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Overview of the role

Controlling and managing the complex manufacturing processes for different materials

Reference Number: ST0659

Details of standard

Occupation summary

This occupation is found in a wide variety of Thermal Process related fields including Casting, Forging, Machining, Coating, Heat treatment and Surface Finishing processes. These specialist areas are also found in a wide range of industries where materials and their processes are fundamental to the technology . Industries as diverse as Medical, Defence, Energy, Oil and Gas, Aerospace and Nuclear all incorporate the skills of Materials Process Engineers. The broad purpose of the occupation is to perform a role which is unique to the materials/manufacturing community, controlling and managing the complex manufacturing processes and support services that are applied to products for the automotive, aerospace, medical, energy and construction sectors. They do this by collecting and organising all the information needed to understand the whole problem, exploring it from all angles, and then finding the most appropriate solution for integration into a sustainable product life cycle. A Materials Process Engineer might typically work in either the problem definition or solution provider environments, making critical decisions in the process and utilities to produce high-quality, cost-effective parts and systems, then testing and accepting the designed solutions. They provide essential support to their associated businesses providing guidance and leadership in improving company metrics of quality, delivery, new product introduction and support key financial and business decisions.. In their daily work, an employee in this occupation interacts with all departments within the companies they work for and at a range of levels within the departments depending on the project in which they are engaged. Their main focus will be with the Engineering team and they will also have  strong links in support of the Operations team. However to fulfil many of the projects, links to finance, supply chain and customer support will be a day to day occurrence and as the activities broaden there will be strong communication to the wider external customer base both in a sales support activity and during technical project discussions. An employee in this occupation will be responsible for implementing new products and processes and for many cost reduction and process improvement initiatives. They have direct responsibility for defining the methods of manufacture of complex engineering systems and the asset base and services which are used to produce high value manufactured products. In many cases weekly and monthly reports will be required at both team level and to senior members of the company.

Typical job titles

Typical job titles include Process Engineer; Product Engineer; Manufacturing Engineer; Materials Engineer; Technologist; Coatings engineer; Surface treatment engineer; Casting Engineer; Fellow; Subject Matter Expert; Senior( Domain Specialist) Engineer eg Welding Engineer,.

Core occupation duties

Duty

Criteria for measuring performance

KSBs

Duty 1 Lead multiple new product introduction or process improvement engineering projects working closely with the operations and engineering teams to prioritise projects in line with ever changing business / customer priorities

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

K1 K2 K3 K4 K5 K6 K27

S1 S2 S3 S4 S5

B1 B2 B3 B4 B5 B6

Duty 2 Takes responsibility for the creation of process rules that ensure product definition will be capable of being manufactured, assembled and repaired in line with project timescales

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

K7 K8 K9

S1 S2 S3 S4 S6 S7 S8

B1 B6

Duty 3 Liaises directly with customers to fully establish working project requirements, status and action plans

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

K2 K4 K5 K10 K11 K12

S1 S2 S4 S9

B1 B3

Duty 4 Leads process improvement activities associated with new and existing manufacturing processes utilising latest techniques and practices by the collection and analysis of data using standard SPC analytical techniques

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

K7 K8 K10 K13 K14 K15 K16

S1 S2 S3 S4 S10 S11 S12

B1 B5 B6

Duty 5 Performs, implements and reviews process risk and mitigation activities utilising tools such as PFMEA and value stream mapping to manage product quality and cost

Cost and quality standards meet business requirements

K5 K9 K14 K17 K18

S1 S2 S3 S4 S13 S14

B2 B4 B6

Duty 6 Understand manufacturing engineering production methods, control strategies and quality issues related to the manufacture of products

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

K13 K17 K19

S1 S7 S12 S14 S16

B1 B6

Duty 7 Identify, implement and share best practices across multiple cells and sites by development of global methods and systems to support design, cost and quality targets

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

Positive relationship with peers

K1 K3 K8 K9 K16 K20

S1 S2 S3 S4 S5

B1 B2 B3 B4

Duty 8 Provide expert materials advice to inform and guide commercial [team] decision making

Work delivered to agreed timescales and cost

K2 K3 K10 K12 K18

S1 S2 S3 S4 S14

B1 B4 B6

Duty 9 Evaluate the latest technological advances and provide a critical analysis of their short and long term implications for the business

Adherence to employer policies and procedures

Excellent interpersonal skills

K6 K8 K10 K12 K15 K18

S1 S2 S4 S8 S9 S14

B1 B3 B5 B6

Duty 10 Accurately review customer drawings and specifications and ensure compliance when creating work instructions and other internal documentation

Compliance to customer specifications

K5 K7 K8 K9 K12

S1 S2 S4 S7 S8 S9

B1 B2 B5 B6

Duty 11 Work with all stakeholders to ensure compliance with quality, environmental and Health and Safety policies

Adherence to employer policies and procedures

K5 K8 K10 K11 K15

S1 S2 S4 S12

B1 B3 B6

Duty 12 Create the detailed process instructions including inspection requirements, design and procure tooling and fixtures in aid of production activities or to improve productivity

Adherence to employer policies and procedures

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

K5 K8 K15 K18 K19 K21

S7 S8 S12

B1 B5 B6

Duty 13 Deliver stable and capable processes to an agreed customer specification and that there are actions in place to support equipment improvement and associated maintenance schedules to ensure capable process continuation

Adherence to employer policies and procedures

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

K5 K8 K9 K13 K14 K15 K16 K17 K22

S1 S6 S7 S8 S9 S10 S11

B1 B3 B5 B6

Duty 14 Produce technical reports as required during interim phases and at completion of project work

Excellent interpersonal skills

Successful review of technical reports

K23 K24

S2

B2 B4

Duty 15 Market and represent the company at customer technical meetings and at local/international conferences and events

Excellent interpersonal skills

Excellent presentation skills

K8 K9 K11 K12 K23

S2 S4

B1 B3 B5

Duty 16 Lead, mentor and manage teams highlighting the importance of networking, communication and taking personnel responsibility in delivering products to a customer

Excellent interpersonal skills

K1 K3 K19 K20 K21 K25

S1 S2 S4 S5

B2 B3 B4


Option duties

Duty

Criteria for measuring performance

KSBs

Duty 17: Ensure the safe and reliable operation, control of the process and close out of quality, process and business improvements in a castings environment


Option title/s

 Materials Process Engineering - Casting

Successful review of case studies with mentors

Successful completion of project

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

K26

S16

B1 B2 B3 B4 B5 B6

Duty 18: Lead the end to end process for casting operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between  business critical departments


Option title/s

 Materials Process Engineering - Casting

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

K26

S16

B1 B2 B3 B4 B5 B6

Duty 19: Ensure casting is integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification


Option title/s

 Materials Process Engineering - Casting

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

K26

S17

B5 B6

Duty 20: Ensure methods and techniques for safe and reliable operation, control  and close out of quality, process and business improvements in a coatings environment


Option title/s

 Materials Process Engineering - Coatings

Successful review of case studies with mentors

Successful completion of project

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

K28

S16

B1 B2 B3 B4 B5 B6

Duty 21: Lead the end to end process for coating operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between  business critical departments


Option title/s

 Materials Process Engineering - Coatings

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to Customer specifications

Productivity standards meet Customer requirements

Cost and quality standards meet Business requirements

K28

S16

B1 B2 B3 B4 B5 B6

Duty 22: Ensure Coatings are integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification


Option title/s

 Materials Process Engineering - Coatings

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

S17

B5 B6

Duty 23: Ensure the safe and reliable operation, control and close out of quality, process and business improvements in a welding environment


Option title/s

 Materials Process Engineering - Welding

Successful review of case studies with mentors

Successful completion of project

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

K29

S16

B1 B2 B3 B4 B5 B6

Duty 24: Lead the end to end process for welding operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between  business critical departments


Option title/s

 Materials Process Engineering - Welding

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to Customer specifications

Productivity standards meet Customer requirements

Cost and quality standards meet Business requirements

K29

S16

B1 B2 B3 B4 B5 B6

Duty 25: Ensure Welding is integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification


Option title/s

 Materials Process Engineering - Welding

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

S17

B5 B6

Duty 26: Ensure the requirements, methods and techniques for safe and reliable operation, control and close out of quality, process and business improvements in a brazing environment


Option title/s

 Materials Process Engineering - Brazing

Successful review of case studies with mentors

Successful completion of project

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

K30

S16

B1 B2 B3 B4 B5 B6

Duty 27: Lead the end to end process for brazing operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between  business critical departments


Option title/s

 Materials Process Engineering - Brazing

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

K30

S16

B1 B2 B3 B4 B5 B6

Duty 28: Ensure Brazing is integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification


Option title/s

 Materials Process Engineering - Brazing

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

S17

B5 B6

Duty 29: Ensure the requirements, methods and techniques for safe and reliable operation, control and close out of quality, process and business improvements in a heat treatment environment


Option title/s

 Materials Process Engineering - Heat Treatment

Successful review of case studies with mentors

Successful completion of project

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

K31

S16

B1 B2 B3 B4 B5 B6

Duty 30: Lead the end to end process for heat treatment operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between  business critical departments


Option title/s

 Materials Process Engineering - Heat Treatment

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

K31

S16

B1 B2 B3 B4 B5 B6

Duty 31: Ensure  Heat Treatment is integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification


Option title/s

 Materials Process Engineering - Heat Treatment

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

S17

B5 B6

Duty 32: Ensure the requirements, methods and techniques for safe and reliable operation, control and close out of quality, process and business improvements in a surface treatment environment


Option title/s

 Materials Process Engineering - Surface Treatment

Successful review of case studies with mentors

Successful completion of project

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

K32

S16

B1 B2 B3 B4 B5 B6

Duty 33: Lead the end to end process for surface treatment operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between  business critical departments


Option title/s

 Materials Process Engineering - Surface Treatment

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

K32

S16

B1 B2 B3 B4 B5 B6

Duty 34: Ensure Surface Treatment is integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification


Option title/s

 Materials Process Engineering - Surface Treatment

Adherence to employer policies and procedures

Work delivered to agreed timescales and cost

Compliance to customer specifications

Productivity standards meet customer requirements

Cost and quality standards meet business requirements

S17

B5 B6

KSBs

Knowledge

K1: Theories of team working

K2: Principles of programme management

K3: Understanding the importance of conflict management

K4: Risk management theories and practice

K5: Principles of Quality Management Systems and implementation in factory environments

K6: New product introduction and technology management - theory

K7: Importance of design for manufacture and assembly

K8: Principles and practices of engineering standards

K9: Principles of process risk management including Process Failure Modes and Effects Analysis (PFMEA)

K10: Principles of Stakeholder management

K11: Importance of working within a regulatory framework

K12: Importance of Intellectual Property, Patents and Export Control

K13: The function of Quality Techniques Systems and Standards

K14: The principles of statistical process control and application techniques (e.g PFMEA)

K15: Change management principles

K16: Principles and practices of knowledge based systems

K17: Principles of Lean Manufacturing

K18: Cost based engineering (including estimating, cost control, cost forecasting, investment appraisal and risk analysis)

K19: Principles of Operations management

K20: Principles of Leadership in Operations Management

K21: Principles of Supply Chain Management

K22: Principles of Asset Management

K23: The principles of effective presentations (including planning, structuring, how and when to engage with the audience,using visual aids, presenting data)

K24: Art of technical report writing

K25: Principles of mentoring people

K26: Fundamentals of casting process and technology

K27: Fundamentals of the product life cycle

K28: Fundamentals of coating processes and technology

K29: Fundamentals of welding processes and technology

K30: Fundamentals of brazing processes and technology

K31: Fundamentals of heat treatment processes and technology

K32: Fundamentals of surface treatment processes and technology

Skills

S1 Work within a team environment. This may include acting as a team leader with people management skills. They undertake risk analysis and problem solving on behalf of the team.

S2 Communicate and present information appropriately and effectively taking account of target audience

S3 Apply appropriate programme management tools. Typically this would include a RACI chart, Project Plans, Load and Capacity analysis and cost analysis.

S4 Actively listen and explain clearly and appropriately to target audience

S5 Mentor and support others using coaching skills and actively support continuous professional development.

S6 Use Process Failure Mode Effect Analysis tool kit appropriately

S7 Operate and control process equipment using continuous improvement methodologies

S8 Apply process control procedures correctly and effectively

S9 Apply appropriate negotiation techniques effectively

S10 Make appropriate use of statistical tools eg Minitab, excel, DMAIC

S11 Make appropriate use of problem solving tools eg 8D, 5 whys

S12 Apply change control tools and practices

S13 Apply risk management tools and techniques

S14 Demonstrate correct application of Value Stream Mapping tools

S15 Apply production control methods eg planning and project management

S16 Correct use of specialist equipment and process knowledge

S17 Correct use of product life cycle concepts

Behaviour


B1: Working collaboratively - is comfortable in working in teams and being a team leader to agreed goals

B2: Professional Commitment - Commitment to corporate values and behaviours through the demonstrating a personal , ethical and professional commitment to society, their profession and the environment, adopting a set of values and behaviours that will maintain and enhance the reputation of the profession as well as their organisation

B3: Commitment to leadership - Taking personal responsibility for their actions, managing projects including resource management within their remit and able to mentor and instruct others in associated standards and best practice

B4: Commitment to the profession Contributing proactively to the continuing development of engineering within their domain

B5: Curiosity and Innovation Utilising own and others creativity to Improve the industry through embracing new technology and the digital world

B6: System Thinking Seeing whole systems and parts and how they connect recognising interdependencies and integration

Qualifications

English and Maths qualifications

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. 

Other qualifications

Mandatory qualification 1: Manufacturing Technology and Management MSc

Level of qualification: 7 (non-integrated degree)

Basis for mandatory qualification: Eligible Type 2 qualification that does not meet any of the above three criteria (i.e. only select if any of the above three criteria do not apply)

Type of qualification

Type 2 off-the-job qualification

 

Mandatory Qualifications University Section

University 1

Provide the names of the universities involved in the development of the apprenticeship standard:

Cranfield

University 2

Provide the names of the universities involved in the development of the apprenticeship standard:

Loughborough

University 3

Provide the names of the universities involved in the development of the apprenticeship standard:

Manchester University


Professional recognition

Institute of Materials, Minerals and Mining / C.Eng

Institution of Mechanical Engineers / C Eng

Chartered Society of Designers / Chartered Designer

Institute of Metal Finishing / Chartered and Incorporated Engineers

Institute of Cast Metal Engineers / Chartered and Incorporated Engineers

NSIRC / CEng

Additional details

Occupational Level: 7
Duration (months): 24

Review

This standard will be reviewed after three years.


Crown copyright © 2019. You may re-use this information (not including logos) free of charge in any format or medium, under the terms of the Open Government Licence. Visit www.nationalarchives.gov.uk/doc/open-government-licence

Status: Approved for delivery
Level: 7
Degree: non-integrated degree
Reference: ST0659
Version: 1
Date updated: 22/03/2019
Approved for delivery: 22 March 2019
Route: Engineering and manufacturing
Typical duration: 24 months
Maximum funding: £17000
Trailblazer contact(s): AWilliams@chromalloy.com
Employers involved in creating the standard: Chromalloy, Permastore Ltd, TRL9 Ltd, The Manufacturing Technology Centre, Turbine Surfaces Technology, Euspen, Siemens, Oerlikon Metco UK Ltd, Ashton and Moore Ltd, Praxair Surface Technologies Ltd, Rolls Royce, Pilkington (NSG) Group, Daido Metal Co Ltd, Wallwork Cambridge, Swinton Electroplating and SEA, Advance Forming Research Centre, Praxair Surface Technologies Ltd, NPL, Indestructible Paint Ltd, KH Consultancy, Crown Packaging Manufacturing UK Ltd, KTN, Poeton Industries, Hardide Coatings Ltd

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Version log

Version Date updated Change Previous version
1 22/03/2019 Funding band first published

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1 11/02/2019 Assessment plan first published

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1 01/02/2019 Standard first published

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