Summary
As the Calcination Apprentice, you will shadow the Calcination Operators to learn all aspects of the role. The aim is for you to become fully competent and able to operate the Calcination Plant independently. You are expected to operate the Calcination Plant safely, correctly, and efficiently whilst always maintaining a strict housekeeping policy.
Wage
£16,363 a year
Training course
Process industry manufacturing technician (level 3)
Hours
Monday - Friday, 8.00am - 4.30pm.
40 hours a week
Possible start date
Monday 1 September
Duration
3 years
Positions available
1
Work
Most of your apprenticeship is spent working. You’ll learn on the job by getting hands-on experience.
What you’ll do at work
* You are expected to keep detailed and accurate records of all the Calcination Plant production data
* Always keep the shift log up to date
* You will conduct regular equipment checks and daily, weekly, and monthly audits
* Complete the Calcination competency workbooks and any other training material required for the role
* You are required to follow company Health and Safety procedures to ensure the safety of yourself and others. (must remain)
* You must always work efficiently to minimise downtime and waste
* You are expected to complete all the Knauf standard quality testing within the expected timeframes
* To minimise downtime, you will liaise effectively with the maintenance team and your managers reporting any potential downtime issues in a timely manner
* Demonstrate a positive attitude towards others
* You will act fast for early identification of equipment problems to prevent operational failure to ensure Calcination Plant KPI’s are achieved
* You must control all activities and deploy labour into Calcination Process by ensuring accurate use of the Control Board
* Anything commensurate to complete your role. (must remain)
Where you’ll work
96 Kings Road
Immingham
DN40 1QS
Training
Apprenticeships include time away from working for specialist training. You’ll study to gain professional knowledge and skills.
College or training organisation
HCF CATCH LIMITED
Your training course
Process industry manufacturing technician (level 3)
Equal to A level
Course contents
* Review instructions or information to understand the task.
* Plan tasks. Identify and organise resources with consideration for safety, environmental impact, quality, and cost.
* Identify hazards and risks in the workplace and personal safety and mitigation measures.
* Apply health, safety, and environmental procedures in compliance with regulations, standards, and guidance.
* Follow environment emergency procedures. For example, make area safe, evacuate.
* Apply sustainability principles for example, minimising waste.
* Apply standard operating procedures (SOPs).
* Check equipment.
* Select, check, and prepare raw materials for process for example, weighing, measuring, control and blending, conditioning, dissolving, and sanitisation.
* Set and adjust processing parameters such as temperature, pressure, speed or time, distance.
* Monitor process for example, take readings and conduct walk-arounds.
* Conduct the control of product streams to maintain specifics.
* Apply quality assurance procedures. For example, density checks, contaminant check, and take samples for laboratory testing.
* Apply intermediate or post-manufacturing procedure for example, labelling, packing, storage, visual inspection, discharge.
* Manage waste streams.
* Clean equipment for example, boil-outs, steam-outs, bake-outs, steam in place SIP, clean in place (CIP).
* Conduct calculations for example, conversations, tare weight, charge weights, yield calculations.
* Store tools and equipment.
* Identify equipment for handover.
* Apply signage and access restriction measures.
* Shut down the process and equipment.
* Isolate process and systems.
* Complete isolation checks.
* Empty equipment for example, drain, purge, vent, and de-pressure.
* Purge, fill, pressurise and leak test.
* Complete post maintenance equipment checks.
* Line-up equipment.
* Connect service connections such as water, electrical, pneumatic, hydraulic for chemical or petrochemical processing.
* De-isolate process, mechanical and electrical systems.
* Complete pre-start up checks.
* Start-up plant and equipment.
* Re-start process.
* Record or enter information - paper based or electronic.
* Interpret data for example, process data, quality control and test procedure data.
* Interpret drawings and graphs.
* Identify issues for example, defects, deviations, process variance, and maintenance requirements.
* Escalate issues outside limits of responsibility.
* Apply problem solving and fault-finding techniques.
* Apply continuous improvement techniques. Make a suggestion for improvement.
* Use information and digital technology for example, management information systems, human machine interfaces, word processing, spreadsheet, email, virtual learning platforms, document sharing platforms. Comply with cyber security requirements.
* Produce written documents for example, handover notes or emails, non-conformances, design change requests.
* Communicate with others verbally for example, colleagues and stakeholders.
* Apply team working principles.
* Plan how to meet personal development needs. Carry out and record planned and unplanned learning and development (CPD) activities.
* Review instructions or information to understand the task.
* Plan tasks. Identify and organise resources with consideration for safety, environmental impact, quality, and cost.
* Identify hazards and risks in the workplace and personal safety and mitigation measures.
* Apply health, safety, and environmental procedures in compliance with regulations, standards, and guidance.
* Follow environment emergency procedures. For example, make area safe, evacuate.
* Apply sustainability principles for example, minimising waste.
* Apply standard operating procedures (SOPs).
* Check equipment.
* Select, check, and prepare raw materials for process for example, weighing, measuring, control and blending, conditioning, dissolving, and sanitisation.
* Set and adjust processing parameters such as temperature, pressure, speed or time, distance.
* Monitor process for example, take readings and conduct walk-arounds.
* Conduct the control of product streams to maintain specifics.
* Apply quality assurance procedures. For example, density checks, contaminant check, and take samples for laboratory testing.
* Apply intermediate or post-manufacturing procedure for example, labelling, packing, storage, visual inspection, discharge.
* Manage waste streams.
* Clean equipment for example, boil-outs, steam-outs, bake-outs, steam in place SIP, clean in place (CIP).
* Conduct calculations for example, conversations, tare weight, charge weights, yield calculations.
* Store tools and equipment.
* Identify equipment for handover.
* Apply signage and access restriction measures.
* Shut down the process and equipment.
* Isolate process and systems.
* Complete isolation checks.
* Empty equipment for example, drain, purge, vent, and de-pressure.
* Purge, fill, pressurise and leak test.
* Complete post maintenance equipment checks.
* Line-up equipment.
* Connect service connections such as water, electrical, pneumatic, hydraulic for chemical or petrochemical processing.
* De-isolate process, mechanical and electrical systems.
* Complete pre-start up checks.
* Start-up plant and equipment.
* Re-start process.
* Record or enter information - paper based or electronic.
* Interpret data for example, process data, quality control and test procedure data.
* Interpret drawings and graphs.
* Identify issues for example, defects, deviations, process variance, and maintenance requirements.
* Escalate issues outside limits of responsibility.
* Apply problem solving and fault-finding techniques.
* Apply continuous improvement techniques. Make a suggestion for improvement.
* Use information and digital technology for example, management information systems, human machine interfaces, word processing, spreadsheet, email, virtual learning platforms, document sharing platforms. Comply with cyber security requirements.
* Produce written documents for example, handover notes or emails, non-conformances, design change requests.
* Communicate with others verbally for example, colleagues and stakeholders.
* Apply team working principles.
* Plan how to meet personal development needs. Carry out and record planned and unplanned learning and development (CPD) activities.
Your training plan
* Process Industry Manufacturing Technician
Level 3 (A level) Apprenticeship Standard
* Year 1 at CATCH in Stallingborough, Grimsby, DN41 8TH.
* Years 2 & 3, on site at Knauf, Immingham, DN40 1QS.
Requirements
Essential qualifications
GCSE in:
* English Language and/or Literature (grade Level 4)
* Maths (grade Level 4)
* Science (grade Level 4)
Let the company know about other relevant qualifications and industry experience you have. They can adjust the apprenticeship to reflect what you already know.
Skills
* Communication skills
* Attention to detail
* Organisation skills
* Problem solving skills
* Analytical skills
* Logical
* Team working
* Initiative