Level 3 Process Operator Apprentice - Ecolab

Cogent Ssc Limited

Cheshire, CW8 4DX

Closes in 15 days (Friday 6 December)

Posted on 7 November 2024

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Summary

Ecolab, the leading global developer of premium cleaning, sanitizing and maintenance products and services for the hospitality, institutional and industrial markets is seeking an Operator Apprentice to join the Weavergate chemical manufacturing site in Northwich.

• Annual wage: £22,990.50 a year

  Minimum wage rates (opens in new tab)

  pay is reviewed annually Post apprenticeship if successful and offered a permanent Operator role salary will be aligned to the plant operator pay scale (based on skills and operating level)

• Training course: Process industry manufacturing technician (level 3)
• Hours: Year 1: 8.00am - 4.00pm. From commencement of year 2 onwards the current plant shift pattern rotates with 1 week of earlies and 1 week of lates: 6.00am - 2.00pm and 1.00pm - 9.00pm. 30minute unpaid break entitlement within working hours.

  37 hours a week

• Possible start date:

  Saturday 1 February

• Duration:

  2 years

• Positions available:

  2

Work

As an apprentice, you’ll work at a company and get hands-on experience. You’ll gain new skills and work alongside experienced staff.

What you’ll do at work

1.      Understand and consistently comply to all safety, health and environmental standards (behavioural and machine) on site and for own work area

2.      Fully run all operations in allocated area to deliver agreed production plan and achieve KPI targets whilst complying with all standard operating procedures

3.      Accurately record, track and monitor all relevant operational performance data taking timely corrective actions or escalating if required

4.      Participate in operational improvement initiatives and use core TPM methodologies to help in identification of losses and their elimination through root cause analysis

5.      Complete routine basic maintenance tasks (TPM AM steps 1-3) and changeovers to maximise machine running times escalating non-standard equipment conditions

6.      Support team by identifying improvement opportunities and raising issues to local leadership team

The Core activities will include:

• Follow all correct start up and shut down procedures. Have awareness and understanding of all potential risks associated with specific role.
• Undertake regular behavioural safety observations and dialogues and timely completion of all associated paperwork (near miss/safety tags/accident reports) to required standard. Complete any resulting actions allocated.
• Follow correct safety procedures at all times including ensuring the plant is correctly isolated and the correct permits are in place before commencing any work on any machine (LOTO procedure).
• Follow site waste management procedures and support energy and waste reduction activities.
• Maintain correct operational conditions and take corrective actions as required.
• Complete all agreed product quality testing, sampling and recording of results through the systems provided.
• Supply all materials (components, bulk product, packaging) to machines to ensure maximum operational efficiency and minimise any losses.
• Maintain 5S standards in own area and support 5S improvement activities by identifying areas for improvement.
• Undertake scheduled basic maintenance activities (e.g. applying cleaning, inspection, lubrication standards to equipment) during planned maintenance slots and complete maintenance documentation required.
• Changeovers - complete basic changeovers including associated washout, and sanitation procedures.
• Attend and contribute in daily review meetings and perform effective shift handovers (written and verbal). Contribute to line logbooks.
• Visually manage relevant production data and information and communicate and share all that is relevant to colleagues in a timely and open manner.
• Assist team members and technical colleagues to improve machine and process efficiency using TPM methodology.
• Participate in TPM Improvement teams as required using range of core tools and techniques to solve problems.

Where you’ll work

Ecolan/Nalco Manufacturing

Winnington Avenue,

Northwich

Cheshire

CW8 4DX

Training

An apprenticeship includes regular training with a college or other training organisation. At least 20% of your working hours will be spent training or studying.

College or training organisation

COGENT SSC 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

• Training will be delivered online

Requirements

Essential qualifications

GCSE in:

• 5 GCSE's including Maths and English (grade 4/C or above)

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
• Logical
• Team working

Other requirements

From 2nd year and if secured in a permanent role this will be shift based work early shifts starting at 6am and late shifts finishing at 9pm. Due to health and safety, all applicants must be 18 years old or older, any applicants younger than 18 will be ineligible.

About this company

Our apprenticeship and graduate services have been supporting science industry employers to attract, retain and develop people who can contribute to business success since 2012.

Company benefits

• 4% flex benefit which can be used to purchase benefits such as additional holidays, dental cover, medical cover etc. If no benefits purchased, then amount is paid as additional salary. • 4 x life assurance • Employee Assistance Programme

After this apprenticeship

• If You are successful in your apprenticeship, you will be eligible to for positions such as: Operator, T1 Operator, Team Coach, Team Leader, Operations Manager.

Ask a question

The contact for this apprenticeship is:

Cogent Ssc Limited

Dylan Bailey

dylan-bailey@cogentskills.com

The reference code for this apprenticeship is VAC1000286408.

Apply now

Closes in 15 days (Friday 6 December)

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After signing in, you’ll apply for this apprenticeship on the company's website.

Company’s application instructions

To apply for this position, please go to the cogent skills vacancies page and complete the application form there.