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Science manufacturing process operative

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

This apprenticeship is in revision and yet to be approved

Key information

  1. Status: In development
  2. Ticked Proposal approved
    Ticked Occupational standard approved
    Ticked End-point assessment plan approved
  3. Reference: ST0422
  4. Level: 2
  5. Typical duration to gateway: 18 months
  6. Typical EPA period: 3 months
  7. Route: Engineering and manufacturing
  8. Date updated: 16/05/2022
  9. Lars code: 249
  10. Example progression routes:
Print occupational standard

Details of the occupational standard

Occupation summary

The occupation is found in science process manufacturing industries.

Science process manufacturing is varied. It includes industries such as biotechnology, chemical, composites, petrochemical, polymer, and pharmaceutical.

Science process industries combine raw materials and apply a science based process or processes - biological, chemical, or physical - to create products. Products are made continuously or in batches.

Process manufacturing industries are highly regulated. The Health and Safety Executive and other industry regulators inspect employers. The Control of Major Accident Hazards (COMAH) Regulations apply to some process manufacturing companies. Employers must manage risks to the employee, product, environment, and sometimes the wider community. 

The broad purpose of the occupation is to complete science-based manufacturing processes to produce materials and products following standard operating procedures. Products are varied and may include battery cells, composite wind turbine parts, drugs, plastic bottles, proteins, and solvents. This involves checking and preparing materials and using specialist science-based manufacturing process plant or equipment. They monitor the process and take action to resolve deviations. Maintaining the work area is part of the role. They contribute to quality control, continuous improvement, and problem solving activities. They also complete work records, which are important in regulated workplaces.

In their daily work, they interact with other science process manufacturing operatives and technicians, along with colleagues from other business functions. They typically report to a shift manager, team leader, or supervisor. 

They are responsible for meeting work schedules. They must work to quality, health and safety, and environment regulations and procedures. This may include wearing personal protective equipment and complying with Control of Substances Hazardous to Health (COSHH).

They may work alone or as part of a team, under supervision.

They work in varied conditions. Some workplaces may be physically demanding. Some may require use of specialist safety equipment. They complete shift work. Sites often run 24 x 7, 365-days a year.

Typical job titles include:

Applications operator Aseptic operation process operator Batch maker Chemical plant process operator Manufacturing process operator Powder handling operative Primary process operator Process operator Process support operator Production process operator Sterile operations process operator

Occupation duties

Duty

KSBs

Duty 1 Carry out process manufacturing operations using or operating plant or equipment in line with standard operating procedures.

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K18 K20 K22

S1 S2 S4 S7 S12 S19 S21

B1 B2 B3 B5 B6

Duty 2 Arrange and prepare materials for process activity.

K1 K2 K3 K4 K5 K6 K9 K10 K11 K12 K13 K16 K18 K19 K20 K21 K22 K23

S1 S2 S3 S4 S5 S12 S13 S17 S19 S21

B1 B2 B3 B5 B6

Duty 3 Carry out pre-start checks of equipment and process before run or as part of handover responsibilities.

K1 K2 K3 K4 K5 K6 K9 K10 K11 K12 K13 K18 K19 K20 K22 K23

S1 S3 S4 S6 S7 S12 S19 S21

B1 B3 B5 B6

Duty 4 Monitor the process and resolve or escalate issues.

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K18 K19 K20 K22 K23

S1 S2 S4 S7 S8 S11 S12 S19 S21

B1 B2 B3 B4 B5 B6

Duty 5 Contribute to quality control: conduct quality checks and escalate concerns.

K1 K2 K3 K4 K5 K6 K7 K8 K9 K12 K13 K14 K18 K19 K20 K22 K23

S1 S2 S4 S9 S11 S12 S17 S19 S20 S21

B1 B3 B4 B5 B6

Duty 6 Contribute to first-line maintenance, directly or through escalation. For example, equipment checks cleaning, and lubrication.

K2 K3 K4 K5 K6 K10 K11 K12 K18 K19 K20 K22 K23

S1 S3 S4 S6 S12 S19 S21

B1 B3 B4 B5 B6

Duty 7 Contribute to continuous improvement and problem-solving activities. For example, work as part of an improvement team, identify issues, and put ideas forward.

K1 K2 K3 K4 K5 K6 K7 K8 K10 K11 K13 K15 K18 K19 K20 K22 K23

S1 S2 S3 S11 S12 S16 S17 S18 S19 S20 S21 S22

B1 B2 B3 B4 B5 B6

Duty 8 Complete process work records - digital or paper, including traceability records.

K2 K3 K4 K5 K6 K12 K13 K17 K18 K19 K20 K22

S1 S3 S4 S11 S12 S17 S18 S19 S20 S21

B1 B3 B5 B6

Duty 9 Contribute to maintaining own work area (housekeeping).

K2 K3 K4 K5 K6 K12 K18 K20 K22

S1 S2 S3 S4 S12 S14 S15 S19 S21

B1 B2 B3 B5 B6

Duty 10 Conduct change over or clean down activities.

K2 K3 K4 K5 K6 K10 K12 K13 K18 K20 K22 K23

S1 S2 S3 S4 S12 S19 S21

B1 B2 B3 B5 B6

Duty 11 Carry out end of process activities. For example, finish, pack, discharge or move goods.

K2 K3 K4 K5 K6 K10 K11 K12 K13 K18 K20 K22

S1 S2 S3 S4 S7 S10 S12 S17 S19 S21

B1 B2 B3 B5 B6


KSBs

Knowledge

K1: Process manufacturing definition. Types of process products across process industries. Types of employers. Types of customers. Back to Duty

K2: Science manufacturing process operative role. Limits of responsibility. Back to Duty

K3: Process industry safety: high-hazard sites and their potential impact, and The Control of Major Accident Hazards Regulations (COMAH). Back to Duty

K4: Awareness of health and safety regulations and requirements and impact on role. Health and Safety at Work Act. Control of Substances Hazardous to Health (COSHH). Manual handling. Slips, trips, and falls. Situational awareness. Safety equipment: guards, signage, fire extinguishers. Back to Duty

K5: Risk assessments and safe systems of work within process industries. Personal Protective Equipment (PPE). Isolation and emergency stop procedures. Back to Duty

K6: Environment and sustainability regulations and role of the Environmental Agency. Types of pollution and control measures: noise, smells, spills, and waste. Efficient use of resources. Recycling. Waste reduction and waste streams. Back to Duty

K7: Fundamentals of process chemistry: liquids, gases, and solids. Back to Duty

K8: The effects of temperature, pressure, and flow on liquids, gases, and solids. Back to Duty

K9: Awareness of process industry methods: measuring of raw ingredients and materials, blending, mixing, combining, melt processing, moulding, extrusion, and formulations. Back to Duty

K10: Common science manufacturing industry plant, equipment, and tools: pumps, valves, temperature gauges, filtration equipment, tanks, vessels and production and processing machinery, and control systems; what they are and what they do. The importance of operational checks. Back to Duty

K11: Automation and digitalisation of manufacturing processes and its benefits. Back to Duty

K12: Standard operating procedures (SOP). What they are and why they are important. Back to Duty

K13: Process and product specifications. Continuous and batch manufacturing. Manufacturing environments. Back to Duty

K14: Quality assurance requirements and monitoring processes. Back to Duty

K15: Basic continuous improvement techniques: 5 Why’s, 5S, KAIZEN. Back to Duty

K16: Stock requirements: control systems, and stock rotation. Back to Duty

K17: Work record requirements and importance of records for traceability and audits. Management information systems. Back to Duty

K18: Verbal communication techniques. Back to Duty

K19: Written communication techniques. Back to Duty

K20: Information technology: digital manufacturing management systems, virtual learning platforms, word processing, and email. General data protection regulation (GDPR). Cyber security. Back to Duty

K21: Work organisation and time management techniques. Back to Duty

K22: Principles of team working. Back to Duty

K23: Equality, diversity, and inclusion. Back to Duty

Skills

S1: Follow procedures in line with process industry health and safety regulations, standards, and guidance. Back to Duty

S2: Follow procedures in line with process industry environmental and sustainability regulations, standards, and guidance. Back to Duty

S3: Follow work instructions. Back to Duty

S4: Follow process manufacturing standard operating procedures. Back to Duty

S5: Conduct material preparation for example, measure, weigh, mix and load materials. Back to Duty

S6: Check and set up science process industry tools, plant, or equipment. Back to Duty

S7: Use science process industry tools, plant, or equipment required for task. Back to Duty

S8: Monitor process manufacturing and take corrective actions to meet specification. Back to Duty

S9: Apply product quality assurance procedures for example, take product samples, inspect products. Back to Duty

S10: Conduct end of process procedures for example, finish, pack, label, discharge, move, and store batches. Back to Duty

S11: Collect and interpret information. Back to Duty

S12: Identify and resolve or report issues. Back to Duty

S13: Store materials, monitor, and rotate stock. Back to Duty

S14: Comply with housekeeping procedures for example, clean equipment and machinery, tidy work area. Back to Duty

S15: Identify and segregate resources for reuse, recycling, and disposal. Back to Duty

S16: Apply basic continuous improvement techniques for example, 5Why's, S5, and KAIZEN. Back to Duty

S17: Perform simple calculations for example, raw material quantity and production calculations. Back to Duty

S18: Record information (text and data) - paper based or electronic for example, quality control documentation, cleaning logs, handover notes, stock inventory systems. Back to Duty

S19: Communicate with colleagues verbally. Back to Duty

S20: Use information technology for example, digital manufacturing management systems, virtual learning platforms, word processing, and email. Comply with GDPR and cyber security procedures. Back to Duty

S21: Apply team building principles. Back to Duty

S22: Carry out and record learning and development. Back to Duty

Behaviours

B1: Put health and safety first. Back to Duty

B2: Consider the environment. Back to Duty

B3: Take ownership for quality of given work. Back to Duty

B4: Adapt to changing work requests. Back to Duty

B5: Team focus to meet work goals for example, work collaboratively. Back to Duty

B6: Seek learning and development opportunities. Back to Duty


Qualifications

English & Maths

Apprentices without level 1 English and maths will need to achieve this level and apprentices without level 2 English and maths will need to take the tests for 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.

Print EPA plan

End-point assessment plan

AP02

Introduction and overview

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

Science manufacturing process operative apprentices, their employers and training providers should read this document.

An approved EPAO must conduct the EPA for this apprenticeship. Employers must select an approved EPAO from the Education and Skills Funding Agency’s Register of end-point assessment organisations (RoEPAO).

A full-time apprentice typically spends 18 months on-programme (this means in training before the gateway) working towards competence as a science manufacturing process operative. The apprentice must spend at least 12 months on-programme. The apprentice must spend at least 20% of their on-programme time completing off-the-job training.

This EPA has 3 assessment methods.

The grades available for each assessment method are:

Assessment method 1 - observation with questions:

Assessment method 2 - interview underpinned by a portfolio of evidence:

Assessment method 3 - multiple-choice test:

The result from each assessment method is combined to decide the overall apprenticeship grade. The following grades are available for the apprenticeship:

EPA summary table

On-programme (typically 18 months)

The apprentice must complete training to develop the knowledge, skills and behaviours (KSBs) of the science manufacturing process operative occupational standard.

The apprentice must complete training towards English and mathematics qualifications at Level 21, if required.

The apprentice must compile a portfolio of evidence.

End-point assessment gateway







The apprentice's employer must be content that the apprentice is working at or above the science manufacturing process operative occupational standard.

The apprentice’s employer must confirm that they think the apprentice:

The apprentice must have passed English and mathematics qualifications at Level 1 and have taken the tests for Level 21. (For those with an education, health and care plan or a legacy statement, the apprenticeship’s English and mathematics minimum requirement is Entry Level 3. British Sign Language (BSL) qualifications are an alternative to English qualifications for those who have BSL as their primary language).

For the interview underpinned by a portfolio of evidence, the apprentice must submit a portfolio of evidence.



The apprentice must submit any policies and procedures as requested by the EPAO.

The apprentice must submit the gateway evidence to the EPAO.

End-point assessment (typically 3 months)

Re-sits and re-takes

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

1For those with an education, health and care plan or a legacy statement, the apprenticeship’s English and mathematics minimum requirement is Entry Level 3. British Sign Language (BSL) qualifications are an alternative to English qualifications for those who have BSL as their primary language.

Length of end-point assessment period

The EPA is taken in the EPA period. The EPA period starts when the EPAO confirms the gateway requirements have been met and is typically 3 months.

The expectation is that the EPAO will confirm the gateway requirements have been met and the EPA starts as quickly as possible.

EPA gateway

The apprentice’s employer must confirm that they think their apprentice is working at or above the science manufacturing process operative occupational standard. The apprentice will then enter the gateway. The employer may take advice from the apprentice's training provider(s), but they must make the decision.

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

These are:

  • achieved English and mathematics Level 1 and taken the tests for Level 21.

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. The portfolio of evidence will typically contain 10 discrete pieces of evidence. Evidence should 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 should not include reflective accounts or any methods of self-assessment. Any employer contributions should focus on direct observation of performance (for example, witness statements) rather than opinions. The evidence provided should be valid and attributable to the apprentice; the portfolio of evidence should contain a statement from the employer and apprentice confirming this.

The EPAO should not assess the portfolio of evidence directly as it underpins the interview. The independent assessor should review the portfolio of evidence to prepare questions for the interview. They are not required to provide feedback after this review.

The apprentice must submit any policies and procedures as requested by the EPAO.

The apprentice must submit the gateway evidence to the EPAO.

The EPA period starts when the EPAO confirms all gateway requirements have been met. The expectation is they will do this as quickly as possible.

Assessment methods

The assessment methods can be delivered in any order.

The result of one assessment method does not need to be known before starting the next.

Observation with questions

Overview

In the observation with questions, an independent assessor observes the apprentice in their workplace and asks questions. The apprentice completes their day-to-day duties under normal working conditions. This allows the apprentice to demonstrate the KSBs mapped to this assessment method through naturally occurring evidence. Simulation is not permitted during the observation.

Rationale

This assessment method is being used because:

Delivery

The observation with questions must be structured to give the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method to the highest available grade.

The independent assessor conducts and assesses the observation with questions.

The independent assessor must only observe one apprentice at a time to ensure quality and rigour and they must be as unobtrusive as possible.

The EPAO must give an apprentice 2 weeks notice of the observation with questions. 

The observation with questions must take 2 hours.

The independent assessor can increase the time of the observation with questions by up to 10%. This time is to allow the apprentice to complete a task or respond to a question if necessary.

The observation may be split into discrete sections held on the same working day.

The EPAO must manage invigilation of the apprentice during the assessment to maintain security of the EPA, in line with their malpractice policy. This includes breaks and moving between locations. 

The independent assessor must explain to the apprentice the format and timescales of the observation with questions before it starts. This does not count towards the assessment time.

The independent assessor should observe the following during the observation:

Activities may be completed in relation to the same process or different processes.

These activities provide the apprentice with the opportunity to demonstrate the KSBs.

Questioning can occur both during and after the observation and the time for questioning is included in the overall assessment time. The independent assessor must ask at least 5 questions. To remain as unobtrusive as possible, independent assessors should ask questions during natural stops between tasks and after completion of work rather than disrupting the apprentice’s flow. Follow-up questions are allowed. The independent assessor must use the questions from the EPAO’s question bank or create their own questions in-line with the EPAO’s training.

The independent assessor must ask questions about KSBs that were not observed to gather assessment evidence. These questions are in addition to the set number of questions for the observation and should be kept to a minimum. The independent assessor can also ask questions to clarify answers given by the apprentice.

The independent assessor must record the KSBs observed, KSBs demonstrated in answers to questions and the grade achieved. The apprentice’s answers to questions must also be recorded.

The independent assessor makes the grading decision. The observation and responses to questions must be assessed holistically by the independent assessor when they are deciding the grade.

Assessment location

The observation with questions must take place in the apprentice’s normal place of work (for example, their employer’s premises or a customer’s premises). Equipment and resources needed for the observation must be provided by the employer and be in good and safe working condition.   

Questioning that occurs after the observation should take place in a quiet room, free from distractions and influence.

Question and resource development

The EPAO must write an assessment specification and question bank. It is recommended this is done in consultation with the employers of this occupation. The EPAO should maintain the security and confidentiality of EPA materials when consulting employers.

The specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must develop a purpose-built question bank and ensure that appropriate quality assurance procedures are in place for example, considering standardisation, training and moderation. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this. The assessment specification and questions must be reviewed at least once a year to ensure they remain fit-for-purpose.

The EPAO must ensure that an apprentice has a different set of questions in the case of re-sits or re-takes.

The EPAO must produce the following material to support this assessment method:

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

Interview underpinned by a portfolio of evidence

Overview

In the interview, the independent assessor asks the apprentice questions. It gives the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method.

Rationale

This assessment method is being used because:

Delivery

The interview must be structured to give the apprentice the opportunity to demonstrate the KSBs mapped to this assessment method to the highest available grade.

The independent assessor conducts and assesses the interview.

The purpose of the independent assessor's questions will be to cover the following themes:

The EPAO must give the 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.

In the interview, the independent assessor must ask at least 7 questions. Follow-up questions are allowed. The independent assessor must use the questions from the EPAO’s question bank or create their own questions in-line with the EPAO’s training.

The independent assessor must keep accurate records of the assessment. The records must include the KSBs met, the grade achieved and answers to questions.

The independent assessor makes all grading decisions.

Assessment location

The interview must take place in a suitable venue selected by the EPAO (for example, the EPAO’s or employer’s premises).

The interview can be conducted by video conferencing. The EPAO must have processes in place to verify the identity of the apprentice and ensure the apprentice is not being aided.

The interview should take place in a quiet room, free from distractions and influence.

Question and resource development

The EPAO must write an assessment specification and question bank. It is recommended this is done in consultation with the employers of this occupation. The EPAO should maintain the security and confidentiality of EPA materials when consulting employers.

The specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must develop a purpose-built question bank and ensure that appropriate quality assurance procedures are in place for example, considering standardisation, training and moderation. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this. The assessment specification and questions must be reviewed at least once a year to ensure they remain fit-for-purpose.

The EPAO must ensure that an apprentice has a different set of questions in the case of re-sits or re-takes.

The EPAO must produce the following material to support this assessment method:

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

Multiple-choice test

Overview

A multiple-choice test is an assessment for asking questions in a controlled and invigilated environment. It gives the apprentice the opportunity to demonstrate the knowledge mapped to this assessment method.

Rationale

This assessment method is being used because:

Delivery

This multiple-choice test must be appropriately structured to give the apprentice the opportunity to demonstrate the knowledge mapped to this assessment method to the highest available grade.

The multiple-choice test can be computer or paper based.

The multiple-choice test must consist of 40 multiple-choice questions.

Multiple-choice questions must have four options, with one correct answer.

The apprentice must be given at least 2 weeks notice of the date and time of the multiple-choice test.

Test administration

The apprentice must have 60 minutes to complete the multiple-choice test.

The multiple-choice test is closed book which means that the apprentice cannot refer to reference books or materials whilst taking the test.

The multiple-choice test must be taken in the presence of an invigilator who is the responsibility of the EPAO. If the test can be taken on-line, specialised (proctor) software can be used to ensure the security of the test.

The EPAO must have an invigilation policy setting out how the multiple-choice test must be conducted. It must state the ratio of apprentices to invigilators for the setting and allow the test to take place in a secure way.

The EPAO must verify the identity of the apprentice.

The EPAO is responsible for the security of the multiple-choice test including the arrangements for on-line testing. The EPAO must ensure that their security arrangements maintain the validity and reliability of the multiple-choice test.

Marking

The multiple-choice test must be marked by an independent assessor or marker employed by the EPAO. They must follow a marking scheme produced by the EPAO. Marking by computer is allowed.

A correct answer gets 1 mark.

Any incorrect or missing answers get zero marks.

The EPAO is responsible for overseeing the marking of the multiple-choice test. The EPAO must ensure standardisation and moderation of written response test.

Assessment location

The apprentice must take the multiple-choice test in a suitably controlled and invigilated environment that is a quiet room, free from distractions and influence. The EPAO must check the venue is suitable.

The multiple-choice test 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.

Question and resource development

The EPAO must write an assessment specification and question bank. It is recommended this is done in consultation with the employers of this occupation. The EPAO should maintain the security and confidentiality of EPA materials when consulting employers.

The specification must be relevant to the occupation and demonstrate how to assess the KSBs mapped to this assessment method. The EPAO must develop a purpose-built question bank and ensure that appropriate quality assurance procedures are in place for example, considering standardisation, training and moderation. The EPAO must ensure that questions are refined and developed to a high standard. The questions must be unpredictable. A question bank of sufficient size will support this. The assessment specification and questions must be reviewed at least once a year to ensure they remain fit-for-purpose.

The EPAO must ensure that an apprentice has a different set of questions in the case of re-sits or re-takes.

The EPAO must produce the following material to support this assessment method:

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

Grading

Observation with questions

Fail - does not meet pass criteria

Theme

KSBs

Pass

Apprentices must demonstrate all the pass descriptors

Distinction

Apprentices must demonstrate all the pass descriptors and all of the distinction descriptors

Health and safety
K5 S1 S14 B1

Prioritises safe systems of work, following procedures in line with process industry health and safety regulations, standards and guidance and complies with housekeeping procedures to maintain a safe and tidy work area. Wears PPE correctly. Explains emergency stop procedures. (K5, S1, S14, B1)

Explains why compliance with health and safety regulations and following safe systems of work is a priority within process industries. (K5, S1, B1)

Work organisation
K21 S3 B3

Takes responsibility to complete allocated tasks within required timescales to the required quality, following work instructions. (K21, S3, B3)

Implements and follows procedures without error, mitigating against potential issues, supporting a right first-time outcome with no back tracking. (K21, S3, B3)

Process operations
K12 S4 S5 S6 S7 S8

Follows process manufacturing standard operating procedures (SOP). (K12, S4)

Conducts material preparation in line with SOP. (S5)

Checks and sets up process industry tools, plant, or equipment in line with SOP. (S6)

Uses process industry tools, plant, or equipment in line with SOP. (S7)

Monitors process and takes corrective action to meet specification in line with SOP. (S8)

Identifies potential issues that could arise in process. Explains how they help prevent them occurring by following SOPs. (K12, S4, S8)

Quality assurance
K14 S9

Applies quality assurance procedures. Identifies any specification deviation, taking action in line with quality assurance procedures. (K14, S9)

Explains the importance of applying product quality assurance procedures and potential consequences of not doing do. (K14, S9)

Communication
K18 S19

Communicates with others using verbal techniques that are suitable for the context and support task completion. (K18, S19)

N/A

Documentation
K17 K19 S11 S18

Collects and interprets information. (S11)

Records information - paper based or electronic - in line with work record requirements using written techniques that are suitable for the context and supports task completion. (K17, K19, S18)

Explains the importance of completing documentation correctly and the potential impact of not doing so. (K17, S11, S18)

Interview underpinned by a portfolio of evidence

Fail - does not meet pass criteria

Theme

KSBs

Pass

Apprentices must demonstrate all the pass descriptors

Distinction

Apprentices must demonstrate all the pass descriptors and all of the distinction descriptors

Science manufacturing process operative’s role
K2 S12 S22 B6

Outlines their process operative role, describing how they identify and resolve or report issues in line with limits of responsibility. (K2, S12)

Outlines learning and development they have completed to support competence in their role. (S22, B6)

 

Identifies how their role impacts on wider manufacturing process operations.  (K2)

Stock control
K16 S13

Describes how they store materials, monitor, and rotate stock in line with stock requirements. (K16, S13)

Describes the importance of accurate stock control and potential impact to the business of not following stock requirements. (K16, S13)

End of process procedures
S10

Describes how they conduct end of process in line with procedures. (S10)

N/A

Environment and sustainability
K6 S2 S15 B2

Outlines the potential impact that process industries have on the environment and how that is controlled through regulations.

Describes how they follow procedures in line with environmental and sustainability regulations, standards, and guidance and how they consider the environment through the efficient use of resources.

Describes how they identify and segregate resources for reuse, recycling, and disposal in line with waste reduction, waste streams, and recycling requirements.

(K6, S2, S15, B2)

Explains how their company’s or industry’s environmental and sustainability practice exceed regulatory requirements, or could be changed to better support, environmental and sustainability targets. (K6)

Continuous improvement
K15 S16

Describes how they apply basic continuous improvement techniques. (K15, S16)

Explains how the continuous improvement techniques they apply contribute to or have the potential to contribute to overall business effectiveness. (K15, S16)

Information technology
K20 S20

Describes how they use IT in the workplace for example, digital manufacturing management systems, virtual learning platforms, word processing and email, and the importance of data protection and cyber security. (K20, S20)

N/A

Team working
K22 K23 S21 B4 B5

Describes how they meet their team's work goals and adapt to changing work requests, applying team working principles and taking account of individuals needs in relation to equality, diversity, and inclusion. (K22, K23, S21, B4, B5)

Explains how their team focus supports wider teams to meet their goals. (K22, S21, B5)

Multiple-choice test

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

Overall EPA grading

The assessment methods contribute equally to the overall EPA pass grade.

Performance in the EPA determines the apprenticeship grade of:

An independent assessor must individually grade the observation with questions and interview underpinned by a portfolio of evidence according to the requirements set out in this EPA plan.

The EPAO must combine the individual assessment method grades to determine the overall EPA grade.

If the apprentice fails one or more assessment methods, they will be awarded an overall EPA 'fail'.

The apprentice must achieve at least a pass in all the assessment methods to get an overall 'pass'. To achieve an overall EPA ‘merit,’ the apprentice must achieve a distinction in one EPA method (the observation with questions or interview underpinned by a portfolio of evidence), and a pass in the other EPA methods. To achieve an overall EPA ‘distinction,’ the apprentice must achieve a distinction in the observation with questions and interview underpinned by a portfolio of evidence, and a pass in the multiple-choice test.

Grades from individual assessment methods must be combined in the following way to determine the grade of the EPA overall.

Observation with questions Interview underpinned by a portfolio of evidence Multiple-choice test Overall Grading
Fail Any grade Any grade Fail
Any grade Fail Any grade Fail
Any grade Any grade Fail Fail
Pass Pass Pass Pass
Distinction Pass Pass Merit
Pass Distinction Pass Merit
Distinction Distinction Pass Distinction

Re-sits and re-takes

If the apprentice fails one or more assessment methods they can take a re-sit or a re-take at their employer’s discretion. The apprentice’s employer needs to agree that a re-sit or re-take is appropriate. A re-sit does not need further learning, whereas a re-take does.The apprentice should have a supportive action plan to prepare for a re-sit or a re-take.

The employer and EPAO agree the timescale for a re-sit or re-take. A re-sit is typically taken within 2 months of the EPA outcome notification. The timescale for a re-take is dependent on how much re-training is required and is typically taken within 4 months of the EPA outcome notification.

Failed assessment methods must be re-sat or re-taken within a 6-month period from the EPA outcome notification, otherwise the entire EPA will need to be re-sat or re-taken in full.

Re-sits and re-takes are not offered to an apprentice wishing to move from pass to a higher grade.

The apprentice will get a maximum EPA grade of pass for a re-sit or re-take, unless the EPAO determines there are exceptional circumstances.

Roles and responsibilities

Roles Responsibilities

Apprentice

As a minimum, the apprentice should:

  • participate in and complete on-programme training to meet the KSBs as outlined in the occupational standard for a minimum of 12 months
  • undertake 20% off-the-job training as arranged by the employer and training provider
  • understand the purpose and importance of EPA
  • undertake the EPA including meeting all gateway requirements

 

Employer

As a minimum, the apprentice's employer must:

  • select the EPAO and training provider 
  • work with the training provider (where applicable) to support the apprentice in the workplace and to provide the opportunities for the apprentice to develop the KSBs
  • arrange and support a minimum of 20% off-the-job training to be undertaken by the apprentice 
  • decide when the apprentice is working at or above the level required by the occupational standard and so is ready for EPA
  • ensure the apprentice is prepared for the EPA
  • require the training provider and EPAO to ensure the EPA is booked in a timely manner

Post-gateway, the employer must: 

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

EPAO

As a minimum, the EPAO must: 

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

Pre-gateway, the EPAO must: 

  • make all necessary contractual arrangements, including agreeing the price of the EPA
  • provide adequate information, advice and guidance documentation to enable the apprentice, employers and training provider to prepare for the EPA
  • arrange for the EPA to take place, in consultation with the employer

At the gateway, the EPAO must: 

  • confirm all gateway requirements have been met as quickly as possible

Post-gateway, EPAOs must: 

  • where the apprentice is not assessed in the workplace, ensure that the apprentice has access to the required resources and liaise with the employer to agree this if necessary.

Independent assessor

As a minimum, an independent assessor must: 

  • have the competence to assess the apprentice at the level of this apprenticeship and hold any required qualifications and experience in line with the requirements of the independent assessor as detailed in the IQA section of this EPA plan
  • understand the occupational standard and the requirements of this EPA
  • have, maintain and be able to evidence, up-to-date knowledge and expertise of the subject matter
  • deliver the end-point assessment in-line with this EPA plan
  • comply with the IQA requirements of the EPAO
  • have no direct connection or conflict of interest with the apprentice, their employer or training provider; in all instances, including when the EPAO is the training provider for example HEI
  • attend induction training
  • attend standardisation events when they begin working for the EPAO, before they conduct an EPA for the first time and a minimum of annually on this apprenticeship 
  • assess each assessment method, as determined by the EPA plan, and without extending the EPA unnecessarily
  • assess against the KSBs assigned to each assessment method, as shown in the mapping of KSBs to assessment methods and as determined by the EPAO, and without extending the EPA unnecessarily
  • make all grading decisions
  • record and report all assessment outcome decisions, for each apprentice, following instructions and using assessment recording documentation provided by the EPAO, in a timely manner
  • use language in the development and delivery of the EPA that is appropriate to the level of the occupational standard
  • mark open (constructed) test answers accurately according to the EPAO’s mark scheme and procedures

Training provider

As a minimum, the training provider should:

  • work with the employer and support the apprentice during the off-the-job training to provide the opportunities to develop the knowledge, skills and behaviours as listed in the occupational standard
  • conduct training covering any knowledge, skill or behaviour requirement agreed as part of the Commitment Statement or the Individual Learning Plan
  • monitor the apprentice’s progress during any training provider led on-programme learning
  • advise the employer, upon request, on the apprentice’s readiness for EPA
  • remain independent from the delivery of the EPA. Where the training provider is the EPAO for example HEI, there must be procedures in place to mitigate against any conflict of interest

Marker

As a minimum, the marker should:

  • attend induction training as directed by the EPAO
  • have no direct connection or conflict of interest with the apprentice, their employer or training provider in all instances including when the EPAO is the training provider for example HEI
  • mark test answers accurately according to the EPAO’s mark scheme and procedures

Invigilator

As a minimum, the invigilators should:

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

Reasonable adjustments

The EPAO must have reasonable adjustments arrangements for the EPA.

This should include:

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

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

Internal quality assurance (IQA)

Internal quality assurance refers to how the EPAO ensures valid, consistent and reliable EPA decisions. The EPAO must adhere to the requirements within the roles and responsibilities section.

They must also:

  • have effective and rigorous quality assurance systems and procedures that ensure fair, reliable and consistent EPA regardless of employer, place, time or independent assessor
  • appoint independent assessors who are competent to deliver the EPA and who:
    • have recent relevant experience of the occupation or sector to at least occupational level 3 gained in the last 2 years or significant experience of the occupation or sector
  • operate induction training for anyone involved in the delivery or assessment of the EPA
  • provide training for independent assessors in good assessment practice, operating the assessment tools and making grading decisions
  • provide ongoing training for markers and invigilators
  • provide standardisation activity for this apprenticeship for independent assessors:
    • before they conduct an EPA for the first time
    • if the EPA is updated
    • periodically as appropriate (a minimum of annually)
  • conduct effective moderation of EPA decisions and grades
  • conduct appeals where required, according to the EPAO’s appeals procedure, reviewing and making final decisions on EPA decisions and grades
  • have no direct connection with the apprentice, their employer or training provider

Professional recognition

Professional body recognition is not relevant to this occupational apprenticeship.

Mapping of KSBs to assessment methods

Knowledge Assessment methods
K1

Process manufacturing definition. Types of process products across process industries. Types of employers. Types of customers.

Back to Grading
Multiple-choice test
K2

Science manufacturing process operative role. Limits of responsibility.

Back to Grading
Interview underpinned by a portfolio of evidence
K3

Process industry safety: high-hazard sites and their potential impact, and The Control of Major Accident Hazards Regulations (COMAH).

Back to Grading
Multiple-choice test
K4

Awareness of health and safety regulations and requirements and impact on role. Health and Safety at Work Act. Control of Substances Hazardous to Health (COSHH). Manual handling. Slips, trips, and falls. Situational awareness. Safety equipment: guards, signage, fire extinguishers.

Back to Grading
Multiple-choice test
K5

Risk assessments and safe systems of work within process industries. Personal Protective Equipment (PPE). Isolation and emergency stop procedures.

Back to Grading
Observation with questions
K6

Environment and sustainability regulations and role of the Environmental Agency. Types of pollution and control measures: noise, smells, spills, and waste. Efficient use of resources. Recycling. Waste reduction and waste streams.

Back to Grading
Interview underpinned by a portfolio of evidence
K7

Fundamentals of process chemistry: liquids, gases, and solids.

Back to Grading
Multiple-choice test
K8

The effects of temperature, pressure, and flow on liquids, gases, and solids.

Back to Grading
Multiple-choice test
K9

Awareness of process industry methods: measuring of raw ingredients and materials, blending, mixing, combining, melt processing, moulding, extrusion, and formulations.

Back to Grading
Multiple-choice test
K10

Common science manufacturing industry plant, equipment, and tools: pumps, valves, temperature gauges, filtration equipment, tanks, vessels and production and processing machinery, and control systems; what they are and what they do. The importance of operational checks.

Back to Grading
Multiple-choice test
K11

Automation and digitalisation of manufacturing processes and its benefits.

Back to Grading
Multiple-choice test
K12

Standard operating procedures (SOP). What they are and why they are important.

Back to Grading
Observation with questions
K13

Process and product specifications. Continuous and batch manufacturing. Manufacturing environments.

Back to Grading
Multiple-choice test
K14

Quality assurance requirements and monitoring processes.

Back to Grading
Observation with questions
K15

Basic continuous improvement techniques: 5 Why’s, 5S, KAIZEN.

Back to Grading
Interview underpinned by a portfolio of evidence
K16

Stock requirements: control systems, and stock rotation.

Back to Grading
Interview underpinned by a portfolio of evidence
K17

Work record requirements and importance of records for traceability and audits. Management information systems.

Back to Grading
Observation with questions
K18

Verbal communication techniques.

Back to Grading
Observation with questions
K19

Written communication techniques.

Back to Grading
Observation with questions
K20

Information technology: digital manufacturing management systems, virtual learning platforms, word processing, and email. General data protection regulation (GDPR). Cyber security.

Back to Grading
Interview underpinned by a portfolio of evidence
K21

Work organisation and time management techniques.

Back to Grading
Observation with questions
K22

Principles of team working.

Back to Grading
Interview underpinned by a portfolio of evidence
K23

Equality, diversity, and inclusion.

Back to Grading
Interview underpinned by a portfolio of evidence
Skill Assessment methods
S1

Follow procedures in line with process industry health and safety regulations, standards, and guidance.

Back to Grading
Observation with questions
S2

Follow procedures in line with process industry environmental and sustainability regulations, standards, and guidance.

Back to Grading
Interview underpinned by a portfolio of evidence
S3

Follow work instructions.

Back to Grading
Observation with questions
S4

Follow process manufacturing standard operating procedures.

Back to Grading
Observation with questions
S5

Conduct material preparation for example, measure, weigh, mix and load materials.

Back to Grading
Observation with questions
S6

Check and set up science process industry tools, plant, or equipment.

Back to Grading
Observation with questions
S7

Use science process industry tools, plant, or equipment required for task.

Back to Grading
Observation with questions
S8

Monitor process manufacturing and take corrective actions to meet specification.

Back to Grading
Observation with questions
S9

Apply product quality assurance procedures for example, take product samples, inspect products.

Back to Grading
Observation with questions
S10

Conduct end of process procedures for example, finish, pack, label, discharge, move, and store batches.

Back to Grading
Interview underpinned by a portfolio of evidence
S11

Collect and interpret information.

Back to Grading
Observation with questions
S12

Identify and resolve or report issues.

Back to Grading
Interview underpinned by a portfolio of evidence
S13

Store materials, monitor, and rotate stock.

Back to Grading
Interview underpinned by a portfolio of evidence
S14

Comply with housekeeping procedures for example, clean equipment and machinery, tidy work area.

Back to Grading
Observation with questions
S15

Identify and segregate resources for reuse, recycling, and disposal.

Back to Grading
Interview underpinned by a portfolio of evidence
S16

Apply basic continuous improvement techniques for example, 5Why's, S5, and KAIZEN.

Back to Grading
Interview underpinned by a portfolio of evidence
S17

Perform simple calculations for example, raw material quantity and production calculations.

Back to Grading
Multiple-choice test
S18

Record information (text and data) - paper based or electronic for example, quality control documentation, cleaning logs, handover notes, stock inventory systems.

Back to Grading
Observation with questions
S19

Communicate with colleagues verbally.

Back to Grading
Observation with questions
S20

Use information technology for example, digital manufacturing management systems, virtual learning platforms, word processing, and email. Comply with GDPR and cyber security procedures.

Back to Grading
Interview underpinned by a portfolio of evidence
S21

Apply team building principles.

Back to Grading
Interview underpinned by a portfolio of evidence
S22

Carry out and record learning and development.

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

Put health and safety first.

Back to Grading
Observation with questions
B2

Consider the environment.

Back to Grading
Interview underpinned by a portfolio of evidence
B3

Take ownership for quality of given work.

Back to Grading
Observation with questions
B4

Adapt to changing work requests.

Back to Grading
Interview underpinned by a portfolio of evidence
B5

Team focus to meet work goals for example, work collaboratively.

Back to Grading
Interview underpinned by a portfolio of evidence
B6

Seek learning and development opportunities.

Back to Grading
Interview underpinned by a portfolio of evidence

Mapping of KSBs to grade themes

Observation with questions - Observation

KSBS GROUPED BY THEME Knowledge Skills Behaviour
Health and safety
K5
S1 S14
B1

Risk assessments and safe systems of work within process industries. Personal Protective Equipment (PPE). Isolation and emergency stop procedures. (K5)

Follow procedures in line with process industry health and safety regulations, standards, and guidance. (S1)

Comply with housekeeping procedures for example, clean equipment and machinery, tidy work area. (S14)

Put health and safety first. (B1)

Work organisation
K21
S3
B3

Work organisation and time management techniques. (K21)

Follow work instructions. (S3)

Take ownership for quality of given work. (B3)

Process operations
K12
S4 S5 S6 S7 S8

Standard operating procedures (SOP). What they are and why they are important. (K12)

Follow process manufacturing standard operating procedures. (S4)

Conduct material preparation for example, measure, weigh, mix and load materials. (S5)

Check and set up science process industry tools, plant, or equipment. (S6)

Use science process industry tools, plant, or equipment required for task. (S7)

Monitor process manufacturing and take corrective actions to meet specification. (S8)

N/A

Quality assurance
K14
S9

Quality assurance requirements and monitoring processes. (K14)

Apply product quality assurance procedures for example, take product samples, inspect products. (S9)

N/A

Communication
K18
S19

Verbal communication techniques. (K18)

Communicate with colleagues verbally. (S19)

N/A

Documentation
K17 K19
S11 S18

Work record requirements and importance of records for traceability and audits. Management information systems. (K17)

Written communication techniques. (K19)

Collect and interpret information. (S11)

Record information (text and data) - paper based or electronic for example, quality control documentation, cleaning logs, handover notes, stock inventory systems. (S18)

N/A

Interview underpinned by a portfolio of evidence - Discussion

KSBS GROUPED BY THEME Knowledge Skills Behaviour
Science manufacturing process operative’s role
K2
S12 S22
B6

Science manufacturing process operative role. Limits of responsibility. (K2)

Identify and resolve or report issues. (S12)

Carry out and record learning and development. (S22)

Seek learning and development opportunities. (B6)

Stock control
K16
S13

Stock requirements: control systems, and stock rotation. (K16)

Store materials, monitor, and rotate stock. (S13)

N/A

End of process procedures

S10

N/A

Conduct end of process procedures for example, finish, pack, label, discharge, move, and store batches. (S10)

N/A

Environment and sustainability
K6
S2 S15
B2

Environment and sustainability regulations and role of the Environmental Agency. Types of pollution and control measures: noise, smells, spills, and waste. Efficient use of resources. Recycling. Waste reduction and waste streams. (K6)

Follow procedures in line with process industry environmental and sustainability regulations, standards, and guidance. (S2)

Identify and segregate resources for reuse, recycling, and disposal. (S15)

Consider the environment. (B2)

Continuous improvement
K15
S16

Basic continuous improvement techniques: 5 Why’s, 5S, KAIZEN. (K15)

Apply basic continuous improvement techniques for example, 5Why's, S5, and KAIZEN. (S16)

N/A

Information technology
K20
S20

Information technology: digital manufacturing management systems, virtual learning platforms, word processing, and email. General data protection regulation (GDPR). Cyber security. (K20)

Use information technology for example, digital manufacturing management systems, virtual learning platforms, word processing, and email. Comply with GDPR and cyber security procedures. (S20)

N/A

Team working
K22 K23
S21
B4 B5

Principles of team working. (K22)

Equality, diversity, and inclusion. (K23)

Apply team building principles. (S21)

Adapt to changing work requests. (B4)

Team focus to meet work goals for example, work collaboratively. (B5)

Contact us about this apprenticeship

Employers involved in creating the standard: Berry Global BHGE British Steel Broanmain Carbon Component Solutions Genuit Group Kouraglobal Numatic Rutland Plastics Solenis

Version log

Version Change detail Earliest start date Latest start date Latest end date
Revised version awaiting implementation In development Not set Not set Not set
1.0 Approved for delivery 27/02/2018 Not set Not set