Foundry Process Operator

Foundries produce metal castings for a wide range of products and industries. Large foundries can produce steel castings up to 350 tonnes, which may be used in a range of products for mills and presses, nuclear, offshore oil and gas, defence, power generation and materials processing industries. Smaller foundries supply castings in a variety of metals, iron, steel, and non-ferrous metals such as aluminium and bronze to the specifications of their customers. These may be used in the manufacture of cars, fridges and mobile phones, as well as items for the medical, aerospace and information, communications and technology (ICT), industries.

Foundry process operators fill a range of jobs within foundries to help produce castings, including sand mill operator, melter, caster and machine moulder.

Normally working between 37 and 39 hours a week foundry process operators usually operate on a shift system, which may include evenings and weekends. Regular overtime may also be available. Most of the work is carried out in the foundry area, although there may be some outside work such as sorting the metal. Working conditions can be hot and dusty, although fume and dust extractors are installed in most foundries. Foundry process operators are expected to wear safety clothing, which may include overalls, safety shoes, hard hats, eye shields, earplugs and gloves.

Salaries range from around £16,000 a year to £30,000 a year.

Foundry process operators need to:

• have a good level of physical fitness
• work well as part of a team and under supervision
• have a responsible attitude
• be aware of health and safety issues
• have good communication skills.

The main regions for foundry employment are the West Midlands, followed by Yorkshire and Humberside and the East Midlands. A move towards production in other materials, such as plastic, has created more opportunities within the industry.

It is possible to work as a foundry process operator without formal qualifications. New entrants can join as unskilled foundry operatives and train to become operators. Applicants may have to pass a medical examination. Apprenticeships may be available in this area and applicants may require three to five GCSEs including English, maths and science. GCSEs in engineering and manufacturing may also be relevant. The Diplomas in engineering, and manufacturing and product design may be relevant for this area of work.

All Apprenticeships involve work-based training combined with block or day release for college courses. Apprentices usually work towards NVQs and, in some cases, BTEC National and Higher National Awards and City & Guilds (C&G) qualifications.

Opportunities exist for foundry process operators to move on to more specialist work as patternmakers or moulders/coremakers.

With training and experience, there may be the option of progressing into supervisory or managerial roles. They may also be able to move into quality control or maintenance work.

Further details