Programme Overview

The Level 2 Lean Manufacturing Operative apprenticeship prepares individuals to work safely, efficiently and effectively in fast-paced production environments. Apprentices learn how to operate processes, follow Standard Operating Procedures (SOPs), perform quality checks, support continuous improvement and deliver high-quality products at speed, often across multiple product types.

This programme develops multi-skilled, safety-conscious operatives who can contribute to process efficiency, build quality into production and support lean manufacturing culture across their organisation.

Who This Programme Is For

• Individuals beginning a career in manufacturing or assembly
• Employers wanting to build a reliable, multi-skilled production workforce
• Operatives working in automotive, engineering, food, FMCG, fabrication, textile, plastics and other manufacturing sectors
• Production environments requiring flexibility, lean thinking and high-quality standards

What Apprentices Will Learn

Health & Safety

• Statutory and organisational safety requirements
• Safe use of tools, machinery, equipment and PPE
• Hazard identification, risk reduction and incident escalation

Environmental Compliance

• Environmental procedures, ISO 14001 awareness
• Waste handling, sustainability and the 4Rs (Reduce, Reuse, Recycle, Recover)

Production Efficiency

• Understanding role expectations, targets and workflow
• Just-in-Time (JIT), takt time and meeting customer lead times

Lean Manufacturing Operations

• SOP adherence, process control and lean principles
• Versatility across multiple process areas

Quality Control

• Data collection, monitoring, error-proofing and documentation
• Understanding quality standards such as ISO 9002

Problem Solving

• Tools such as A3, 5 Whys, Pareto, graphs and matrices
• Escalation procedures and team-based problem solving

Continuous Improvement

• Kaizen, waste elimination, visualisation and flow improvements

Communication

• Professional communication: oral, written, electronic and visual boards

Workplace Organisation (5S)

• Maintaining clean, organised, safe and efficient work areas

Core Skills Developed

• Working safely at all times
• Following SOPs and producing quality work
• Using tools, machines and equipment correctly
• Conducting checks, inspections and process monitoring
• Problem solving within the limits of responsibility
• Recording data, completing documentation and reporting faults
• Supporting continuous improvement (Kaizen, 5S, waste reduction)
• Communicating clearly with supervisors and team members
• Maintaining a clean, efficient working environment

Specialist Options (Choose ONE)

1. Production / Assembly Operative

• Following assembly sequences
• Positioning, aligning and securing components
• Conducting assembly checks and using fastening methods
• Identifying and resolving assembly issues

2. Inspection / Quality Assurance Operative

• Collecting samples, conducting inspections and tests
• Interpreting data and recording results
• Identifying non-conforming products
• Handling and segregating defect components

3. Logistics / Material Handling Operative

• Safely moving materials using appropriate equipment
• Completing transfer documentation
• Checking load condition, alignment and safety
• Understanding lifting, handling and storage procedures

4. Production Processing / Finishing Operative

• Performing one type of finishing/processing method
• Following predetermined sequences
• Monitoring and controlling processing operations
• Conducting quality checks on finished products

Professional Behaviours

Apprentices will demonstrate:

• Reliability and punctuality
• Respect, equality and teamwork
• Adaptability to change
• Calmness under pressure
• Openness, honesty and professional communication
• Attention to detail
• Positive attitude and willingness to developDelivery Model (ESTAR Approach)
  • Blended learning with online theory, workplace practice and tutor-led workshops
  • Practical coaching aligned to real production environments
  • Monthly progress reviews with employer involvement
  • Portfolio evidence covering full knowledge, skills and behaviours
  • Specialist option training tailored to employer organisation
  • Typical duration 12–18 months, depending on operational environment
  • Full EPA preparation including mock tests and practice interviews

End-Point Assessment (EPA)

Gateway Requirements:

• English and Maths at required level
• Completed portfolio
• Employer confirmation of competence

EPA Methods:

1. Observation with Questions
2. Interview Underpinned by Portfolio
3. Multiple-Choice Test (40 questions)

Grading:

Fail / Pass / Merit / Distinction