UK

United Kingdom · Operations · Senior (5-8 years)

Senior Factory Manager

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  • Experience bandSenior (5-8 years)
  • Direct reportsNo direct reports
  • Reports toFactory Manager or Plant Manager
  • UK framework levelUsually a manager, or the deepest specialist in a team

Also advertised as Senior Production Manager · Manufacturing Operations Lead · Site Operations Manager (Senior) · Production Department Head

Built on 43,079 real UK job descriptions we analysed · grounded in what real qualifications cover

Two short quizzes about you

1From this job to a course

The qualifications matched to this job

EAL Level 4 Diploma in Engineering and Advanced Manufacturing (Development Competence) Excellence, Achievement & Learning Limited · Level 4 · covers 1 of 10 standards
GQA PAA\VQ-SET Level 3 NVQ Diploma in Signmaking GQA Qualifications Limited · Level 3 · covers 1 of 10 standards
GQA Level 3 NVQ Diploma in Print Administration GQA Qualifications Limited · Level 3 · covers 1 of 10 standards
EAL Level 4 NVQ Diploma in Engineering Manufacture Excellence, Achievement & Learning Limited · Level 4 · covers 1 of 10 standards
EAL Level 4 NVQ Extended Diploma in Engineering Manufacture Excellence, Achievement & Learning Limited · Level 4 · covers 1 of 10 standards
GQA Level 3 NVQ Diploma In Machine Printing GQA Qualifications Limited · Level 3 · covers 1 of 10 standards

Matched from the standards this job is measured against: a suggestion, not an official ruling.

The units you would start with

Lead mechanical manufacturing or inspection activities EAL Level 4 Diploma in Engineering and Advanced Manufacturing (Development Competence)
Plan and Monitor Production Process in a Signmaking Environment GQA PAA\VQ-SET Level 3 NVQ Diploma in Signmaking
Plan, schedule and monitor print production GQA Level 3 NVQ Diploma in Print Administration
Plan work to meet production requirements GQA Level 3 NVQ Diploma In Machine Printing

The future skills this job leans on

AI Fluency working with AI as a thinking partner
Data Fluency turning numbers into a decision
Systems Fluency seeing the whole picture
Your Plan Illustration

Built for Senior Factory Manager

4 units that map to this job, from the qualifications that cover it.

  1. Lead mechanical manufacturing or inspection activities Excellence, Achievement & Learning Limited · covers 1 of 10 standards Level 4
  2. Plan and Monitor Production Process in a Signmaking Environment GQA Qualifications Limited · covers 1 of 10 standards Level 3
  3. Plan, schedule and monitor print production GQA Qualifications Limited · covers 1 of 10 standards Level 3
  4. Plan work to meet production requirements GQA Qualifications Limited · covers 1 of 10 standards Level 3
These are the real units behind this job, in the order they rank for it. Nothing here is marked done, because this plan has not been started by anyone yet. Yours would fill in as you go.

2AI and this work

Will AI change your work as a Senior Factory Manager?

Nobody can say exactly how. Here is what this job is being asked for next, and where to start.

The new skills this role is being asked for

  • Data Storytelling & Visualisation
  • Basic AI Prompt Engineering for Operations
Why each one is rising

The future skills this job leans on

We'll only ever tell you what we can actually back up. No hype, no scare tactics.

What happens when you start

Next, a free account. We build your Senior Factory Manager plan as you set up, starting with the free Data Fluency module. No card.

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Keep this read. One email with what AI is changing in this job, the new skills it asks for and where to start free. Nothing else follows unless you confirm your address.

3What this role really is

A senior factory manager keeps production lines running, and works out how to make them run better and safer. You solve the problems that stop production, and coach teams to do the same.

4What you'd actually use

The tools this job runs on, and how well you'd need to know each one.

ERP System (e.g., SAP S/4HANA, Oracle NetSuite) Advanced

Configuring production modules, troubleshooting data discrepancies (e.g., inventory accuracy, work order status), pulling complex reports for analysis, and training supervisors on system use.

MES (Manufacturing Execution System) (e.g., Rockwell FactoryTalk, Siemens Opcenter) Advanced

Analysing MES data to identify bottlenecks, configuring new product recipes or routings, developing custom reports to track specific KPIs, and optimising data collection points.

CMMS (Computerised Maintenance Management System) (e.g., Fiix, UpKeep, IBM Maximo) Intermediate

Analysing maintenance backlogs and trends, developing preventive maintenance plans based on failure data, and ensuring work orders are properly closed out and documented.

QMS (Quality Management System) (e.g., MasterControl, ETQ Reliance) Advanced

Conducting root cause analysis (RCA) within the QMS, managing CAPA (Corrective and Preventive Action) workflows, and authoring/approving Standard Operating Procedures (SOPs) related to quality.

BI / Analytics Tools (e.g., Power BI, Tableau) Intermediate

Building custom dashboards connecting MES and ERP data to visualise OEE, scrap rates, and other KPIs. You'll use DAX/calculated fields to create new metrics and insights for your team and management.

Collaboration Platforms (e.g., MS Teams, Slack) Advanced

Creating dedicated channels for Kaizen events, integrating alerts from MES/CMMS for rapid response, managing team permissions, and running virtual shift handover meetings.

5What you get to decide, and how that grows

Power in a job isn't your title. It's what you're allowed to decide. Here's how it grows as you move up.

The choiceComing in Where you are nowThe step above
Process Improvement Methodology Follows chosen methodology (e.g., 5 Whys, Kaizen) under supervision. Selects appropriate methodology for routine problems; consults on complex ones. Defines and implements the best methodology for complex workstream problems; coaches others on selection.
Production Schedule Adjustments Escalates any deviation from schedule to supervisor. Makes minor, short-term adjustments within shift; informs supervisor. Approves short-term schedule changes within own area (up to 24 hours) to optimise flow, consulting with Planning for broader impact.
Budget for Small Projects/Tools No independent budget authority; requests all purchases. Can authorise small purchases up to £500 for immediate operational needs. Recommends and informs on budget spend up to £10K for improvement projects; consults on anything higher.
Quality Deviation Resolution Identifies deviation, quarantines product, escalates to supervisor/Quality. Conducts initial root cause analysis, proposes containment and corrective actions; seeks approval from Quality. Leads root cause analysis, approves containment and corrective actions within defined parameters, makes decisions on product disposition (rework/scrap) in consultation with Quality.

6How you'll be judged

The scoreboard, and what is not on it. The hard targets, how often each is actually looked at, and the quiet signals that never reach a dashboard.

Overall Equipment Effectiveness (OEE) for your area
This is a big one. It's about how well our machines are actually running when they're supposed to. It combines availability, performance, and quality.
Target · Increase OEE by 5% year-on-year for your assigned production area (e.g., from 65% to 70%).

If your area's OEE was 68% last year, we'd expect to see it consistently above 71% by the end of this year, with a clear plan on how you're getting there.

Scrap Rate & Rework Costs
How much material are we throwing away or having to fix? This directly hits our bottom line.
Target · Reduce scrap rate by 15% and rework hours by 10% within 12 months for your workstreams.

If Line 3's scrap was typically 3% of production, you'd be aiming to get that down to 2.55% or less, alongside reducing the time spent fixing those products.

Lost Time Incidents (LTI) & Near Miss Reporting
Safety is non-negotiable. This measures serious incidents and how proactive we are at catching potential problems before they become real ones.
Target · Zero LTIs in your managed areas, and a 20% increase in near-miss reports (shows proactive safety culture).

Your area should have no incidents where someone needs time off work, and you'd be seeing more operators reporting small hazards, which is actually a good sign of engagement.

On-Time, In-Full (OTIF) Delivery for your production batches
Are we making what we promised, when we promised it, and is it all there? This directly impacts customer satisfaction.
Target · Maintain >98% OTIF for all production orders within your scope.

If you're responsible for the packaging line, 98 out of every 100 customer orders should leave the factory complete and on time.

Process Improvement Leadership
It's about how effectively you lead and embed continuous improvement. Are you just doing projects, or are you creating a culture where everyone looks for better ways?
  • You'll be leading at least 4 significant Kaizen events per year, with clear, documented improvements. Your team will be actively suggesting and implementing small improvements. You'll be the go-to person for solving complex operational issues, not just reacting to them.
Team Development & Mentorship
How well are you building capability in your team? Are you helping people grow and take on more responsibility?
  • You'll have clear development plans for your direct reports (if any) and key operators. You'll be regularly providing constructive feedback and coaching. We'd see junior team members taking on more complex tasks and showing real growth under your wing. You'll be seen as a trusted advisor.
Cross-Functional Collaboration
Are you playing nicely with others? Can you get different departments like Maintenance, Quality, and Engineering to work together effectively to solve problems?
  • You'll be regularly invited to cross-departmental meetings, and your input will be sought. You'll successfully resolve inter-departmental conflicts without needing your boss to step in. Projects involving multiple teams will run smoothly because of your ability to get everyone on the same page.

7Would you like it

Both sides. What people enjoy, and what grinds them down.

What people enjoy
Solving Complex Problems

You'll be the one digging into why a machine keeps failing, or why a specific defect keeps appearing. You enjoy the detective work and the satisfaction of finding a lasting solution.

Spending a few hours with the maintenance team and operators, using a fishbone diagram to figure out why the packing machine keeps jamming, then implementing a Poka-Yoke solution.

Driving Tangible Improvement

You get a real kick out of seeing the numbers move—OEE going up, scrap coming down. You love leading a Kaizen event and seeing the results hit the floor immediately.

Leading a team to reduce changeover time on a critical line by 20%, then seeing that directly translate into more production capacity and happier customers.

Developing and Mentoring People

You enjoy coaching your supervisors and operators, helping them understand 'why' we do things, and empowering them to solve problems themselves. You're invested in their growth.

Spending time with a new supervisor, walking them through a challenging production issue, and guiding them to their own solution, rather than just telling them what to do.

What frustrates people
  • The Firefighting Treadmill: You'll meticulously plan your week with improvement projects, but 80% of your time often gets consumed by unforeseen equipment breakdowns, quality spills, or personnel issues. It's hard to get ahead when you're constantly putting out fires.
  • The Squeeze Play: You're constantly caught between senior management's aggressive cost-cutting targets and the maintenance team's legitimate need for budget to perform preventative work on aging equipment. It's a tough balancing act.
  • "We've Always Done It This Way": Battling cultural inertia and resistance to change from veteran operators or supervisors who are sceptical of new processes or technologies. Getting buy-in can feel like pushing water uphill.
  • Accountability Without Control: Being held 100% accountable for a missed shipment when the root cause was a supplier delivering faulty parts or the sales team accepting an order with an impossible lead time. It's frustrating when you can't control all the variables.
  • The Data Lie: The dashboard shows OEE is 85%, but you know from your Gemba walks that operators are using workarounds or misreporting downtime to keep the numbers green. Getting to the real truth can be a challenge.
  • Union vs. Management Dynamics: Navigating the complex, often adversarial relationship between union leadership and company objectives, where a simple process change can become a lengthy grievance procedure. It requires patience and negotiation.
What this role does not give you
  • A quiet, predictable office environment. You'll be on the shop floor a lot.
  • A role where you can always stick to your planned schedule. Expect daily disruptions.
  • A job where every idea you have gets implemented immediately. Change takes time and persuasion.
  • A purely strategic role. You'll be hands-on, solving real problems, not just theorising.

8Who you work with

Your work directly impacts our ability to deliver products on time, to the right quality, and at a competitive cost. You're a critical link in ensuring our operational excellence, driving down waste, and keeping our people safe. Get it right, and you're directly contributing to our profitability and customer satisfaction. Get it wrong, and you're costing us money and reputation.

Inside the business
  • Factory Manager / Plant Manager (your boss, for strategic input)
  • Maintenance Manager (for equipment reliability and uptime)
  • Quality Manager (for product standards and defect reduction)
  • Engineering Manager (for process design and new equipment)
  • Supply Chain & Planning Teams (for raw material flow and production schedules)
  • Health & Safety Officer (for ensuring a safe working environment)
  • HR Business Partner (for staffing, training, and employee relations)
Outside the business
  • Key Equipment Vendors (for maintenance contracts and upgrades)
  • Auditors (for quality and safety compliance checks)
  • Senior Clients (occasionally, for plant tours or specific quality discussions)

9What you need before you start

Not a wish list. The things you would be expected to already have.

  • Proven track record of leading production teams or workstreams in a manufacturing environment for at least 3-5 years.
  • Demonstrable experience in applying Lean Manufacturing principles (e.g., leading Kaizen events, VSM) with measurable results.
  • Solid understanding of OEE calculation and how to drive improvements in availability, performance, and quality.
  • Experience with an ERP system (like SAP or Oracle) and a Manufacturing Execution System (MES) is non-negotiable.
  • Strong analytical skills, comfortable working with production data to identify trends and root causes.
  • Excellent communication skills, both verbal and written, capable of engaging with operators, engineers, and senior management.
  • A genuine commitment to safety and quality, with a proactive approach to identifying and mitigating risks.

10What to practise next

Where the job is going, and what to do about it starting this week.

Advanced MES & ERP Integration

The future of manufacturing is seamless data flow. You'll need to understand not just how to use our MES and ERP systems individually, but how they connect, where the data flows, and how to troubleshoot integration issues. This will be critical for accurate reporting and real-time decision making.

Data mapping between systems · Middleware and APIs · Troubleshooting data discrepancies · Real-time data synchronisation

  • This month: Work closely with our IT team to understand the data architecture and integration points between our core systems.
  • Next month: Take ownership of resolving any data discrepancies between MES and ERP for your area, rather than just escalating.
  • Month 3: Map out the critical data flows for your workstreams, identifying potential points of failure or delay.
  • Month 4: Propose an improvement to a data integration process that will enhance accuracy or speed.

Quick win: Spend an hour with an IT colleague to understand the basics of our system integrations. Ask 'how does this data get from here to there?'

Digital Twin Concepts for Operations

Digital twins – virtual replicas of our physical factory processes or equipment – are becoming powerful tools for simulation, optimisation, and predictive maintenance. While you won't build them, understanding their potential will allow you to ask the right questions and use the insights they provide.

What a digital twin is · Simulation applications · Predictive analytics via digital twins · Optimisation opportunities

  • This month: Read up on digital twin technology in manufacturing (e.g., articles from McKinsey, Gartner).
  • Next month: If we have simulation software (like Arena or AnyLogic), get a basic demo and understand its capabilities.
  • Month 3: Identify a specific operational problem in your area where a digital twin could potentially offer a solution or insight.
  • Month 4: Work with Engineering to explore a small-scale simulation project for a process improvement idea.

Quick win: Watch a few YouTube videos explaining digital twins in manufacturing. It's a great way to grasp the concept quickly.

11Staying current once you are in

What people here do to keep up
  • Attend industry conferences and workshops focused on manufacturing excellence, Industry 4.0, or Lean methodologies.
  • Participate in cross-functional improvement projects that expose you to different parts of the business.
  • Join professional organisations like the Institute of Operations Management (IOM) or the Manufacturing Technologies Association (MTA).
  • Seek out mentorship from experienced Factory Managers or Operations Directors within our organisation.
  • Actively read industry publications and thought leadership pieces to stay ahead of trends.

12The rising capability

The rising capability

Zavmo analysis

What's rising in its place

This is where the work is heading, and the higher pay with it. Get fluent here and the shift stops being a threat and starts being your edge.

Data Storytelling & Visualisation

We're drowning in data from our MES, ERP, and quality systems. The challenge isn't collecting it; it's making sense of it and communicating insights effectively to different audiences—from an operator on the line to the Plant Manager. Simply showing a spreadsheet won't cut it anymore; you need to tell a compelling story with the data.

  • Audience-specific dashboards
  • Narrative structure for data
  • Avoiding 'chart junk'
  • Interactive reporting

Basic AI Prompt Engineering for Operations

AI tools are becoming embedded in everything, from drafting reports to optimising schedules. As a Senior Factory Manager, you won't be building the AI, but you'll need to know how to 'talk' to it effectively to get the best results. The people who master this will be significantly more productive.

  • Clear and concise prompting
  • Contextualisation
  • Iterative prompting
  • Output validation

13What you’ll use

What you’ll use

Skills this role draws on

Technical

  • Lean Manufacturing
  • Six Sigma (DMAIC)
  • Total Productive Maintenance (TPM)
  • Overall Equipment Effectiveness (OEE) Analysis
  • Theory of Constraints (TOC)
  • Production Planning & Scheduling

14The pathway

The pathway

How you actually get there, here

How you become one varies far more by country than what one does. This is the UK route. Most people take one of these ways in; the right one depends on where you're starting from.

  1. 1

    Shift Manager / Area Manager (L2)

    3-5 years

    Skills to master

    • Mastering daily production targets, managing shift-level safety and quality, effective team leadership, basic problem-solving (e.g., 5 Whys), and managing shift-level personnel issues.

    You're ready to move on when

    • Consistently hitting shift KPIs (OEE, scrap, safety).
    • Demonstrating strong leadership and problem-solving skills on the shop floor.
    • Successfully resolving minor conflicts and coaching operators effectively.
    • Proactively identifying and escalating systemic issues.
  2. 2

    Production Engineer (with leadership aspirations)

    4-6 years

    Skills to master

    • Deep technical understanding of manufacturing processes, process optimisation, equipment reliability, data analysis, and project management. You'd need to layer on people leadership and operational execution skills.

    You're ready to move on when

    • Successfully delivered several process improvement or capital projects.
    • Strong analytical skills, using data to drive engineering solutions.
    • Demonstrating an interest in the 'people' side of operations and team dynamics.
    • Proactively engaging with production teams to understand operational challenges.
  3. 3

    Quality Manager / Supervisor (L2-L3)

    5-7 years

    Skills to master

    • Deep expertise in quality management systems, root cause analysis, statistical process control, and auditing. You'd need to broaden your scope to include production scheduling, cost management, and overall operational leadership.

    You're ready to move on when

    • Successfully reduced defect rates and managed CAPA processes.
    • Strong understanding of product quality standards and customer expectations.
    • Demonstrating an ability to influence production teams to adopt quality best practices.
    • Proactively identifying quality risks in new processes or products.

15Where this role leads

The long view: This work can lead to running a full manufacturing site as a factory or plant manager, or overseeing several sites as a director of operations.

The ten Future Fluencies

Zavmo analysis

The credential is what you can do today. These are what keep you valuable.

A qualification proves you can do the job as it's defined today. These ten are what decide whether you're still the obvious person for it in five years. They're the capabilities employers are now writing into senior roles faster than people are learning them. Zavmo weaves them through whatever you study, so you come out with both: the credential and the fluency.

The highlighted ones are the Fluencies your role leans on hardest, from how Senior Factory Manager is actually changing.

Where it leads

Roles this leads to

The record names a next step, but the catalogue has no page for it yet:

  • Assistant Factory Manager / Operations Lead (L4)

How you would learn this

One to one, on the work you already do

A tutor sets the task against your own job and marks the reasoning, at your pace. There is no cohort to fall behind.

A lesson from Lead mechanical manufacturing or inspection activities, worked against Senior Factory Manager.

Lead mechanical manufacturing or inspection activities Level 4

Applied to your work in Senior Factory Manager

This unit aims to enable learners to lead mechanical manufacturing or inspection activities, including organising tasks, supervising team members, monitoring quality, addressing issues, ensuring health and safety compliance, and maintaining accurate records.

How the thinking builds
  1. 1 Remember
  2. 2 Understand
  3. 3 Apply
  4. 4 Analyse
  5. 5 Evaluate
  6. 6 Create
An illustration of a Zavmo lesson, built from this role’s own route. The unit, its objective and every criterion above are the awarding body’s own words, not an example.

It is £70 a month, billed monthly. Your free first module is Future Fluency, and you can cancel any time.

See Your Progress Grow Illustration
Senior Factory Manager
  • Lean Manufacturing
  • Six Sigma (DMAIC)
  • Total Productive Maintenance (TPM)
  • Overall Equipment Effectiveness (OEE) Analysis
  • Theory of Constraints (TOC)
  • Production Planning & Scheduling
This is your Mind Palace on learn.zavmo.ai. Every skill above comes from this role's own record, not an example borrowed from another job. A node lights up when you evidence it, and what you build stays yours between jobs. That is the part a course cannot do.

16The detail, folded away

Everything else the record holds

The career branches in full, how AI is already showing up in the day-to-day, and the questions people ask about this job. Here when you want them, out of the way while you decide.

Where it leads next, rung by rung

Where it leads

The career path, and where it branches

Senior Factory Manager is a start, not a ceiling. Each step below asks for new skills and hands back more autonomy.

  1. Assistant Factory Manager / Operations Lead (L4)

    3-5 years in current role

    This is a significant step up, moving from owning workstreams to deputising for the overall Factory Manager. You'll be managing functional leaders (like Maintenance and Quality Managers) and taking accountability for major site-level KPIs.

    • Capital Project Management Leading significant investment projects (e.g., new equipment lines).
    • Vendor Management Managing relationships with key suppliers and service providers.
    • Talent Acquisition & Development Playing a key role in hiring and developing the next layer of leadership.
    • Advanced Data Analytics Using BI tools to model complex operational scenarios.
Working with AI on the job

Working with AI

Where AI is starting to help

Let's be real, running a factory means a lot of moving parts, unexpected problems, and mountains of data. What if you could cut through the noise, predict issues before they happen, and free up your time for the stuff that truly matters? AI isn't just for tech companies anymore; it's here to make your life as a Senior Factory Manager a whole lot easier.

We're embedding smart AI tools right into our operations, and you, as a Senior Factory Manager, will be at the forefront of using them. These aren't just futuristic concepts; they're practical applications that will help you make better decisions, faster, and give you back valuable time you currently spend on repetitive tasks. Imagine less time firefighting and more time leading strategic improvements.

Predictive Maintenance Automation

Imagine knowing a machine is about to fail before it actually breaks down. AI analyses real-time sensor data (vibration, heat, pressure) from our critical machinery, spotting patterns that indicate an impending issue. It then automatically generates a high-priority work order in our CMMS for the maintenance team. You'll spend less time in reactive breakdown meetings and more time preventing them.

AI-Powered Quality Inspection

Our machine vision systems, powered by AI algorithms, can scan products on the line at lightning speed. They'll identify microscopic defects, colour inconsistencies, or assembly errors that are either invisible to the human eye or simply too fatiguing for manual inspectors to catch consistently. This means fewer quality issues reaching customers and less time spent on painful root cause analysis after the fact.

Production Schedule Optimisation

Building the perfect production schedule is a nightmare, isn't it? This AI tool analyses historical production data, real-time changeover times, and current customer orders to recommend the most efficient production sequence. It minimises downtime between batches and maximises our throughput, giving you a much more robust schedule to work with, and less time tweaking it manually.

Automated Shift Reporting

Tired of manually pulling numbers for your end-of-shift reports? Our AI drafts the initial summary by pulling key metrics (units produced, downtime events, scrap numbers) directly from the MES and ERP. It presents it in a standardised format for you to quickly review, add your crucial context, and then send it off. It's about getting the data to you, not making you chase it.

Common questions

Common questions

How do you become a Senior Factory Manager?

Common routes in include Shift Manager / Area Manager (3-5 years), Production Engineer (with leadership aspirations) (4-6 years) and Quality Manager / Supervisor (L2-L3) (5-7 years). Times vary with prior experience.

Where can a Senior Factory Manager progress to?

This role can lead on to Assistant Factory Manager / Operations Lead (3-5 years in current role), depending on the skills you build.

What new skills matter most for a Senior Factory Manager?

Increasingly, Data Storytelling & Visualisation and Basic AI Prompt Engineering for Operations. These are the skills our record of this role lists as growing.

Free tools

Want a read on where you stand?

Three free tools, no account needed. Each one ends with a role, a level and a way in.

Read the Zavmo manifesto to understand how you will be taught Meet your tutors

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17Where to go from here

Other roles at Level 5

Same depth of qualification, different job. Useful if the work appeals but this particular role does not.

 More jobs in operations

Stay in the field you know and move sideways rather than up.
If you leave this industry

The skills built in this role carry across manufacturing industries, from automotive and aerospace to food and beverage and pharmaceuticals. Lean, Six Sigma, and operational excellence work the same way wherever you apply them, so there is scope to move between sectors.

This role profile is © 2026 Growth Engineering Technologies Ltd. Built from UK occupational standards and regulated qualification data, and written for Zavmo.

You're not behind. You're right on time. The shift is only just beginning. Your role won't look the same in two years. Be the one who leads the change, not the one it happens to. Start my free Data Fluency module What happens next: a free account, then we build your plan as you set up. No card. Build your plan, see your roadmap and meet the twelve tutors matched to you. All free. When you're ready to start learning, it's £70 a month, billed monthly. Cancel any time and billing stops.