Advanced Apprenticeship (Level 3) Mechatronics Maintenance Technician

• Five GCSE’s at Grade C/4 (or above) including Level 2 or GCSE C/4 or above in English, Maths and Science.
• If an Apprentice has not already achieved Level 2 (GCSE C/4 or above) English & Maths they must: -Study for and achieve Functional Skills Level 2 English & Maths.
• Initial Assessment on enrolment Level 2 Maths & English

Level 3 BTEC Diploma in Advanced Manufacturing Engineering (Development Technical Knowledge)

Level 3 Mechatronics Maintenance Technician Apprenticeship

Knowledge

K1: Information technology: spreadsheets, presentations, word processing, email and digital collaboration tools.

K2: The typical engineering problems which may arise within the maintenance environment.

K3: How to plan and communicate activities.

K4: Principles of equity, diversity, and inclusion in the workplace. Unconscious bias. Conscious inclusion.

K5: Fundamentals of engineering maintenance: documentation, safety checks, standard operating procedures, estimating planned equipment downtime, cost management and document validity.

K6: Engineering materials and consumables, their structure, properties and characteristics, how and why engineering materials can fail.

K7: Engineering standards and regulations requiring compliance in the engineering workplace: British Safety (BS) or European standards (EN) and wiring regulations.

K8: Health and safety regulations to include Health and Safety at Work Act 1974, Control of Substances Hazardous to Health (COSHH), Reporting Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR), Safe Systems of Work, Risk Assessments, Manual Handling, Lifting Operations and Lifting Equipment Regulations (LOLER), working at height, personal protective equipment (PPE), Provisions and Use of Work Equipment Regulations (PUWER), Noise Regulations, Display Equipment Regulations, confined spaces, Dangerous substances and Explosive atmospheres regulations.

K9: Organisational safety compliance requirements: permits to work, risk assessment, method statements, near miss and accident reporting, hazard reduction hierarchy including use of PPE.

K10: Principles and procedures to identify and mitigate risks associated with electrical, mechanical, gas, air and fluids: isolation, dissipation of stored energy, lock off, tag out and verifying procedures.

K11: Principles and procedures to identify and mitigate hazards associated with work equipment: trailing leads or hoses, damaged tools and equipment, and damaged or poor fitting handles.

K12: Principles, techniques and processes of sensory testing: sight, touch and smell.

K13: Principles of mechanical, electrical, electronic, control, robotic and AI applications. Knowledge of key technologies, fluid power, hydraulic, electrical, electronic, programmable logic controller's (PLC's), robotics, mechanical, control systems and how these are combined in complex mechatronics systems.

K14: Fault finding techniques used in reactive maintenance on complex integrated systems: half split, input output, six point technique, function or performance testing, unit or component substitution and equipment diagnostics.

K15: Documentation: validity, compliance, traceability and audit, approval and change management processes.

K16: Quality management systems and accreditations: ISO9001.

K17: Maintenance and storage of software programmes and back-up copies.

K18: Processes and techniques of planned and preventative maintenance activities. Principles of equipment selection and use and minimising down time.

K19: Principles, techniques and processes of non-destructive testing in a mechatronics maintenance environment.

K20: Condition monitoring methods and equipment used. How the information gained supports the planning of maintenance activities.

K21: Engineering, mathematical and scientific principles, methods and techniques used in the mechatronics maintenance environment: graphical expressions, symbols, formulae, units, measures, calculations and scaling.

K22: Principles of using and calibrating electrical and mechanical testing and measuring equipment.

K23: Types of engineering drawings and diagrams and their purpose.

K24: Principles, procedures and benefits of full operational and functional tests and checks on maintained, repaired and installed equipment.

K25: Principles, processes and importance of maintaining documentation: accuracy, engineering discipline and signatures.

K26: Environmental hazards that can arise from maintenance operations. Types of pollution and control measures: noise, smells, spills, and waste. Environmental permits. Waste Electrical and Electronic Equipment Directive (WEEE).

K27: Sustainability principles and processes: the 3 ‘R's’ (Reduce, Re-use, Recycle), segregation and disposal of waste and by-products.

K28: Principles and techniques of good housekeeping including '4S' and '5S'.

K29: Continuous improvement methods, concepts and techniques to collect and record data including graphical techniques.

K30: Data analysis principles used to identify trends and issues impacting operational performance.

K31: Verbal communication techniques. Giving and receiving information. Matching style to audience. Barriers in communication and how to overcome them.

K32: Written communication techniques. Plain English principles. Engineering terminology. Report writing.

K33: Non-verbal communication techniques: gestures, facial expressions, tone of voice and body language.

K34: Principles and techniques for manufacturing, repairing and refurbishing components using hand and machine tools.

K35: Principles and techniques of conducting initial assessment of equipment that requires maintenance.

K36: Techniques and processes used in reactive maintenance and repair activities on complex engineered systems such as electrical, electronic, mechanical, fluid power and control systems

Skills

S1: Use information technology, for example to create documentation, communication and information management.

S2: Obtain, read and interpret task related documentation, such as work instructions, quality control documents, drawings, operation manuals, specifications and service manuals.

S3: Record information for example job sheets, risk assessments, equipment service records, test results, handover documents and manufacturers' documentation, asset management records, work sheets, checklists, waste environmental records and any legal reporting requirements.

S4: Conduct initial assessment of equipment that requires maintenance.

S5: Formulate plans setting out the methodology of the maintenance activity including timescales and resources.

S6: Select, prepare and use material, consumables, tools and equipment.

S7: Comply with health and safety regulations and organisational requirements applicable in the workplace. For example, COSHH, PUWER, LOLER, PPE and applying safe systems of work.

S8: Apply dynamic risk assessment, hazard identification and risk mitigation principles and techniques.

S9: Apply isolation principles and techniques to equipment undergoing maintenance, including dissipation of stored energies as required.

S10: Manufacture, repair and refurbish components using hand and machine tools.

S11: Restore the workplace on completion of the maintenance activity. Handover resources, consumables and equipment to process owner.

S12: Apply the techniques and processes used in reactive maintenance and repair activities on complex engineered systems such as electrical, electronic, mechanical, fluid power and control systems.

S13: Produce, maintain, update, record and store documentation including electronic items such as PLC and robot programmes.

S14: Apply techniques and processes used in planned and preventative maintenance activities on engineered systems such as electrical, electronic, mechanical, fluid power and control systems.

S15: Apply functional testing and checking techniques and processes after maintenance interventions, and handover to the operational team.

S16: Apply techniques and processes used in condition monitoring, non-destructive or sensory testing. Record findings and take necessary actions.

S17: Apply calculation techniques such as, feeds, speeds, tolerances, electrical calculations using Ohms law, power calculations and cable sizing calculations.

S18: Select, use and confirm calibration of electrical and mechanical testing and measuring equipment.

S19: Produce sketches or drawings to support maintenance activities.

S20: Communicate in writing. Prepare communications, documents and reports on technical matters.

S21: Segregate, separate and dispose of waste streams and by-products.

S22: Apply 4S or 5S principles of housekeeping to the work environment.

S23: Identify opportunities and make recommendations to improve operational performance.

S24: Apply continuous improvement techniques.

S25: Communicate with others verbally. Negotiate with colleagues or stakeholders. For example, to access equipment or arrange access to equipment.

S26: Follow equity, diversity and inclusion procedures.

S27: Carry out and record planned and unplanned learning and development activities.

S28: Apply fault finding techniques used in reactive maintenance on complex integrated systems including half split, input output, six point technique, function or performance testing, unit or component substitution and equipment diagnostics.

Behaviours

B1: Supportive of the needs and concerns of others, for example relating to diversity and inclusion.

B2: Committed to continued professional development (CPD) to maintain and enhance competence.

B3: Take personal responsibility for their own sustainable working practices.

B4: Take personal responsibility for and promote health and safety.

B5: Act in a professional manner.

This occupation is found in the aerospace, aviation, automotive, defence, logistics, pharmaceutical, energy, food and drink, and wider advanced manufacturing and engineering sectors which utilise automated equipment with integrated systems and interfaces, where the equipment contains a blend of technologies such as mechanical, electrical, electronic and control, and fluid power.

Starts

• The apprenticeship programme will start in September.

Enrolment

• The enrolment process will be completed prior to the start date of the apprenticeship.

Delivery

• The apprenticeship will be delivered at Loughborough College for two days per week (Term time only)

Pearson

Skills England/ESFA

Level 4, 5 & 6 Apprenticeship standards

Level 4 Higher National Certificate in Engineering

Full-time employment

Current Delivery Involves:

• Two days per week (term time only) at Loughborough College
• A progress review every 12 weeks with dedicated trainer assessor and line manager / workplace mentor
• Observations and professional discussions with dedicated trainer assessor in the workplace