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.
| Duty | KSBs |
|---|---|
|
Duty 1 Carry out process manufacturing operations using or operating plant or equipment in line with standard operating procedures. |
|
|
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 |
|
Duty 3 Carry out pre-start checks of equipment and process before run or as part of handover responsibilities. |
|
|
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 |
|
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 |
|
Duty 6 Contribute to first-line maintenance, directly or through escalation. For example, equipment checks cleaning, and lubrication. |
|
|
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 |
|
Duty 8 Complete process work records - digital or paper, including traceability records. |
K2 K3 K4 K5 K6 K12 K13 K17 K18 K19 K20 K22 |
|
Duty 9 Contribute to maintaining own work area (housekeeping). |
K2 K3 K4 K5 K6 K12 K18 K20 K22 |
|
Duty 10 Conduct change over or clean down activities. |
|
|
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 |
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
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
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
English and maths qualifications form a mandatory part of all apprenticeships and must be completed before an apprentice can pass through gateway. The requirements are detailed in the current version of the apprenticeship funding rules.
| Version | Change detail | Earliest start date | Latest start date |
|---|---|---|---|
| 1.1 | Standard and end-point assessment plan revised | 22/08/2022 | Not set |
| 1.0 | Approved for delivery | 27/02/2018 | 21/08/2022 |
Crown copyright © 2025. You may re-use this information (not including logos) free of charge in any format or medium, under the terms of the Open Government Licence. Visit www.nationalarchives.gov.uk/doc/open-government-licence