Accelerate Programme: L2 Lean Manufacturing Operative

2 Level 2 Lean Manufacturing Operative

Ideal for individuals working in a manufacturing environment

2 Level 2 Lean Manufacturing Operative

Ideal for individuals operating in a manufacturing environment.

Who is this course for?

This level 2 course is ideal for individuals working in a manufacturing environment and will make up most of your improvement project team.

What topics are covered?

Knowledge Statements:

Health & Safety: Relevant statutory, organisational and health and safety regulations relating to lean manufacturing operations and safe practices.
Environmental: Compliance procedures/systems in line with regulatory requirements e.g. ISO 14001 or other relevant environmental standards.
Production: Their individual roles and responsibilities within the organisation and the flexibility required to deliver products to meet customers costs/delivery targets/requirements e.g. Just in time (JIT).
Lean Manufacturing Operations: Manufacturing standard operation procedures (SOPs) adherence and development of lean processes.
Quality Control: Process equipment monitoring, data collection, error proofing and operating procedures e.g. ISO 9002 or other relevant quality standards.
Problem Solving: The tools and methods of effective problem solving using data, reports and documents to resolve production related issues e.g. A3 report, graphs, matrices and escalate concerns.
Continuous Improvement: How to study and identify ways to improve the safety, quality, cost or process efficiency using lean manufacturing tools e.g. kaizen.
Communication: How to share information using a range of methods within the manufacturing environment e.g. oral, written, electronic, information boards, visual displays.
Work Place Organisation: How to maintain a safe and efficient work site through work place organisation e.g. 5s and process ownership.
The correct methods of handling and storing the samples.
Where to obtain the necessary job instructions, inspection/quality procedures and product specifications that are used, and how to interpret them.
How to identify which samples, products and materials do not meet the quality requirements.
Procedures for the handling and segregation of defect components.
Specific safe working practices and environmental regulations that need to be observed.

Skill Statements:

Health & Safety: Work safely at all times, complying with health and safety legislation, regulations, and other relevant guidelines. Identifying risks within their processes and support/carry out countermeasure activities to improve safe working. Manage tooling, equipment and materials daily in-line with supplier standards e.g. COSHH (Control of Substances Hazardous to Health).
Environmental: Comply with environmental procedures and systems and contribute to the achievement of specific standards e.g. ISO 14001 or other relevant environmental standards and use the 4R’s (Reduce, Re-use, Recycle, Recover) where possible.
Production: Demonstrate their ability to carry out their role effectively, efficiently and flexibly maintaining lean manufacturing principles to meet customer’s demands e.g. JIT.
Lean Manufacturing Operations: Demonstrate their skill and knowledge following SOPs and building their versatility across a number of processes and process areas. Select and use appropriate tools, equipment and materials to carry out the manufacturing operation.
Quality Control: Demonstrate appropriate process documentation control. Accurately completing check sheets, monitoring process and equipment data efficiently and legibly using the correct terminology required to meet the quality standard e.g. ISO 9002.
Problem Solving: Demonstrate their ability to identify and resolve problems within the lean manufacturing environment using effective problem solving tools and techniques. Manage problems that may occur during the manufacturing process within the limits of their responsibility and escalate as appropriate.
Continuous Improvement: Generate ideas and contribute to process improvement activities individually or as part of a team through fact finding and analysis to improve the safety, environment, quality, cost or production process. Identifying and eliminating the 7 wastes (defects, over production, transportation, waiting, inventory, motion and processing).
Communication: Demonstrate communication skills which include oral, written, electronic (PC), information boards or visual displays to effectively share information.
Work Place Organisation: Maintains and monitors the work site efficiently and effectively at all times using the elements of sifting, sorting, sweeping, spick & span (5’s) within the lean manufacturing environment.
Obtain and follow the correct Job instructions, inspection/quality procedures and product specifications in accordance with time constraints and the roles and responsibilities identified for the inspection/quality assurance activity.
Collect production samples at the required frequency in accordance with inspection specification and operating procedures.
Carryout inspection and testing activities using the specified methods and equipment.
Prepare, Handle, transfer and store samples safely and correctly in accordance with quality control procedures.
Accurately interpret the data/results gained from the inspection and testing procedures being used.
Record and report inspection findings to relevant person.

Behaviour Statements:

Punctual, reliable and takes responsibility for their own actions.
Show respect for others, having regard for diversity and equality.
Respond positively to change in the working environment.
Integrates within the team and supports others.
Can work independently and effectively in challenging situations.
Maintains quality of work under pressure.
An open and honest communicator.
Listens to other people’s opinions.
A positive and respectful attitude.
Follows instructions and guidance and demonstrates attention to detail.
Seeks opportunities to develop and adapt to different situations, environments or technologies.

Diploma Units:

Mandatory Units:

LMOK2-001: Health and safety within a manufacturing environment.
LMOK2-002: Communicating and working effectively within a manufacturing environment.
LMOK2-003: Working relationships and individual rights and responsibilities within a manufacturing environment.
LMOK2-004: Application of workplace organisation.
LMOK2-005: Work-related problem-solving techniques.
LMOK2-006: Preparing for manufacturing operations.

Logistics/Material Handling Role Optional Unit:

Production/Assembly Role Optional Unit:

Inspection/Quality Assurance Role Optional Unit:

Qualifications involved

Lean Manufacturing Operative Standard (Knowledge, Skills & Behaviours)
Level 2 Diploma in Manufacturing (Knowledge and Skills)
Level 2 Award in Health & Safety in the Workplace
Functional Skills Level 1 Maths (progressing to level 2)
Functional Skills Level 1 English (progressing to level 2)

How does the programme run?

Download a PDF version of the scheme of work here.

Alternative qualifications

Level 3 Improvement Technician

Level 4 Improvement Practitioner

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