Controlling and managing the complex manufacturing processes for different materials
This standard has options. Display duties and KSBs for:
This occupation is found in a wide variety of Thermal Process related fields including Casting, Forging, Machining, Coating, Heat treatment and Surface Finishing processes. These specialist areas are also found in a wide range of industries where materials and their processes are fundamental to the technology . Industries as diverse as Medical, Defence, Energy, Oil and Gas, Aerospace and Nuclear all incorporate the skills of Materials Process Engineers.
The broad purpose of the occupation is to perform a role which is unique to the materials/manufacturing community, controlling and managing the complex manufacturing processes and support services that are applied to products for the automotive, aerospace, medical, energy and construction sectors. They do this by collecting and organising all the information needed to understand the whole problem, exploring it from all angles, and then finding the most appropriate solution for integration into a sustainable product life cycle. A Materials Process Engineer might typically work in either the problem definition or solution provider environments, making critical decisions in the process and utilities to produce high-quality, cost-effective parts and systems, then testing and accepting the designed solutions. They provide essential support to their associated businesses providing guidance and leadership in improving company metrics of quality, delivery, new product introduction and support key financial and business decisions.
In their daily work, an employee in this occupation interacts with all departments within the companies they work for and at a range of levels within the departments depending on the project in which they are engaged. Their main focus will be with the Engineering team and they will also have strong links in support of the Operations team. However to fulfil many of the projects, links to finance, supply chain and customer support will be a day to day occurrence and as the activities broaden there will be strong communication to the wider external customer base both in a sales support activity and during technical project discussions.
An employee in this occupation will be responsible for implementing new products and processes and for many cost reduction and process improvement initiatives. They have direct responsibility for defining the methods of manufacture of complex engineering systems and the asset base and services which are used to produce high value manufactured products. In many cases weekly and monthly reports will be required at both team level and to senior members of the company.
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Duty 1 Lead multiple new product introduction or process improvement engineering projects working closely with the operations and engineering teams to prioritise projects in line with ever changing business / customer priorities |
1 Adherence to employer polices and procedures 2 Work delivered to agreed timescales and cost 3 Compliance to Customer specifications |
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Duty 2 Takes responsibility for the creation of process rules that ensure product definition will be capable of being manufactured, assembled and repaired in line with project timescales |
3 Compliance to Customer specifications 4 Productivity standards meet Customer requirements 5 Cost and quality standards meet Business requirements |
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Duty 3 Liaises directly with customers to fully establish working project requirements, status and action plans |
1 Adherence to employer polices and procedures 2 Work delivered to agreed timescales and cost 3 Compliance to Customer specifications |
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Duty 4 Leads process improvement activities associated with new and existing manufacturing processes utilising latest techniques and practices by the collection and analysis of data using standard SPC analytical techniques |
3 Compliance to Customer specifications 4 Productivity standards meet Customer requirements 5 Cost and quality standards meet Business requirements |
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Duty 5 Performs, implements and reviews process risk and mitigation activities utilising tools such as PFMEA and value stream mapping to manage product quality and cost |
5 Cost and quality standards meet Business requirements | |
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Duty 6 Understand manufacturing engineering production methods, control strategies and quality issues related to the manufacture of products |
3 Compliance to Customer specifications 4 Productivity standards meet Customer requirements 5 Cost and quality standards meet Business requirements |
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Duty 7 Identify, implement and share best practices across multiple cells and sites by development of global methods and systems to support design, cost and quality targets |
4 Productivity standards meet Customer requirements 5 Cost and quality standards meet Business requirements 6 Positive relationship with peers |
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Duty 8 Provide expert materials advice to inform and guide commercial [team] decision making |
2 Work delivered to agreed timescales and cost | |
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Duty 9 Evaluate the latest technological advances and provide a critical analysis of their short and long term implications for the business |
1 Adherence to employer polices and procedures 7 Excellent interpersonal skills |
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Duty 10 Accurately review customer drawings and specifications and ensure compliance when creating work instructions and other internal documentation |
3 Compliance to Customer specifications | |
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Duty 11 Work with all stakeholders to ensure compliance with quality, environmental and Health and Safety policies |
1 Adherence to employer polices and procedures | |
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Duty 12 Create the detailed process instructions including inspection requirements, design and procure tooling and fixtures in aid of production activities or to improve productivity |
1 Adherence to employer polices and procedures 3 Compliance to Customer specifications 4 Productivity standards meet Customer requirements 5 Cost and quality standards meet Business requirements |
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Duty 13 Deliver stable and capable processes to an agreed customer specification and that there are actions in place to support equipment improvement and associated maintenance schedules to ensure capable process continuation |
1. Adherence to employer polices and procedures 3 Compliance to Customer specifications 4 Productivity standards meet Customer requirements 5 Cost and quality standards meet Business requirements |
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Duty 14 Produce technical reports as required during interim phases and at completion of project work |
7. Excellent interpersonal skills 8. Successful review of technical reports |
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Duty 15 Market and represent the company at customer technical meetings and at local/international conferences and events |
7 Excellent interpersonal skills 9. Presentation Skills |
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Duty 16 Lead, mentor and manage teams highlighting the importance of networking, communication and taking personnel responsibility in delivering products to a customer |
7 Excellent interpersonal skills |
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Duty 17 Ensure the safe and reliable operation, control of the process and close out of quality, process and business improvements in a castings environment |
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Duty 18 Lead the end to end process for casting operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between business critical departments |
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Duty 19 Ensure casting is integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification |
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Duty 20 Ensure methods and techniques for safe and reliable operation, control and close out of quality, process and business improvements in a coatings environment |
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Duty 21 Lead the end to end process for coating operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between business critical departments |
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Duty 22 Ensure Coatings are integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification |
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Duty 23 Ensure the safe and reliable operation, control and close out of quality, process and business improvements in a welding environment |
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Duty 24 Lead the end to end process for welding operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between business critical departments |
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Duty 25 Ensure Welding is integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification |
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Duty 26 Ensure the requirements, methods and techniques for safe and reliable operation, control and close out of quality, process and business improvements in a brazing environment |
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Duty 27 Lead the end to end process for brazing operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between business critical departments |
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Duty 28 Ensure Brazing is integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification |
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Duty 29 Ensure the requirements, methods and techniques for safe and reliable operation, control and close out of quality, process and business improvements in a heat treatment environment |
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Duty 30 Lead the end to end process for heat treatment operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between business critical departments |
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Duty 31 Ensure Heat Treatment is integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification |
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Duty 32 Ensure the requirements, methods and techniques for safe and reliable operation, control and close out of quality, process and business improvements in a surface treatment environment |
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Duty 33 Lead the end to end process for surface treatment operations, for example digital systems, emerging process technologies, alignment of services and specifications and methods and techniques for maintenance. Interface with operations assets and laboratory functions and understand links between business critical departments |
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Duty 34 Ensure Surface Treatment is integrated in the end to end process for the product lifecycle for example product verification, design proving, material applications and methods related to conformance to customer specification |
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K1: Theories of team working
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K2: Principles of programme management
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K3: Understanding the importance of conflict management
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K4: Risk management theories and practice
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K5: Principles of Quality Management Systems and implementation in factory environments
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K6: New product introduction and technology management - theory
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K7: Importance of design for manufacture and assembly
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K8: Principles and practices of engineering standards
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K9: Principles of process risk management including Process Failure Modes and Effects Analysis (PFMEA)
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K10: Principles of Stakeholder management
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K11: Importance of working within a regulatory framework
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K12: Importance of Intellectual Property, Patents and Export Control
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K13: The function of Quality Techniques Systems and Standards
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K14: The principles of statistical process control and application techniques (e.g PFMEA)
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K15: Change management principles
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K16: Principles and practices of knowledge based systems
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K17: Principles of Lean Manufacturing
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K18: Cost based engineering (including estimating, cost control, cost forecasting, investment appraisal and risk analysis)
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K19: Principles of Operations management
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K20: Principles of Leadership in Operations Management
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K21: Principles of Supply Chain Management
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K22: Principles of Asset Management
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K23: The principles of effective presentations (including planning, structuring, how and when to engage with the audience,using visual aids, presenting data)
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K24: Art of technical report writing
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K25: Principles of mentoring people
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K26: Fundamentals of casting process and technology
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K27: Fundamentals of the product life cycle
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K28: Fundamentals of coating processes and technology
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K29: Fundamentals of welding processes and technology
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K30: Fundamentals of brazing processes and technology
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K31: Fundamentals of heat treatment processes and technology
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K32: Fundamentals of surface treatment processes and technology
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S1: Work within a team environment. This may include acting as a team leader with people management skills. They undertake risk analysis and problem solving on behalf of the team.
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S2: Communicate and present information appropriately and effectively taking account of target audience
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S3: Apply appropriate programme management tools. Typically this would include a RACI chart, Project Plans, Load and Capacity analysis and cost analysis.
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S4: Actively listen and explain clearly and appropriately to target audience
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S5: Mentor and support others using coaching skills and actively support continuous professional development.
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S6: Use Process Failure Mode Effect Analysis tool kit appropriately
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S7: Operate and control process equipment using continuous improvement methodologies
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S8: Apply process control procedures correctly and effectively
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S9: Apply appropriate negotiation techniques effectively
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S10: Make appropriate use of statistical tools eg Minitab, excel, DMAIC
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S11: Make appropriate use of problem solving tools eg 8D, 5 whys
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S12: Apply change control tools and practices
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S13: Apply risk management tools and techniques
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S14: Demonstrate correct application of Value Stream Mapping tools
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S15: Apply production control methods eg planning and project management
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S16: Correct use of specialist equipment and process knowledge
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S17: Correct use of product life cycle concepts
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B1: Working collaboratively - is comfortable in working in teams and being a team leader to agreed goals
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B2: Professional Commitment -
Commitment to corporate values and behaviours through the demonstrating a personal , ethical and professional commitment to society, their profession and the environment, adopting a set of values and behaviours that will maintain and enhance the reputation of the profession as well as their organisation
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B3: Commitment to leadership -
Taking personal responsibility for their actions, managing projects including resource management within their remit and able to mentor and instruct others in associated standards and best practice
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B4: Commitment to the profession
Contributing proactively to the continuing development of engineering within their domain
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B5: Curiosity and Innovation
Utilising own and others creativity to Improve the industry through embracing new technology and the digital world
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B6: System Thinking
Seeing whole systems and parts and how they connect recognising interdependencies and integration
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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.
| High Level Qualification |
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Manufacturing Technology and Management MSc Level: 2 |
This standard aligns with the following professional recognition:
7
24
this apprenticeship will be reviewed in accordance with our change request policy.
| Version | Change detail | Earliest start date | Latest start date |
|---|---|---|---|
| 1.1 | End point assessment plan revised | 14/10/2024 | Not set |
| 1.0 | Approved for delivery | 22/03/2019 | 13/10/2024 |
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