Complete process manufacturing activities to produce polymer products to a specification.
Polymer processing technicians work in the process manufacturing sector.
A polymer is a substance or material made of long repeating chains of molecules. There are several types of polymers. They have different properties: light, heavy, strong, tough, and flexible, depending on the type of molecules bonded and how they are bonded. They are used for a wide variety of purposes in both everyday consumer products and highly demanding technical applications. Elastomer and rubber for example, are used for tyres and components such as seals and gaskets. PVC is used for water pipes, window frames, and cable insulation. Nylon and polyester are used in clothing. And plastics are used in mobile phones, computer hardware, automotive, medical devices, aerospace, disability aides, water bottles, and vacuum cleaners.
Polymer processing technicians produce polymer products to a specification. They work in a production facility - often on a large scale, using a range of machinery, control systems and engineering equipment. Products are made using continuous or in batch processes. Polymer processing technicians set up or configure equipment and tooling and prepare materials for processing. They run and monitor the process, adjusting parameters. They use unique technologies and processes such as extrusion, blow moulding, thermoforming, rotational moulding, injection moulding, internal mixing, and calendering. They undertake quality control, complete work records, and participate in improvement. They may also complete preventative maintenance and prepare polymer process equipment for maintenance and overhaul.
They work with other members of the production team. They also have contact with people from other functions such as, 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 usually report to a production manager.
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 as part of a small or large manufacturing team. They work with minimal supervision and are responsible for the quality of their own work. They may work shifts.
Polymer process technician
Polymer processing technician
Process technician
Production technician
This is a summary of the key things that you – the apprentice and your employer need to know about your end-point assessment (EPA). You and your employer should read the EPA plan for the full details. It has information on assessment method requirements, roles and responsibilities, and re-sits and re-takes.
An EPA is an assessment at the end of your apprenticeship. It will assess you against the knowledge, skills, and behaviours (KSBs) in the occupational standard. Your training will cover the KSBs. The EPA is your opportunity to show an independent assessor how well you can carry out the occupation you have been trained for.
Your employer will choose an end-point assessment organisation (EPAO) to deliver the EPA. Your employer and training provider should tell you what to expect and how to prepare for your EPA.
The length of the training for this apprenticeship is typically36 months. The EPA period is typically3 months.
The overall grades available for this apprenticeship are:
When you pass the EPA, you will be awarded your apprenticeship certificate.
The EPA gateway is when the EPAO checks and confirms that you have met any requirements required before you start the EPA. You will only enter the gateway when your employer says you are ready.
The gateway requirements for your EPA are:
Observation with questions
You will be observed by an independent assessor completing your work. It will last at least 3 hours. They will ask you at least 6 questions.
Interview
You will have a interview with an independent assessor. It will last 60 minutes. They will ask you at least 11 questions.The questions will be about certain aspects of your occupation. You need to compile a portfolio of evidence before the EPA gateway. You can use it to help answer the questions.
Test or examination
You will complete a multiple-choice test. It will be closed book, meaning you will not have access to any books or reference materials.
The test will have 40 multiple-choice questions. You will have 60 minutes to complete it.
You should speak to your employer if you have a query that relates to your job.
You should speak to your training provider if you have any questions about your training or EPA before it starts.
You should receive detailed information and support from the EPAO before the EPA starts. You should speak to them if you have any questions about your EPA once it has started.
If you have a disability, a physical or mental health condition or other special considerations, you may be able to have a reasonable adjustment that takes this into account. You should speak to your employer, training provider and EPAO and ask them what support you can get. The EPAO will decide if an adjustment is appropriate.
This apprenticeship aligns with The Science Council for Registered Science Technician (RSciTech). Upon successful completion of the apprenticeship and upon receipt of the apprenticeship certificate, individuals are eligible to apply for RSciTech through a shortened application route. Individuals also need to be a member of a professional body that is licensed by the Science Council to be awarded this status. Further information is on the Science Council’s website.
Please contact the professional body for more details.
This apprenticeship aligns with The Institute of Materials, Minerals and Mining for Engineering Technician (EngTech).
Please contact the professional body for more details.
Polymer processing technicians work in the process manufacturing sector.
A polymer is a substance or material made of long repeating chains of molecules. There are several types of polymers. They have different properties: light, heavy, strong, tough, and flexible, depending on the type of molecules bonded and how they are bonded. They are used for a wide variety of purposes in both everyday consumer products and highly demanding technical applications. Elastomer and rubber for example, are used for tyres and components such as seals and gaskets. PVC is used for water pipes, window frames, and cable insulation. Nylon and polyester are used in clothing. And plastics are used in mobile phones, computer hardware, automotive, medical devices, aerospace, disability aides, water bottles, and vacuum cleaners.
Polymer processing technicians produce polymer products to a specification. They work in a production facility - often on a large scale, using a range of machinery, control systems and engineering equipment. Products are made using continuous or in batch processes. Polymer processing technicians set up or configure equipment and tooling and prepare materials for processing. They run and monitor the process, adjusting parameters. They use unique technologies and processes such as extrusion, blow moulding, thermoforming, rotational moulding, injection moulding, internal mixing, and calendering. They undertake quality control, complete work records, and participate in improvement. They may also complete preventative maintenance and prepare polymer process equipment for maintenance and overhaul.
They work with other members of the production team. They also have contact with people from other functions such as, 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 usually report to a production manager.
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 as part of a small or large manufacturing team. They work with minimal supervision and are responsible for the quality of their own work. They may work shifts.
Polymer process technician
Polymer processing technician
Process technician
Production technician
| Duty | KSBs |
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Duty 1 Prepare polymer equipment and materials for processing. For example, complete tool changes, set machine parameters. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K27 K28 K33 K39 |
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Duty 2 Run and monitor polymer processes, adjusting parameters such as speed, temperature, pressure, and time. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K25 K27 K28 K34 K35 K39 |
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Duty 3 Complete secondary operations such as assembling, printing, decorating, cooling operations, packing, and labelling. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K20 K21 K23 K25 K26 K27 K28 K34 K39 |
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Duty 4 Complete quality control processes. For example, conduct grade parameter checks (size, colour, weight). Take samples for laboratory testing. Perform material testing (melt flow index (MFI), moisture, tensile etc). |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K27 K28 K29 K35 K36 K39 |
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Duty 5 Resolve process, quality and operating environment issues when operating out of normal parameters. For example, out of specification parameter. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K26 K27 K28 K29 K33 K35 K36 K38 K39 K40 K41 K42 |
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Duty 6 Conduct handover responsibilities - providing information to or receiving information from other shifts or maintenance teams. |
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Duty 7 Complete process documentation - digital or paper based. For example, process and production records, traceability records, quality assurance records. |
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Duty 8 Maintain the work area (housekeeping) following safety, environmental and risk management systems. Ensure waste is separated, segregated, and handled in accordance with environmental standards. |
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Duty 9 Establish a process involving new or modified equipment, tooling or material and report on the outcomes. Carry out process trials and capability studies. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K26 K27 K28 K29 K33 K34 K35 K38 K39 K40 K41 K42 K43 |
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Duty 10 Conduct first line routine maintenance (daily and preventative) and testing of polymer processing equipment. For example, checking guarding, lubrication, cleaning of tooling, safety checks, and inspection for wear and tear. |
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Duty 11 Prepare polymer process equipment for maintenance and overhaul. |
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Duty 12 Support internal audits to ensure regulatory compliance. |
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Duty 13 Participate in continuous improvement activities. For example, identifying ways to contribute to sustainability by reducing energy use and waste, improving cycle times, tool trialling. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K26 K28 K29 K32 K33 K34 K35 K37 K38 K39 K40 K41 K42 K43 |
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Duty 14 Participate in risk assessment activities. |
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Duty 15 Participate in root cause investigations for quality related issues and implement the corrective action to ensure that failures are non-repeatable and production is ongoing. |
K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K26 K27 K28 K29 K35 K36 K37 K38 K39 K40 K41 K42 |
K1: Polymer industry awareness: range of polymer products, manufacturing environments, types of customers.
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K2: Polymer process technician’s role. Limits of responsibility. Escalation procedures.
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K3: Health and safety regulations, standards, and guidance. Control of Substances Hazardous to Health (COSHH). Electrical safety and compliance. Emergency procedures. Fire safety. Health and Safety at Work Act – responsibilities. Incident and near miss reporting and investigation. Lifting Operations and Lifting Equipment Regulations (LOLER). Legionella. Lone working. Management of health and safety at work. Manual handling. Noise regulation. Permits to work. Provision and Use of Work Equipment Regulations (PUWER). Safety signage and purpose. Slips trips and falls. The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR). Working at Height.
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K4: Health, safety, and environmental practice. Polymer manufacturing safety hazards – risks they pose and their management: temperature, pressure, and fumes. Polymer processing safety guidance. Risk assessment and safe systems of work. Personal Protective Equipment (PPE) requirements. Resource reuse, recycling, and waste handling procedures.
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K5: Environmental and sustainability regulations, standards, and guidance. Environmental hazards that can arise from polymer operations. Environmental management systems standard. Environmental Protection Act. Environmental signage and notices. Carbon footprint of different types of polymers and materials used in production: how that can be mitigated for by selection and whole of lifecycle considerations.
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K6: Principles of sustainability and circular economy. Energy efficiency and reuse of polymers. Principles of control and management of emissions and waste.
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K7: Chemical terms associated with polymers: element, atomic mass, molecule, functional group, monomer, oligomer, polymer, polymerisation, molecular weight, molecular weight distribution, bonding, and tacticity.
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K8: Polymerisation processes: addition polymerisation, condensation polymerisation, catalyst, conditions. Sources of chemical materials; crude oil derived and bio-materials.
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K9: Thermal characteristics of polymers: glass transition temperature, melting temperature, processing temperature, specific heat, heat capacity, heat distortion temperature, melt density, thermal stability.
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K10: Classes of material: thermoplastics, thermosets, elastomers, rubbers, thermoplastic elastomers, commodity, engineering and high-performance materials, molecular structure, blends, and alloys.
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K11: Rheology behaviour: viscosity, shear stress, shear rate, newtonian flow, non-newtonian flow, viscosity-temperature relationships, flow measurement methods and indexes.
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K12: Key differences in processing different classes of polymers: melt processing, malleable state forming, cooling, and curing processes, importance and influence of controlling cooling and curing aspects of polymer processing.
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K13: Influence of morphology on physical and mechanical properties of polymers.
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K14: Polymer materials: definition, classifications, properties, applications, products, and terminology.
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K15: Factors affecting the glass transition temperature of polymers.
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K16: Factors affecting the degree of crystallinity of polymers: molecular and processing.
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K17: Material data sheets, understanding test methods and data reported; physical, mechanical, thermal, optical, electrical, flammability properties of polymers.
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K18: Formulating ingredients: reinforcing and non-reinforcing fillers (glass fibre, carbon black), mineral oils, plasticisers, flame retardants, additives (antioxidants, UV absorbers, antiozonants, slip additives, lubricants, anti-static agents, anti-fog), thermal stabilisers, processing aids, curing agents (sulphur, peroxides, phenolics), colourants, flame retardants, impact modifiers, coupling agents, release agents, anti-microbial, fungicides and biocides, scavengers, detectable, anti-counterfeit, and biodegradable. Purpose, benefits, and limitations.
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K19: The impact of re-used and re-cycled polymers on the processing conditions and final product properties.
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K20: Continuous and batch techniques. Production requirements: product specification, processing specification, rate of production. Material safety data sheet, product labelling and product codes; the importance of identifying non-conforming materials and products. Manufacturing control. Overall Equipment Effectiveness (OEE). Stock control.
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K21: The basic parts and functions of polymer processing plant and equipment: pneumatic and hydraulic systems and components, mechanical systems, electrical and electronic systems and components, heating and cooling arrangements, machine controls, material delivery and collection systems, guards and safety devices, cutting and forming, and service supply and connection methods, and support services.
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K22: Types of mould tools, formers and dies: purpose, features, construction, materials, damage and non-conformance checking requirements, and mounting methods (bolts, clamps, quick release).
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K23: Polymer processes and techniques: extrusion (polymer compounding, profile, film, filament, sheet, wire, and cable) injection moulding, blow moulding, compression moulding, rotational moulding, processing of polyurethane, thermoforming, internal mixing of polymer compounds, milling (two roll mill), calendaring, manual and automated layup techniques for elastomers, 3D Printing.
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K24: Polymer processing material preparation requirements: formulations, drying, weighing, conveying, mixing, blending, and colouring of polymers.
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K25: Machine operating parameters: temperature, pressure, speed or timings, and distance. Impact of changes on the quality of the components. Adjustments required to resolve issues.
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K26: Polymer post processing techniques: assembling, printing, decorating, cooling operations, packing, and labelling.
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K27: Standard operating procedures: their purpose and why they are important, how they are developed and maintained.
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K28: Quality, cost, and delivery (QCD) standards and their importance in the workplace.
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K29: Quality assurance, testing, inspection, and sampling methods. Process and control systems.
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K30: Documentation requirements: documentation control, auditable records.
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K31: Purpose of audits and why they are important.
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K32: Preventative maintenance strategy and practice.
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K33: British standards for engineering representations, drawings, and graphical information.
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K34: Application of digital systems to support manufacture: CAD (computer-aided design), CAM (computer-aided manufacturing), CMM (coordinate measuring machine), and 3D printing.
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K35: Data analysis methods and techniques.
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K36: Problem solving and fault-finding techniques: root cause analysis, 5-Whys.
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K37: Continuous improvement (CI) methodologies and tools: lean, KAIZEN, 5S, workplace organisation.
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K38: Information and digital technology. Document sharing platforms, email, management information systems, spreadsheet, virtual learning platforms, word processing, process and control systems, presentation software. General data protection regulation (GDPR). Cyber security.
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K39: Planning, prioritising, and time management techniques.
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K40: Principles of team working. Equality, diversity and inclusion.
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K41: Verbal communication techniques.
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K42: Written communication techniques. Report writing techniques.
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K43: Presentation techniques.
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S1: Review instructions or information. For example, work instructions, sampling requirements, drawings dimensioning, labelling, formulations, machine settings.
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S2: Plan task and identify and organise resources with consideration for safety, environmental impact, security, quality and cost.
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S3: Identify and document hazards and risks in the workplace.
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S4: Apply health, safety, and environmental procedures in compliance with regulations and standards. For example, daily machine checks, wearing personal protective equipment.
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S5: Apply sustainability principles for example, in choice of materials, minimising waste.
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S6: Segregate resources for reuse, recycling, and handling.
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S7: Select, check, and prepare materials for polymer processing for example, weighing, control and blending, and conditioning.
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S8: Select, configure (for example, replace or change inserts) and check mould tools, formers, dies or other process equipment.
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S9: Check installation and function of processing equipment for the process.
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S10: Connect service connections such as water, electrical, pneumatic, hydraulic.
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S11: Check hand tools, equipment and machinery including calibration record where applicable.
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S12: Set or check machine settings using instructions such as temperature, pressure, speed or time, distance.
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S13: Adjust machine setting for the speeds, positions, pressures and safety of the mould tool, former or die movement to meet product specification.
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S14: Start up manufacturing processes.
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S15: Monitor process feedback and adjust process parameters.
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S16: Shut down manufacturing processes.
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S17: Devise machine settings such as temperature, pressure, speed or time, distance for new or modified equipment, tooling or material.
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S18: Test and evaluate machine settings for new or modified equipment, tooling or material.
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S19: Select and apply optimal machine settings for new or modified equipment, tooling or material (for example, capability study).
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S20: Interpret data for example, process data, quality control and test procedure data. Use data to inform action.
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S21: Identify process faults and resolve.
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S22: Apply post processing techniques for example, assembly, printing, decorating, cooling operations, packing, and labelling.
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S23: Follow quality assurance processes during manufacture.
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S24: Perform quality control checks. For example, conduct parameter checks (size, colour, weight), and take samples.
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S25: Identify quality issues and resolve for example, defects, maintenance requirements.
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S26: Escalate issues outside limits of responsibility.
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S27: Apply preventative maintenance practices. For example, checking guarding, lubrication, cleaning of tooling, safety checks, and inspection for wear and tear.
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S28: Apply continuous improvement techniques. Devise suggestions for improvement. For example, improving the effectiveness of existing production, improving the energy consumption or waste profile of processes and procedures to improve the sustainability or carbon footprint of a product, process or task.
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S29: Apply team working principles.
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S30: Communicate with others verbally for example, colleagues and stakeholders.
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S31: Record or enter information - paper based or electronic. For example, process and production records, traceability records, and quality assurance records.
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S32: Present information.
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S33: Communicate in written form in the workplace for example, handover notes or emails, non-conformances, design change requests, technical reports.
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S34: Use information and digital technology. Comply with GDPR and cyber security regulations and policies.
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S35: Plan how to meet personal development needs. Carry out and record planned and unplanned continued professional development (CPD) activities. Evaluate CPD against plans made.
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B1: Prioritise health, safety, and the environment.
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B2: Consider the environment and sustainability when using resources and carrying out processes.
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B3: Take responsibility for the quality of their own work.
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B4: Team-focus to meet work goals including a commitment to equality and diversity.
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B5: Respond and adapt to work demands.
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B6: Committed to continued professional development.
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Apprentices without level 2 English and maths will need to achieve this level prior to taking the End-Point Assessment. For those with an education, health and care plan or a legacy statement, the apprenticeship’s English and maths minimum requirement is Entry Level 3. A British Sign Language (BSL) qualification is an alternative to the English qualification for those whose primary language is BSL.
This standard aligns with the following professional recognition:
V1.0
This document explains the requirements for end-point assessment (EPA) for the polymer processing technician apprenticeship. End-point assessment organisations (EPAOs) must follow this when designing and delivering the EPA.
Polymer processing technician apprentices, their employers and training providers should read this document.
A full-time polymer processing technician apprentice typically spends 36 months on-programme (this means in training before the gateway). The apprentice must spend at least 12 months on-programme and complete the required amount of off-the-job training in line with the apprenticeship funding rules.
The apprentice must complete their training and meet the gateway requirements before starting their EPA. The EPA will assess occupational competence.
An approved EPAO must conduct the EPA for this apprenticeship. Employers must select an approved EPAO from the register of end-point assessment organisations (RoEPAO).
This EPA has 3 assessment methods.
The grades available for each assessment method are below.
Assessment method 1 - observation with questions:
Assessment method 2 - interview underpinned by a portfolio of evidence:
Assessment method 3 - multiple-choice test:
The result from each assessment method is combined to decide the overall apprenticeship grade. The following grades are available for the apprenticeship:
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On-programme - typically 36 months
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The apprentice must:
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End-point assessment gateway
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The apprentice’s employer must be content that the apprentice has attained sufficient KSBs to complete the apprenticeship. The apprentice must:
For the interview underpinned by a portfolio of evidence, the apprentice must submit a portfolio of evidence.
The apprentice must submit the gateway evidence to their EPAO, including any organisation specific policies and procedures requested by the EPAO. |
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End-point assessment - typically 3 months
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The grades available for each assessment method are below
Observation with questions:
Interview underpinned by a portfolio of evidence:
Multiple-choice test:
Overall EPA and apprenticeship can be graded:
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Professional recognition
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This apprenticeship aligns with:
This apprenticeship aligns with:
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Re-sits and re-takes
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The EPA is taken in the EPA period. The EPA period starts when the EPAO confirms the gateway requirements have been met and is typically 3 months.
The EPAO should confirm the gateway requirements have been met and start the EPA as quickly as possible.
The apprentice’s employer must be content that the apprentice has attained sufficient KSBs to complete the apprenticeship. The employer may take advice from the apprentice's training provider, but the employer must make the decision. The apprentice will then enter the gateway.
The apprentice must meet the gateway requirements before starting their EPA.
They must:
Portfolio of evidence requirements:
The apprentice must compile a portfolio of evidence during the on-programme period of the apprenticeship. It should only contain evidence related to the KSBs that will be assessed by this assessment method. It will typically contain 10 discrete pieces of evidence. Evidence must be mapped against the KSBs. Evidence may be used to demonstrate more than one KSB; a qualitative as opposed to quantitative approach is suggested.
Evidence sources may include:
This is not a definitive list; other evidence sources can be included.
The portfolio of evidence should not include reflective accounts or any methods of self-assessment. Any employer contributions should focus on direct observation of performance (for example, witness statements) rather than opinions. The evidence provided should be valid and attributable to the apprentice; the portfolio of evidence should contain a statement from the employer and apprentice confirming this.
The EPAO should not assess the portfolio of evidence directly as it underpins the interview. The independent assessor should review the portfolio of evidence to prepare questions for the interview. They are not required to provide feedback after this review.
The apprentice must submit the gateway evidence to their EPAO, including any organisation specific policies and procedures requested by the EPAO.
The assessment methods can be delivered in any order.
The result of one assessment method does not need to be known before starting the next.
In the observation with questions, an independent assessor observes the apprentice in their workplace and asks questions. The apprentice completes their day-to-day duties under normal working conditions. Simulation is not allowed. It gives the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method.
This assessment method is being used because:
The observation with questions must be structured to give the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method to the highest available grade.
An independent assessor must conduct and assess the observation with questions.
The independent assessor must only observe one apprentice at a time to ensure quality and rigour. They must be as unobtrusive as possible.
The EPAO must give the apprentice 2 weeks' notice of the observation with questions.
The observation must take 3 hours.
The independent assessor can increase the time of the observation with questions by up to 10%. This time is to allow the apprentice to complete a task or respond to a question if necessary.
The observation may be split into discrete sections held on the same working day.
The EPAO must manage invigilation of the apprentice during the assessment, to maintain security of the EPA, in line with their malpractice policy. This includes breaks and moving between locations.
The independent assessor must explain to the apprentice the format and timescales of the observation with questions before it starts. This does not count towards the assessment time.
The independent assessor should observe the following during the observation:
Activities may relate to the same or different processes or products.
These activities provide the apprentice with the opportunity to demonstrate the KSBs mapped to this assessment method.
The independent assessor must ask questions. Questioning can occur both during and after the observation.
The purpose of the questioning is to assess the apprentice's level of competence against the grading descriptors.
The time for questioning is included in the overall assessment time. The independent assessor must ask at least 6 questions. To remain as unobtrusive as possible, the independent assessor should ask questions during natural stops between tasks and after completion of work rather than disrupting the apprentice’s flow. The independent assessor must use the questions from the EPAO’s question bank or create their own questions in line with the EPAO’s training. Follow-up questions are allowed where clarification is required.
The independent assessor must ask questions about KSBs that were not observed to gather assessment evidence. These questions are in addition to the above set number of questions for the observation with questions and should be kept to a minimum.
The independent assessor must make the grading decision. The independent assessor must assess the observation and responses to questions holistically when deciding the grade.
The independent assessor must keep accurate records of the assessment. They must record:
The observation with questions must take place in the apprentice’s normal place of work for example, their employer’s premises or a customer’s premises. Equipment and resources needed for the observation must be provided by the employer and be in good and safe working condition.
Questioning that occurs after the observation should take place in a quiet room, free from distractions and influence.
The EPAO must develop a purpose-built assessment specification and question bank. It is recommended this is done in consultation with employers of this occupation. The EPAO should maintain the security and confidentiality of EPA materials when consulting with employers. The assessment specification and question bank must be reviewed at least once a year to ensure they remain fit-for-purpose.
The assessment specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this.
The EPAO must produce the following materials to support the observation with questions:
The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation and moderation.
In the interview, an independent assessor asks the apprentice questions. It gives the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method.
The apprentice can refer to and illustrate their answers with evidence from their portfolio of evidence.
This assessment method is being used because:
The interview must be structured to give the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method to the highest available grade.
An independent assessor must conduct and assess the interview.
The purpose 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 however, the portfolio of evidence is not directly assessed.
The interview must last for 60 minutes. The independent assessor can increase the time of the interview by up to 10%. This time is to allow the apprentice to respond to a question if necessary.
The independent assessor must ask at least 11 questions. The independent assessor must use the questions from the EPAO’s question bank or create their own questions in line with the EPAO’s training. Follow-up questions are allowed where clarification is required.
The independent assessor must make the grading decision.
The independent assessor must keep accurate records of the assessment. They must record:
The interview must take place in a suitable venue selected by the EPAO for example, the EPAO’s or employer’s premises.
The interview can be conducted by video conferencing. The EPAO must have processes in place to verify the identity of the apprentice and ensure the apprentice is not being aided.
The interview should take place in a quiet room, free from distractions and influence.
The EPAO must develop a purpose-built assessment specification and question bank. It is recommended this is done in consultation with employers of this occupation. The EPAO should maintain the security and confidentiality of EPA materials when consulting with employers. The assessment specification and question bank must be reviewed at least once a year to ensure they remain fit-for-purpose.
The assessment specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this.
The EPAO must ensure that apprentice has a different set of questions in the case of re-sits or re-takes.
The EPAO must produce the following materials to support the interview underpinned by a portfolio of evidence:
The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation and moderation.
In the multiple-choice test, the apprentice answers questions in a controlled and invigilated environment. It gives the apprentice the opportunity to demonstrate the knowledge mapped to this assessment method.
This assessment method is being used because:
The multiple-choice test must be structured to give the apprentice the opportunity to demonstrate the knowledge mapped to this assessment method to the highest available grade.
The test can be computer or paper based.
The test will consist of 40 multiple-choice questions.
Multiple-choice questions must have four options, including one correct answer.
The apprentice must be given at least 2 weeks’ notice of the date and time of the test.
The apprentice must have 60 minutes to complete the test.
The test is closed book which means that the apprentice cannot refer to reference books or materials whilst taking the test.
The test must be taken in the presence of an invigilator who is the responsibility of the EPAO.
The EPAO must have an invigilation policy setting out how the test must be conducted. It must state the ratio of apprentices to invigilators for the setting and allow the test to take place in a secure way.
The EPAO is responsible for the security of the test including the arrangements for on-line testing. The EPAO must ensure that their security arrangements maintain the validity and reliability of the test.
The test must be marked by an independent assessor or marker employed by the EPAO. They must follow a marking scheme produced by the EPAO. Marking by computer is allowed where question types support this.
A correct answer gets 1 mark.
Any incorrect or missing answers get zero marks.
The EPAO is responsible for overseeing the marking, standardisation and moderation of the test.
The apprentice must take the test in a suitably controlled and invigilated environment that is a quiet room, free from distractions and influence. The EPAO must check the venue is suitable.
The test could take place remotely if the appropriate technology and systems are in place to prevent malpractice. The EPAO must verify the apprentice’s identity and ensure invigilation of the apprentice for example with, and not limited to, 360-degree cameras and screen sharing facilities.
The EPAO must develop a purpose-built assessment specification and question bank. It is recommended this is done in consultation with employers of this occupation. The EPAO should maintain the security and confidentiality of EPA materials when consulting with employers. The assessment specification and question bank must be reviewed at least once a year to ensure they remain fit-for-purpose.
The assessment specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this.
The EPAO must ensure that apprentice has a different set of questions in the case of re-sits or re-takes.
The EPAO must produce the following materials to support the test:
The EPAO must ensure that the EPA materials are subject to quality assurance procedures including standardisation and moderation.
Fail - does not meet pass criteria
|
Theme
KSBs
|
Pass
The apprentice must demonstrate all of the pass descriptors
|
Distinction
The apprentice must demonstrate all of the pass descriptors and all of the distinction descriptors
|
|---|---|---|
|
Work preparation
K39 S1 S2 |
Reviews instructions or information to understand the task's requirements. (S1) Plans the task and identifies and organises resources required to complete it using planning, prioritising, and time management techniques with consideration for safety, environmental impact, security, quality and cost. (K39, S2) |
Justifies the balance of cost, quality, safety, security, and environmental factors in planning decisions. (K39, S2) |
|
Maintain the work area: health, safety, and environment
K4 S3 S4 S6 B1 |
Identifies and documents hazards and risks in the workplace. (S3) Prioritises and applies health, safety, and environmental procedures in compliance with regulations and standards mitigating against risks including segregating resources for reuse, recycling, and waste handling in line with company procedure. (K4, S4, S6, B1) |
Justifies complying with and prioritising health, safety, and environmental procedures in their work. (K4, S4, B1) |
|
Tools and equipment
S8 S9 S10 S11 |
Selects, configures, and checks mould tools, formers, dies, or other process equipment in line with procedures ensuring suitability for the task. (S8) Checks the installation and function of processing equipment for the process ensuring suitability for the task. (S9) Connects service connections in line with procedures ensuring suitability for the task. (S10) Checks hand tools, equipment, and machinery in line with procedures ensuring suitability for the task including checking calibration record if applicable. (S11) |
Completes procedures efficiently for example, performs activities simultaneously to save time, avoids issues with no need to back-track. (S8, S9, S10, S11) |
|
Materials
K24 S7 |
Selects, checks, and prepares materials considering formulations, drying, weighing, conveying, mixing, blending and colouring of polymers in line with specification. (K24, S7) |
Minimises waste in the preparation process for example, ensures bag is empty, only mixes what they need. Explains why it is important to follow the material preparation procedures. (K24, S7) |
|
Polymer processing and secondary operations
K27 S12 S13 S14 S15 S16 S22 |
Sets or checks machine settings using instructions. Adjusts machine settings for the speeds, positions, pressure, speed or time, distance to meet product specification. Starts up manufacturing processes in line with SOP. Monitors process feedback and adjusts process parameters to maintain specification. Shuts down manufacturing processes in line with SOP. Applies post processing techniques in line with SOP. (S12, S13, S14, S15, S16, S22) Outlines how SOPs support the tasks and why they are important, and how they are developed and maintained in their workplace. (K27) |
Applies techniques in the manufacturing process to achieve production efficiencies for example, minimises defects, operates above standard cycle speed parameters, quickly establishes correct operating conditions from test runs. (S12, S13, S14, S15, S16, S22) |
|
Quality assurance
K29 S23 S24 S25 B3 |
Takes responsibility for the quality of their own work by applying quality assurance processes and control checks, identifying and resolving issues in line with procedures. (K29, S23, S24, S25, B3) |
Justifies the use of quality assurance and quality control methods for polymer manufacturing. (K29, S23, S24, S25, B3) |
|
Preventative maintenance
K32 S27 |
Applies preventative maintenance practices in line with strategy and company practice. (K32, S27) |
Explains the benefits of preventative maintenance practices. (K32, S27) |
|
Verbal communication
K41 S30 |
Uses verbal communication techniques suitable for the context. (K41, S30) |
None |
|
Documentation
K30 S31 |
Records or enters data for work tasks - paper based or electronic - in line with company procedures for documentation control and auditable records. (K30, S31) |
None |
Fail - does not meet pass criteria
|
Theme
KSBs
|
Pass
Apprentices must demonstrate all of the pass descriptors
|
Distinction
Apprentices must demonstrate all of the pass descriptors and all of the distinction descriptors
|
|---|---|---|
|
Polymer technician's role
K2 K28 S26 B5 |
Outlines their role as a polymer technician including their limits of responsibility, how they escalate issues, and how they respond and adapt to work demands in line with organisational requirements including quality, cost and delivery (QCD) standards. (K2, K28, S26, B5) |
None |
|
Sustainability
K6 S5 B2 |
Describes how they consider and apply the principles of sustainability and the circular economy including energy efficiency, reuse of polymers, and control of emissions and waste. (K6, S5, 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, S5, B2) |
|
Establishing a new process
K25 S17 S18 S19 |
Describes how they devise, test and evaluate, and select machine settings including temperature, pressure, speed or timings, and distance for new or modified equipment, tooling or material to meet specification, resolving issues. (K25, S17, S18, S19) |
Explains how they make adjustments to determine the optimum settings for the process. Explains how adjustments influence the final product. (K25, S17, S18, S19) |
|
Using data
K35 S20 |
Describes how they interpret data and use it to inform actions using data analysis methods and techniques. (K35, S20) |
Explains the impact data collection and interpretation has on quality control. (K35, S20) |
|
Problem solving
K36 S21 |
Describes how they identify and resolve process faults using a simple root cause analysis technique for example, 5 Whys. (K36, S21) |
Explains their use of a more advanced technique to verify solution for example, six-sigma tools or design of experiments. (K36, S21) |
|
Continuous improvement
K37 S28 |
Describes how they have applied continuous improvement techniques including lean, KAIZEN, 5S, and workplace organisation, to devise a viable suggestion for improvement to a polymer related issue or process. (K37, S28) |
Evaluates the potential impact of the improvement suggestion. (K37, S28)
|
|
Written communication
K42 S33 |
Describes how they apply written communication and report writing techniques to produce communications in their work suitable for context. (K42, S33) |
None |
|
Information technology
K38 S34 |
Describes how they use information technology in work tasks in compliance with GDPR and organisational cyber security regulations and policies. (K38, S34) |
None |
|
Team working
K40 S29 B4 |
Describes how they apply team working principles to meet work goals in line with their company's policy on equality, diversity, and inclusion. (K40, S29, B4) |
Explains how their team focus and commitment to inclusivity extends to wider teams or stakeholders. (K40, S29, B4) |
|
Presenting information
K43 S32 |
Describes how they present information using presentation techniques suitable for the context. (K43, S32) |
None |
|
Continued professional development
S35 B6 |
Describes the planned and unplanned continued professional development (CPD) activities they have carried out and recorded to meet personal development needs, showing a commitment to future CPD. Evaluates what the impact of their CPD has been and how it has benefited the business. (S35, B6) |
None |
| Grade | Minimum marks required | Maximum marks required |
|---|---|---|
| Fail | 0 | 27 |
| Pass | 28 | 40 |
Performance in the EPA determines the overall grade of:
An independent assessor must individually grade the observation with questions and interview underpinned by a portfolio of evidence in line with this EPA plan.
The EPAO must combine the individual assessment method grades to determine the overall EPA grade.
If the apprentice fails one assessment method or more, they will be awarded an overall fail.
To achieve an overall pass, the apprentice must achieve at least a pass in all the assessment methods. To achieve an overall EPA merit, the apprentice must achieve a distinction in one assessment method (observation with questions or interview underpinned by a portfolio of evidence) and a pass in the 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 must be combined in the following way to determine the grade of the EPA overall.
| Observation with questions | Interview underpinned by a portfolio of evidence | Multiple-choice test | Overall Grading |
|---|---|---|---|
| Any grade | Any grade | Fail | Fail |
| Any grade | Fail | Any grade | Fail |
| Fail | Any grade | Any grade | Fail |
| Pass | Pass | Pass | Pass |
| Distinction | Pass | Pass | Merit |
| Pass | Distinction | Pass | Merit |
| Distinction | Distinction | Pass | Distinction |
If the apprentice fails one assessment method or more, they can take a re-sit or a re-take at their employer’s discretion. The apprentice’s employer needs to agree that a re-sit or re-take is appropriate. A re-sit does not need further learning, whereas a re-take does. The apprentice should have a supportive action plan to prepare for a re-sit or a re-take.
The employer and the EPAO should agree the timescale for a re-sit or re-take. A re-sit is typically taken within 2 months of the EPA outcome notification. The timescale for a re-take is dependent on how much re-training is required and is typically taken within 4 months of the EPA outcome notification.
Failed assessment methods must be re-sat or re-taken within a 6-month period from the EPA outcome notification, otherwise the entire EPA will need to be re-sat or re-taken in full.
Re-sits and re-takes are not offered to an apprentice wishing to move from pass to a higher grade.
The apprentice will get a maximum EPA grade of pass for a re-sit or re-take, unless the EPAO determines there are exceptional circumstances.
| Roles | Responsibilities |
|---|---|
|
Apprentice |
As a minimum, the apprentice should:
|
|
Employer |
As a minimum, the apprentice's employer must:
|
|
EPAO |
As a minimum, the EPAO must:
|
|
Independent assessor |
As a minimum, an independent assessor must:
|
|
Training provider |
As a minimum, the training provider must:
|
|
Marker |
As a minimum, the marker must:
|
|
Invigilator |
As a minimum, the invigilator must:
|
The EPAO must have reasonable adjustments arrangements for the EPA.
This should include:
Adjustments must maintain the validity, reliability and integrity of the EPA as outlined in this EPA plan.
Internal quality assurance refers to the strategies, policies and procedures that an EPAO must have in place to ensure valid, consistent and reliable EPA decisions.
EPAOs for this EPA must adhere to the requirements within the roles and responsibilities table.
They must also appoint independent assessors who:
Affordability of the EPA will be aided by using at least some of the following:
This apprenticeship aligns with:
This apprenticeship aligns with:
| Knowledge | Assessment methods |
|---|---|
|
K1
Polymer industry awareness: range of polymer products, manufacturing environments, types of customers. Back to Grading |
Multiple-choice test |
|
K2
Polymer process technician’s role. Limits of responsibility. Escalation procedures. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K3
Health and safety regulations, standards, and guidance. Control of Substances Hazardous to Health (COSHH). Electrical safety and compliance. Emergency procedures. Fire safety. Health and Safety at Work Act – responsibilities. Incident and near miss reporting and investigation. Lifting Operations and Lifting Equipment Regulations (LOLER). Legionella. Lone working. Management of health and safety at work. Manual handling. Noise regulation. Permits to work. Provision and Use of Work Equipment Regulations (PUWER). Safety signage and purpose. Slips trips and falls. The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR). Working at Height. Back to Grading |
Multiple-choice test |
|
K4
Health, safety, and environmental practice. Polymer manufacturing safety hazards – risks they pose and their management: temperature, pressure, and fumes. Polymer processing safety guidance. Risk assessment and safe systems of work. Personal Protective Equipment (PPE) requirements. Resource reuse, recycling, and waste handling procedures. Back to Grading |
Observation with questions |
|
K5
Environmental and sustainability regulations, standards, and guidance. Environmental hazards that can arise from polymer operations. Environmental management systems standard. Environmental Protection Act. Environmental signage and notices. Carbon footprint of different types of polymers and materials used in production: how that can be mitigated for by selection and whole of lifecycle considerations. Back to Grading |
Multiple-choice test |
|
K6
Principles of sustainability and circular economy. Energy efficiency and reuse of polymers. Principles of control and management of emissions and waste. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K7
Chemical terms associated with polymers: element, atomic mass, molecule, functional group, monomer, oligomer, polymer, polymerisation, molecular weight, molecular weight distribution, bonding, and tacticity. Back to Grading |
Multiple-choice test |
|
K8
Polymerisation processes: addition polymerisation, condensation polymerisation, catalyst, conditions. Sources of chemical materials; crude oil derived and bio-materials. Back to Grading |
Multiple-choice test |
|
K9
Thermal characteristics of polymers: glass transition temperature, melting temperature, processing temperature, specific heat, heat capacity, heat distortion temperature, melt density, thermal stability. Back to Grading |
Multiple-choice test |
|
K10
Classes of material: thermoplastics, thermosets, elastomers, rubbers, thermoplastic elastomers, commodity, engineering and high-performance materials, molecular structure, blends, and alloys. Back to Grading |
Multiple-choice test |
|
K11
Rheology behaviour: viscosity, shear stress, shear rate, newtonian flow, non-newtonian flow, viscosity-temperature relationships, flow measurement methods and indexes. Back to Grading |
Multiple-choice test |
|
K12
Key differences in processing different classes of polymers: melt processing, malleable state forming, cooling, and curing processes, importance and influence of controlling cooling and curing aspects of polymer processing. Back to Grading |
Multiple-choice test |
|
K13
Influence of morphology on physical and mechanical properties of polymers. Back to Grading |
Multiple-choice test |
|
K14
Polymer materials: definition, classifications, properties, applications, products, and terminology. Back to Grading |
Multiple-choice test |
|
K15
Factors affecting the glass transition temperature of polymers. Back to Grading |
Multiple-choice test |
|
K16
Factors affecting the degree of crystallinity of polymers: molecular and processing. Back to Grading |
Multiple-choice test |
|
K17
Material data sheets, understanding test methods and data reported; physical, mechanical, thermal, optical, electrical, flammability properties of polymers. Back to Grading |
Multiple-choice test |
|
K18
Formulating ingredients: reinforcing and non-reinforcing fillers (glass fibre, carbon black), mineral oils, plasticisers, flame retardants, additives (antioxidants, UV absorbers, antiozonants, slip additives, lubricants, anti-static agents, anti-fog), thermal stabilisers, processing aids, curing agents (sulphur, peroxides, phenolics), colourants, flame retardants, impact modifiers, coupling agents, release agents, anti-microbial, fungicides and biocides, scavengers, detectable, anti-counterfeit, and biodegradable. Purpose, benefits, and limitations. Back to Grading |
Multiple-choice test |
|
K19
The impact of re-used and re-cycled polymers on the processing conditions and final product properties. Back to Grading |
Multiple-choice test |
|
K20
Continuous and batch techniques. Production requirements: product specification, processing specification, rate of production. Material safety data sheet, product labelling and product codes; the importance of identifying non-conforming materials and products. Manufacturing control. Overall Equipment Effectiveness (OEE). Stock control. Back to Grading |
Multiple-choice test |
|
K21
The basic parts and functions of polymer processing plant and equipment: pneumatic and hydraulic systems and components, mechanical systems, electrical and electronic systems and components, heating and cooling arrangements, machine controls, material delivery and collection systems, guards and safety devices, cutting and forming, and service supply and connection methods, and support services. Back to Grading |
Multiple-choice test |
|
K22
Types of mould tools, formers and dies: purpose, features, construction, materials, damage and non-conformance checking requirements, and mounting methods (bolts, clamps, quick release). Back to Grading |
Multiple-choice test |
|
K23
Polymer processes and techniques: extrusion (polymer compounding, profile, film, filament, sheet, wire, and cable) injection moulding, blow moulding, compression moulding, rotational moulding, processing of polyurethane, thermoforming, internal mixing of polymer compounds, milling (two roll mill), calendaring, manual and automated layup techniques for elastomers, 3D Printing. Back to Grading |
Multiple-choice test |
|
K24
Polymer processing material preparation requirements: formulations, drying, weighing, conveying, mixing, blending, and colouring of polymers. Back to Grading |
Observation with questions |
|
K25
Machine operating parameters: temperature, pressure, speed or timings, and distance. Impact of changes on the quality of the components. Adjustments required to resolve issues. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K26
Polymer post processing techniques: assembling, printing, decorating, cooling operations, packing, and labelling. Back to Grading |
Multiple-choice test |
|
K27
Standard operating procedures: their purpose and why they are important, how they are developed and maintained. Back to Grading |
Observation with questions |
|
K28
Quality, cost, and delivery (QCD) standards and their importance in the workplace. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K29
Quality assurance, testing, inspection, and sampling methods. Process and control systems. Back to Grading |
Observation with questions |
|
K30
Documentation requirements: documentation control, auditable records. Back to Grading |
Observation with questions |
|
K31
Purpose of audits and why they are important. Back to Grading |
Multiple-choice test |
|
K32
Preventative maintenance strategy and practice. Back to Grading |
Observation with questions |
|
K33
British standards for engineering representations, drawings, and graphical information. Back to Grading |
Multiple-choice test |
|
K34
Application of digital systems to support manufacture: CAD (computer-aided design), CAM (computer-aided manufacturing), CMM (coordinate measuring machine), and 3D printing. Back to Grading |
Multiple-choice test |
|
K35
Data analysis methods and techniques. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K36
Problem solving and fault-finding techniques: root cause analysis, 5-Whys. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K37
Continuous improvement (CI) methodologies and tools: lean, KAIZEN, 5S, workplace organisation. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K38
Information and digital technology. Document sharing platforms, email, management information systems, spreadsheet, virtual learning platforms, word processing, process and control systems, presentation software. General data protection regulation (GDPR). Cyber security. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K39
Planning, prioritising, and time management techniques. Back to Grading |
Observation with questions |
|
K40
Principles of team working. Equality, diversity and inclusion. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K41
Verbal communication techniques. Back to Grading |
Observation with questions |
|
K42
Written communication techniques. Report writing techniques. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
K43
Presentation techniques. Back to Grading |
Interview underpinned by a portfolio of evidence |
| Skill | Assessment methods |
|---|---|
|
S1
Review instructions or information. For example, work instructions, sampling requirements, drawings dimensioning, labelling, formulations, machine settings. Back to Grading |
Observation with questions |
|
S2
Plan task and identify and organise resources with consideration for safety, environmental impact, security, quality and cost. Back to Grading |
Observation with questions |
|
S3
Identify and document hazards and risks in the workplace. Back to Grading |
Observation with questions |
|
S4
Apply health, safety, and environmental procedures in compliance with regulations and standards. For example, daily machine checks, wearing personal protective equipment. Back to Grading |
Observation with questions |
|
S5
Apply sustainability principles for example, in choice of materials, minimising waste. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S6
Segregate resources for reuse, recycling, and handling. Back to Grading |
Observation with questions |
|
S7
Select, check, and prepare materials for polymer processing for example, weighing, control and blending, and conditioning. Back to Grading |
Observation with questions |
|
S8
Select, configure (for example, replace or change inserts) and check mould tools, formers, dies or other process equipment. Back to Grading |
Observation with questions |
|
S9
Check installation and function of processing equipment for the process. Back to Grading |
Observation with questions |
|
S10
Connect service connections such as water, electrical, pneumatic, hydraulic. Back to Grading |
Observation with questions |
|
S11
Check hand tools, equipment and machinery including calibration record where applicable. Back to Grading |
Observation with questions |
|
S12
Set or check machine settings using instructions such as temperature, pressure, speed or time, distance. Back to Grading |
Observation with questions |
|
S13
Adjust machine setting for the speeds, positions, pressures and safety of the mould tool, former or die movement to meet product specification. Back to Grading |
Observation with questions |
|
S14
Start up manufacturing processes. Back to Grading |
Observation with questions |
|
S15
Monitor process feedback and adjust process parameters. Back to Grading |
Observation with questions |
|
S16
Shut down manufacturing processes. Back to Grading |
Observation with questions |
|
S17
Devise machine settings such as temperature, pressure, speed or time, distance for new or modified equipment, tooling or material. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S18
Test and evaluate machine settings for new or modified equipment, tooling or material. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S19
Select and apply optimal machine settings for new or modified equipment, tooling or material (for example, capability study). Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S20
Interpret data for example, process data, quality control and test procedure data. Use data to inform action. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S21
Identify process faults and resolve. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S22
Apply post processing techniques for example, assembly, printing, decorating, cooling operations, packing, and labelling. Back to Grading |
Observation with questions |
|
S23
Follow quality assurance processes during manufacture. Back to Grading |
Observation with questions |
|
S24
Perform quality control checks. For example, conduct parameter checks (size, colour, weight), and take samples. Back to Grading |
Observation with questions |
|
S25
Identify quality issues and resolve for example, defects, maintenance requirements. Back to Grading |
Observation with questions |
|
S26
Escalate issues outside limits of responsibility. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S27
Apply preventative maintenance practices. For example, checking guarding, lubrication, cleaning of tooling, safety checks, and inspection for wear and tear. Back to Grading |
Observation with questions |
|
S28
Apply continuous improvement techniques. Devise suggestions for improvement. For example, improving the effectiveness of existing production, 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 |
|
S29
Apply team working principles. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S30
Communicate with others verbally for example, colleagues and stakeholders. Back to Grading |
Observation with questions |
|
S31
Record or enter information - paper based or electronic. For example, process and production records, traceability records, and quality assurance records. Back to Grading |
Observation with questions |
|
S32
Present information. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S33
Communicate in written form in the workplace for example, handover notes or emails, non-conformances, design change requests, technical reports. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S34
Use information and digital technology. Comply with GDPR and cyber security regulations and policies. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
S35
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, safety, and the environment. Back to Grading |
Observation with questions |
|
B2
Consider the environment and sustainability when using resources and carrying out processes. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
B3
Take responsibility for the quality of their own work. Back to Grading |
Observation with questions |
|
B4
Team-focus to meet work goals including a commitment to equality and diversity. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
B5
Respond and adapt to work demands. Back to Grading |
Interview underpinned by a portfolio of evidence |
|
B6
Committed to continued professional development. Back to Grading |
Interview underpinned by a portfolio of evidence |
| KSBS GROUPED BY THEME | Knowledge | Skills | Behaviour |
|---|---|---|---|
|
Work preparation
K39 S1 S2 |
Planning, prioritising, and time management techniques. (K39) |
Review instructions or information. For example, work instructions, sampling requirements, drawings dimensioning, labelling, formulations, machine settings. (S1) Plan task and identify and organise resources with consideration for safety, environmental impact, security, quality and cost. (S2) |
None |
|
Maintain the work area: health, safety, and environment
K4 S3 S4 S6 B1 |
Health, safety, and environmental practice. Polymer manufacturing safety hazards – risks they pose and their management: temperature, pressure, and fumes. Polymer processing safety guidance. Risk assessment and safe systems of work. Personal Protective Equipment (PPE) requirements. Resource reuse, recycling, and waste handling procedures. (K4) |
Identify and document hazards and risks in the workplace. (S3) Apply health, safety, and environmental procedures in compliance with regulations and standards. For example, daily machine checks, wearing personal protective equipment. (S4) Segregate resources for reuse, recycling, and handling. (S6) |
Prioritise health, safety, and the environment. (B1) |
|
Tools and equipment
S8 S9 S10 S11 |
None |
Select, configure (for example, replace or change inserts) and check mould tools, formers, dies or other process equipment. (S8) Check installation and function of processing equipment for the process. (S9) Connect service connections such as water, electrical, pneumatic, hydraulic. (S10) Check hand tools, equipment and machinery including calibration record where applicable. (S11) |
None |
|
Materials
K24 S7 |
Polymer processing material preparation requirements: formulations, drying, weighing, conveying, mixing, blending, and colouring of polymers. (K24) |
Select, check, and prepare materials for polymer processing for example, weighing, control and blending, and conditioning. (S7) |
None |
|
Polymer processing and secondary operations
K27 S12 S13 S14 S15 S16 S22 |
Standard operating procedures: their purpose and why they are important, how they are developed and maintained. (K27) |
Set or check machine settings using instructions such as temperature, pressure, speed or time, distance. (S12) Adjust machine setting for the speeds, positions, pressures and safety of the mould tool, former or die movement to meet product specification. (S13) Start up manufacturing processes. (S14) Monitor process feedback and adjust process parameters. (S15) Shut down manufacturing processes. (S16) Apply post processing techniques for example, assembly, printing, decorating, cooling operations, packing, and labelling. (S22) |
None |
|
Quality assurance
K29 S23 S24 S25 B3 |
Quality assurance, testing, inspection, and sampling methods. Process and control systems. (K29) |
Follow quality assurance processes during manufacture. (S23) Perform quality control checks. For example, conduct parameter checks (size, colour, weight), and take samples. (S24) Identify quality issues and resolve for example, defects, maintenance requirements. (S25) |
Take responsibility for the quality of their own work. (B3) |
|
Preventative maintenance
K32 S27 |
Preventative maintenance strategy and practice. (K32) |
Apply preventative maintenance practices. For example, checking guarding, lubrication, cleaning of tooling, safety checks, and inspection for wear and tear. (S27) |
None |
|
Verbal communication
K41 S30 |
Verbal communication techniques. (K41) |
Communicate with others verbally for example, colleagues and stakeholders. (S30) |
None |
|
Documentation
K30 S31 |
Documentation requirements: documentation control, auditable records. (K30) |
Record or enter information - paper based or electronic. For example, process and production records, traceability records, and quality assurance records. (S31) |
None |
| KSBS GROUPED BY THEME | Knowledge | Skills | Behaviour |
|---|---|---|---|
|
Polymer technician's role
K2 K28 S26 B5 |
Polymer process technician’s role. Limits of responsibility. Escalation procedures. (K2) Quality, cost, and delivery (QCD) standards and their importance in the workplace. (K28) |
Escalate issues outside limits of responsibility. (S26) |
Respond and adapt to work demands. (B5) |
|
Sustainability
K6 S5 B2 |
Principles of sustainability and circular economy. Energy efficiency and reuse of polymers. Principles of control and management of emissions and waste. (K6) |
Apply sustainability principles for example, in choice of materials, minimising waste. (S5) |
Consider the environment and sustainability when using resources and carrying out processes. (B2) |
|
Establishing a new process
K25 S17 S18 S19 |
Machine operating parameters: temperature, pressure, speed or timings, and distance. Impact of changes on the quality of the components. Adjustments required to resolve issues. (K25) |
Devise machine settings such as temperature, pressure, speed or time, distance for new or modified equipment, tooling or material. (S17) Test and evaluate machine settings for new or modified equipment, tooling or material. (S18) Select and apply optimal machine settings for new or modified equipment, tooling or material (for example, capability study). (S19) |
None |
|
Using data
K35 S20 |
Data analysis methods and techniques. (K35) |
Interpret data for example, process data, quality control and test procedure data. Use data to inform action. (S20) |
None |
|
Problem solving
K36 S21 |
Problem solving and fault-finding techniques: root cause analysis, 5-Whys. (K36) |
Identify process faults and resolve. (S21) |
None |
|
Continuous improvement
K37 S28 |
Continuous improvement (CI) methodologies and tools: lean, KAIZEN, 5S, workplace organisation. (K37) |
Apply continuous improvement techniques. Devise suggestions for improvement. For example, improving the effectiveness of existing production, improving the energy consumption or waste profile of processes and procedures to improve the sustainability or carbon footprint of a product, process or task. (S28) |
None |
|
Written communication
K42 S33 |
Written communication techniques. Report writing techniques. (K42) |
Communicate in written form in the workplace for example, handover notes or emails, non-conformances, design change requests, technical reports. (S33) |
None |
|
Information technology
K38 S34 |
Information and digital technology. Document sharing platforms, email, management information systems, spreadsheet, virtual learning platforms, word processing, process and control systems, presentation software. General data protection regulation (GDPR). Cyber security. (K38) |
Use information and digital technology. Comply with GDPR and cyber security regulations and policies. (S34) |
None |
|
Team working
K40 S29 B4 |
Principles of team working. Equality, diversity and inclusion. (K40) |
Apply team working principles. (S29) |
Team-focus to meet work goals including a commitment to equality and diversity. (B4) |
|
Presenting information
K43 S32 |
Presentation techniques. (K43) |
Present information. (S32) |
None |
|
Continued professional development
S35 B6 |
None |
Plan how to meet personal development needs. Carry out and record planned and unplanned continued professional development (CPD) activities. Evaluate CPD against plans made. (S35) |
Committed to continued professional development. (B6) |
Contact us about this apprenticeship
| Version | Change detail | Earliest start date | Latest start date | Latest end date |
|---|---|---|---|---|
| 1.0 | Approved for derlivery | 09/08/2023 | Not set | Not set |
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