to Grading
Interview underpinned by a portfolio of evidence
S22

Investigate a problem to identify the underlying cause. Identify a solution to the problem.

Back to Grading
Interview underpinned by a portfolio of evidence
S23

Apply continuous improvement techniques. Devise suggestions for improvement. For example, improving the energy consumption or waste profile of processes and procedures to improve the sustainability or carbon footprint of a product, process, or task.

Back to Grading
Interview underpinned by a portfolio of evidence
S24

Apply team working principles.

Back to Grading
Interview underpinned by a portfolio of evidence
S25

Communicate with others verbally for example, colleagues and stakeholders.

Back to Grading
Observation with questions
S26

Communicate in written form in the workplace for example, handover notes or emails, non-conformances, design change requests.

Back to Grading
Interview underpinned by a portfolio of evidence
S27

Use information technology for work tasks. Comply with GDPR and cyber security regulations and policies.

Back to Grading
Interview underpinned by a portfolio of evidence
S28

Plan how to meet personal development needs. Carry out and record planned and unplanned continued professional development (CPD) activities. Evaluate CPD against plans made.

Back to Grading
Interview underpinned by a portfolio of evidence
Behaviour Assessment methods
B1

Prioritise health and safety.

Back to Grading
Observation with questions
B2

Consider the environment and sustainability.

Back to Grading
Interview underpinned by a portfolio of evidence
B3

Demonstrate professional integrity.

Back to Grading
Interview underpinned by a portfolio of evidence
B4

Take responsibility for the quality of work.

Back to Grading
Observation with questions
B5

Team-focus with commitment to inclusivity.

Back to Grading
Interview underpinned by a portfolio of evidence
B6

Respond and adapt to work demands or situations.

Back to Grading
Interview underpinned by a portfolio of evidence
B7

Committed to continued professional development.

Back to Grading
Interview underpinned by a portfolio of evidence

Mapping of KSBs to grade themes

Observation with questions - Observation

KSBS GROUPED BY THEME Knowledge Skills Behaviour
Planning
K37
S2

Planning, prioritising, and time management techniques. (K37)

Plan work. Identify and organise resources. (S2)

N/A

Work environment: health and safety, environment
K4
S3 S4 S5 S19
B1

Health and safety practice. Risk assessment and risk mitigation in composites process manufacturing environment. Personal protective equipment (PPE) requirements: selection, inspection, operation, wearing, and disposal. (K4)

Identify hazards and risks in the workplace. (S3)

Apply health and safety procedures in compliance with regulations and standards. (S4)

Apply environmental and sustainability procedures in compliance with regulations and standards. (S5)

Segregate resources for reuse, recycling, and disposal. (S19)

Prioritise health and safety. (B1)

Tools and equipment
K16
S8 S9 S10

Plant, equipment, machinery, and hand tools used within composites manufacture: application and operation. (K16)

Select and check hand tools, equipment and machinery including calibration record. (S8)

Use or operate hand tools, equipment, and machinery. (S9)

Store mould tools, hand tools, and equipment. (S10)

N/A

Materials

S11

N/A

Select, check, and prepare materials for example, weigh resins, cut reinforcement. (S11)

N/A

Composite processing
K22 K23 K26
S1 S7 S13 S14 S15

Composite mould tool preparation and operation. (K22)

Composite manufacture processes and principles: moulding, laminating, and curing. (K23)

Standard operating procedures, drawings, and work instructions: what are they, why they are important. (K26)

Review drawings, instructions, or information to understand task. (S1)

Prepare and use mould tools. (S7)

Apply laminate to mould for example, cut, add darts, corner definition, orientation, position, and order. (S13)

Complete preparation for and start curing process for example, select and apply consumables for example vacuum bag, infuse with resin, add heat or pressure. (S14)

Extract product from mould (break out). (S15)

N/A

Quality assurance
K28
S12 S16
B4

Quality assurance, testing and inspection methods. (K28)

Follow quality control processes during manufacture for example, check for contaminants, record batch numbers or expiry dates. (S12)

Conduct final product quality assurance procedure. For example, conduct grading parameters checks (size, appearance, weight), and take samples for laboratory testing. (S16)

Take responsibility for the quality of work. (B4)

Communication
K34
S25

Verbal communication techniques. Composite industry terminology. (K34)

Communicate with others verbally for example, colleagues and stakeholders. (S25)

N/A

Documentation
K29
S20

Documentation requirements. (K29)

Record or enter data - paper based or electronic. For example, process and production records, traceability records, and quality assurance records. (S20)

N/A

Interview underpinned by a portfolio of evidence - Discussion

KSBS GROUPED BY THEME Knowledge Skills Behaviour
Composite technician's role
K2 K27
S18
B3

Composite technician’s role. Limits of responsibility. Escalation procedures. (K2)

Quality, cost, and delivery (QCD) standards and their importance in the workplace. (K27)

Escalate issues outside limits of responsibility. (S18)

Demonstrate professional integrity. (B3)

Sustainability
K6
S6
B2

Principles of sustainability and circular economy. Energy efficiency and reuse of materials. Recycling procedures. Principles of control and management of emissions and waste. (K6)

Apply sustainability principles for example, in choice of materials, minimising waste. (S6)

Consider the environment and sustainability. (B2)

Design and manufacture - tools and processes
K19 K20 K21

Awareness of application of digital systems to support manufacture: CAD (computer-aided design), CAM (computer-aided manufacturing), CMM (coordinate measuring machine), and additive manufacture. (K19)

Composite tooling and product design process awareness. (K20)

Composite mould tool manufacture methods, techniques, and considerations. (K21)

N/A

N/A

Composite process risk and repairs
K24 K25

Process risk in composite manufacture and mitigation. Defect types and causes. (K24)

Composite repair techniques: step, scarf, gel, resin injection, and riveting. (K25)

N/A

N/A

Problem solving and continuous improvement
K31 K32
S17 S21 S22 S23

Problem solving: root cause analysis, 5-Whys. (K31)

Continuous improvement (CI) techniques: lean, 6-sigma, KAIZEN, and 5S. (K32)

Identify issues for example, de-laminations, inclusions, surface defects, surface imperfections, and maintenance requirements. (S17)

Interpret data for example, defect data and geometrical measurements. Use data to validate suggestions. (S21)

Investigate a problem to identify the underlying cause. Identify a solution to the problem. (S22)

Apply continuous improvement techniques. Devise suggestions for improvement. For example, improving the energy consumption or waste profile of processes and procedures to improve the sustainability or carbon footprint of a product, process, or task. (S23)

N/A

Written communication
K35
S26

Written communication techniques. (K35)

Communicate in written form in the workplace for example, handover notes or emails, non-conformances, design change requests. (S26)

N/A

Information technology
K33
S27

Information technology. Management information systems, word processing, spreadsheet, email, virtual learning platforms, document sharing platforms. General data protection regulation (GDPR). Cyber security. (K33)

Use information technology for work tasks. Comply with GDPR and cyber security regulations and policies. (S27)

N/A

Team working
K36
S24
B5 B6

Principles of team working. Equality, diversity and inclusion. (K36)

Apply team working principles. (S24)

Team-focus with commitment to inclusivity. (B5)

Respond and adapt to work demands or situations. (B6)

Continued professional development

S28
B7

N/A

Plan how to meet personal development needs. Carry out and record planned and unplanned continued professional development (CPD) activities. Evaluate CPD against plans made. (S28)

Committed to continued professional development. (B7)

Contact us about this apprenticeship

Employers involved in creating the standard: Aerotron, IMET, LM Wind Power, McClaren, Multi-Ply, Teledyne CML Composites

Version log

Version Change detail Earliest start date Latest start date Latest end date
Revised version awaiting implementation in revision Not set Not set Not set
1.0 Approved for delivery 16/02/2017 Not set Not set

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