BPIF LEVEL 2 LEAN MANUFACTURING

BRIT ISHPRINT.COM

OVERVIEWTHE BPIF LEVEL 2 LEAN MANUFACTURING COURSE HAS BEEN DESIGNED TO PROVIDE AN EFFECTIVE CURRICULUM TO DEVELOP AND STRETCH THE KNOWLEDGE, SKILLS AND BEHAVIOURS THAT ARE REQUIRED TO BE AN AMBITIOUS AND SKILLED LEAN MANUFACTURER.

COURSE DESIGN & JUSTIFICATION Although the BPIF Level 2 Lean Manufacturing Programme has been designed

with the needs of the printing industry in mind, it is also designed to prepare

individuals to enter lean manufacturing roles in associated industries.

WHAT IS THIS QUALIFICATION?

This qualification is a Level 2 Diploma in Manufacturing (Knowledge and Skills) and

is a Vocational Related Qualification (VRQ). It will give learners knowledge and

understanding of a range of manufacturing related activities. The qualification covers

the intermediate knowledge and understanding that is required by someone working in

the manufacturing sector.

It takes a hands-on approach to foundation manufacturing training by providing learners

with: • Improved knowledge, skills and behaviours (current and future leaders)• Abilitiy to develop more strategic thinking

• Assistance with improved business performance

To support the BPIF learners’ future opportunity for progression within the printing

industry, or associated industries, the programme has been designed to include an EAL

Level 2 diploma in manufacturing, which is a gateway requirement for the End Point

Assessment (EPA).

The course will also incorporate a level 2 NVQ in the relevant print pathway to expand

the lean manufacturing methods into their print related job roles. Success in the

qualification and the standard provides learners with the flexibility for progression in

industries.

THE COURSE

BENEFITS

• Increased productivity• Improved motivation and engagement in

the workplace• Improved quality of work• Staff will achieve an industry recognised

qualification• Helps longer term succession planning• Visible commitment and investment

(delegates and team members)• Helps with career progression planning

BENEFITS FOR EMPLOYERS Benefits for employers include:

• Improved knowledge, skills and behaviours to improve performance

• Help with career progression • Increased job satisfaction • Increased confidence • Raised profile within your organisation • Platform for further learning and

progression

BENEFITS FOR LEARNERS Benefits for learners include:

CORE KNOWLEDGE A Lean Manufacturing Operative will have the following knowledge and understanding of:

1) Health & Safety: Relevant statutory, organisational and health and safety regulations relating to lean manufacturing operations and safe practices

2) Environmental: Compliance procedures/systems in line with regulatory requirements e.g. ISO 14001 or other relevant environmental standards

3) 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)

4) Lean Manufacturing Operations: Manufacturing standard operation procedures (SOPs) adherence and development of lean processes

5) Quality Control: Process equipment monitoring, data collection, error proofing and operating procedures e.g. ISO 9002 or other relevant quality standards

6) 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

7) Continuous Improvement: How to study and identify ways to improve the safety, quality, cost or process efficiency using lean manufacturing tools e.g. kaizen

8) Communication: How to share information using a range of methods within the manufacturing environment e.g. oral, written, electronic, information boards, visual displays

9) Work Place Organisation: How to maintain a safe and efficient work site through work place organisation e.g. 5s and process ownership

1) 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 working2) 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

3) 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

4) 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

5) 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

6) 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

7) 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)

8) Communication: Demonstrate communication skills which include oral, written, electronic (PC), information boards or visual displays to effectively share information

CORE SKILLSA Lean Manufacturing Operative will have the skill and understanding to:

1) Punctual, reliable and takes responsibility for their own actions

2) Show respect for others, having regard for diversity and equality

3) Respond positively to change in the working environment

4) Integrates within the team and supports others

5) Can work independently and effectively in challenging situations

6) Maintains quality of work under pressure7) An open and honest communicator, who

listens to other people’s opinions8) A positive and respectful attitude9) Follows instructions and guidance and

demonstrates attention to detail10) Seeks opportunities to develop and adapt

to different situations, environments or technologies

1) Lean Manufacturing Operative End-Point Assessment

2) GQA Level 2 NVQ Relevant Print Qualification

3) City & Guilds Maths Functional Skills Level 1

COURSE TARGETS All learners on the course are expected to achieve the following:

4) City & Guilds English Functional Skills Level 1

5) The opportunity to progress to the Print Technician Level 3 Standard

CORE BEHAVIOURSA Lean Manufacturing Operative requires the behaviours that will ensure they are:

1) One-to-one sessions to meet the needs of individual learners

2) Specialist support for learners with special educational needs and/or disabilities

3) Telephone, email and video support – 5 days a week

4) Access to the BPIF Virtual Learning Environment (VLE) – 7 days a week

COURSE SUPPORT The course consists of the following support:

5) Access to the BPIF E-Portfolio System – 7 days a week

6) Access to the BPIF Maths and English E-Learning System – 7 days a week

7) An assigned personal tutor

90%of employers who used the BPIF for training were likely or extremely likely to recommend the BPIF for their training

of employers reported improved productivity

71%of apprentices agreed their chances of earning a higher wage in the future had increased

74%of employers reported improved product or service quality

78%

above the national average

Employers gave the BPIF the

highest rating for satisfaction which

is more than

25%

CONTACT

Andrew Bracey – andrew.bracey@bpif.org.uk – 07801 981 312

Ben Johnstone – ben.johnstone@bpif.org.uk – 07841 070 234

Max Walkington – max.walkington@bpif.org.uk – 07719 964 561