Foundry Process Operator
What is the work like?
As a foundry process operator or foundry worker, you could be responsible for a range of duties within a foundry, depending on its size.
You could work as one or more of the following:
- sand mill operator – adding materials like resin to sand mixing machinery, which makes the mixtures for moulds
- cupola attendant (also melter or furnaceman) – controlling the furnaces that melt the metal
- wax assembler – putting together the wax patterns used in 'investment' casting
- ladleperson (or caster) – transferring molten metal from the furnace to the moulds, using crane-mounted ladles or small hand-carried containers
- die caster – operating die casting machines
- burner (also radiac operator) – removing excess metal from castings with a high temperature flame, grinding disc or electric arc equipment
- fettler – grinding surplus metal off castings with abrasive wheels
- shot blaster – using shot blasting machinery to clean castings with a stream of steel pellets
- welder – repairing and assembling castings.
You would also use a forklift truck to move castings and raw materials around the factory and to storage areas.
What qualifications and experience will employers look for?
Although there are no set entry requirements, previous experience in engineering or production work, or a forklift licence may be helpful, although not essential.
Alternatively, you could take a college course which would teach you some of the skills needed for this type of work. Courses include:
- BTEC First Certificate in Engineering
- BTEC National Certificate/Diploma in Manufacturing Engineering
- City & Guilds Certificate in Engineering
You may also be able to get into this job through an apprenticeship scheme with an engineering company or foundry. The range of Apprenticeships available in your area will depend on the local jobs market and the types of skills employers need from their workers. For more information on Apprenticeships, visit www.apprenticeships.org.uk.
Regardless of the route you take, you will need to be physically fit and you may have to pass a medical at the interview stage.
What further training and development can I do?
Once you are in employment, you could take work-based NVQ qualifications, including:
- Performing Manufacturing Operations levels 1 and 2
- Performing Engineering Operations levels 1 and 2
- Materials Processing and Finishing levels 2 and 3.
With a Level 3 NVQ, you could improve your chances of promotion by applying for registration as an engineering technician (EngTech) with the Engineering Council.
See the Institute of Cast Metal Engineers website for more details about work-based training and qualifications.
Where can I go for more information?
National Metalforming Centre47 Birmingham Road
West Bromwich
West Midlands
B70 6PY
Watford
Hertfordshire
WD18 0JT
Tel: 0800 282167
If you would like to discuss your career options with a learning adviser at Careers Advice, call 0800 100 900 or use our online enquiry form
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What salary and other benefits can I expect?
- Salaries for foundry process operators start between £11,000 and £13,000 a year.
- Average rates for experienced operators are between £13,000 and £16,000 a year.
- Operators with extra duties may earn up to £18,000 a year.
Income can be increased with shift allowances and overtime.
Figures are intended as a guideline only.
What are the hours and working conditions?
You would normally work around 37 hours a week, on a shift system which could include nights and weekends. There may be opportunities for overtime.
Foundry work can be strenuous and conditions could get very hot and dusty. You would wear protective overalls, safety footwear and eye shields for most jobs.
What skills and knowledge will I need?
- good fitness levels
- good communication skills
- the ability to follow instructions
- the ability to work under supervision and as part of a team
- the ability to work on a range of different tasks
- an awareness of health and safety.
What opportunities are there?
You would normally find work in traditional industrial regions, for example South Yorkshire and the West Midlands.
With experience, you could progress to supervisory jobs or into more skilled foundry work, such as a patternmaking, moulding or coremaking. You may also be able to use your skills to transfer to other areas of engineering, for instance welding and fabrication.
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