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Foundry process operator

  • Hours

    37 per week

  • Starting salary

    £13,000 + per year



The work

Foundries produce metal castings for a wide range of products and industries like aerospace, marine and automotive engineering. 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 might work as one or more of the following:

  • sand mill operator – making 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
  • die caster – operating die casting machines
  • burner (also radiac operator) – removing excess metal from the castings
  • fettler – grinding surplus metal off castings with abrasive wheels
  • shot blaster – using shot blasting machinery to clean castings.

You would use a forklift truck or cranes to move castings and raw materials around the factory and to storage areas.


Hours

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 physically tough and conditions could get hot and dusty. You would wear protective overalls, hard hats, safety footwear, ear plugs and goggles.


Income

Basic salaries can be between £13,000 and £18,000 a year. Operators with extra duties may earn around £24,000. Highest salaries may be around £30,000.

Overtime and shift allowances can increase these amounts.

Figures are intended as a guideline only.


Entry requirements

Although there are no set entry requirements, you will improve your chances of finding work if you have previous experience in engineering or production work, or a forklift truck licence.

Alternatively, you could take a college course before looking for work, which would teach you some of the skills needed. Relevant courses include:

  • BTEC Certificate in Engineering
  • BTEC Diploma in Manufacturing Engineering
  • City & Guilds Certificate in Engineering
  • EAL Certificate in Engineering.

You may be able to get into this career by completing an apprenticeship 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. To find out more, visit the Apprenticeships website.

To get on to an Apprenticeship, you will usually need GCSEs (grades A-E) in subjects such as English, maths, science and technology, or equivalent qualifications.

Whichever route you take, you will be expected to be physically fit, and you may have to pass a medical at the interview stage.

For more general information about engineering as a career, see the Tomorrow’s Engineers website.


Training and development

Once you are working, your employer may encourage you to take one of the following NVQ Cerificates or Diplomas:

  • 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). See the Engineering Council website for more details.

For more details about work-based training and qualifications, see the Institute of Cast Metal Engineers (ICME) website.


Skills and knowledge

  • a good level of fitness
  • 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.

More information

SEMTA (Sector Skills Council for Science, Engineering and Manufacturing Technologies in the UK) (Opens new window)
14 Upton Road
Watford
Hertfordshire
WD18 0JT
Tel: 0845 643 9001
www.semta.org.uk

Women into Science, Engineering and Construction (Opens new window)
Athlone Wing
Old Building
Great Horton Road
Bradford
BD7 1AY
Tel: 01274 436485
www.theukrc.org/wise

Tomorrow's Engineers (Opens new window)
EngineeringUK
Weston House
246 High Holborn
London
WC1V 7EX
Email: careers@engineeringuk.com
Tel: 020 3206 0400
www.tomorrowsengineers.org.uk

Institute of Cast Metal Engineers (Opens new window)
47 Birmingham Road
West Bromwich
West Midlands
B70 6PY
www.icme.org.uk

Institution of Engineering and Technology (IET) (Opens new window)
Michael Faraday House
Stevenage
Hertfordshire
SG1 2AY
Tel: 01438 313 311
www.theiet.org


Opportunities

You would normally find work in traditional industrial regions, such as South Yorkshire and the Midlands.

With experience, you could progress to supervisory jobs or into more skilled foundry work, such as a patternmaking, moulding or coremaking. With further training, you could move into to other areas of engineering, such as welding and fabrication.

You may find the following useful for job vacancies and general reading: (links open in new window)

Job profiles are based on the latest information supplied to us by industry bodies, such as Sector Skills Councils. Please be aware that with the introduction of the Qualifications and Credit Framework (Opens in a new window) there has been, and will continue to be, changes to vocational qualifications. For more information, please check with industry bodies directly.

We do not accept responsibility for the content of external sites.


Related industry information

Industry summary

The metals industry is part of the engineering manufacturing, science and mathematics sector, represented by Semta Sector Skills Council. This sector also includes the following industries: automotive manufacture; electronics and electrical equipment manufacture; mechanical equipment manufacture; transport equipment manufacture, including marine and aerospace; and science. Across the sector as a whole, the workforce comprises approximately 2 million people, working across around 75,000 companies. UK engineering and science turnover is over £250 billion. British engineering exports amount to 37% of total UK exports of goods and services. The UK is Europe’s top location for investment in pharmaceutical and biotechnology research and development.

The UK metals industry comprises:

  • Manufacture of basic metals – companies that are involved in the smelting and refining of ferrous (e.g. iron and steel) and non‐ferrous metals (e.g. copper, silver, aluminium) as well as those that produce bars, rods, tubes and carry out casting of metals.
  • Manufacture of fabricated metal products – companies that manufacture structural metal products (such as tanks, reservoirs, prefabricated metal buildings, steam generators), treating and coating of metal, manufacture of cutlery, tools and general hardware and other fabricated metal products (such as metal packaging, screws, washers and other metal fasteners). This has the largest number of employees of all of the metals sub‐industries.
  • Wholesale metals and scrap – companies involved in the wholesale of metals and metal ores and wholesale of waste and scrap. Energy savings can be made from the recycling of metals, especially aluminium, rather than extraction from ores. There is much interest in how to make‐up components with a view to disassembly and recycling at the end of a products lifecycle.

Research developments in the molecular structure of the materials and manufacturing processes have led to their extended use in modern buildings, vehicles, engines and turbines that as well as having applications in the aircraft industry, help to harness the energy of wind and waves.

Key facts:

  • There are an estimated 412,600 people employed in the metals industry, across 33,240 workplaces in Great Britain.
  • The greatest concentrations of employment in the metals industry are in the West Midlands, Yorkshire and the Humber and the North West.
  • 90% of the metals workforce is full‐time.
  • In engineering, an estimated 6% of the workforce is self‐employed.

Jobs in the industry range from: metallurgist, materials technician, materials engineer/scientist, foundry moulder/coremaker, foundry patternmaker, heat treatment operator, foundry process operator, manufacturing production manager, quality control inspector, sheet metal worker, welder, labourers in process and plant operations.


National and regional data

East Midlands – There are an estimated 37,700 employees in the regional workforce, in over 2,900 companies. There is a total requirement of 8,530 employees needed in the region between 2007 and 2014. Skills gaps in the region include: metal workers; Computer Aided Design (CAD); assembly line/production robotics; tool setting; tool makers; pattern making; and foundry skills. 48% of the workforce is employed as sheet metal workers. The largest industries in terms of employment are metal products, mechanical equipment, aerospace and automotive. Engineering employment is geographically concentrated around Derby City, Leicester City, South Derbyshire, Charnwood, Hinckley and Bosworth and Ashfield.

East of England – There are an estimated 28,100 employees in the regional workforce, in just over 3,340 companies. There is a total requirement of 9,960 employees needed in the region between 2007 and 2014. Skills gaps in the region include: welding skills; Computer Aided Design (CAD); tool setting; fabrication; Computer Aided Manufacture (CAM); Material Requirement Planning (MRP11); assembly line/production robotics; manufacturing; and toolmakers. 51% of the workforce is employed as sheet metal workers. The largest industries in terms of employment are mechanical equipment, electronics and metal products. Engineering employment is geographically concentrated around Peterborough, Huntingdonshire, South Cambridgeshire, Luton and Basildon.

London – There are an estimated 12,700 employees in the regional workforce, in just over 2,030 companies. There is a total requirement of 8,700 employees needed in the region between 2007 and 2014. Skills gaps in the region include: Computer Aided Design (CAD); Material Requirement Planning (MRP11); CNC machine operation; tool setting; fabrication; metal workers; toolmakers; carpentry/woodwork; and machine operator (unspecified). 47% of the workforce is employed as sheet metal workers. The largest industries in terms of employment are mechanical equipment, electronics and metal products. Engineering employment is geographically concentrated around Barking and Dagenham, Hillingdon, Ealing and Hounslow.

North East – There are an estimated 22,700 employees in the regional workforce, in 1,180 companies. There is a total requirement of 4,875 employees needed in the region between 2007 and 2014. Skills gaps in the region include: metal workers; Computer Aided Design (CAD); Materials requirement Planning (MRP11); welding skills; and craft skills. 56% of the workforce is employed as sheet metal workers. The largest industries in terms of employment are mechanical equipment, metal products and automotive. Engineering employment is geographically concentrated around Newcastle upon Tyne, Gateshead, Sunderland and Sedgefield.

North West – There are an estimated 44,300 employees in the regional workforce, in 3,700 companies. There is a total requirement of 13,595 employees needed in the region between 2007 and 2014. Skills gaps in the region include: CNC machine operation; technical drawing; welding skills; general engineering skills; moulding skills; fabrication; metal workers; and grinding. 49% of the workforce is employed as sheet metal workers. The largest industries in terms of employment are metal products, mechanical equipment and aerospace. Engineering employment is geographically concentrated around Fylde, Knowsley, Crewe and Nantwich, Stockport, Oldham and Preston.

South East – There are an estimated 33,000 employees in the regional workforce, in just over 4,300 companies. There is a total requirement of 10,120 employees needed in the region between 2007 and 2014. Skills gaps in the region include: Computer Aided Design (CAD); welding skills; assembly line/production robotics; fabrication; Computer Aided Manufacture (CAM); Computer Aided Engineering (CAE); Materials Requirement Planning (MRP); Materials Requirement Planning (MRP11); Statistical Process Control (SPC); tool setting; craft skills; general machining; metal workers; precision engineering; and foundry skills. 46% of the workforce is employed as sheet metal workers. Engineering employment is geographically concentrated around West Berkshire, Basingstoke and Deane, Milton Keynes, Eastleigh, Portsmouth, Crawley and Medway.

South West – There are an estimated 31,400 employees in the regional workforce, in just under 2,870 companies. There is a total requirement of 7,460 employees needed in the region between 2007 and 2014. Skills gaps in the region include: CNC machine operation; Computer Aided Design (CAD); Computer Aided Engineering (CAE); Computer Aided Manufacture (CAM); Materials Requirement Planning (MRP11); tool setting; welding skills; general engineering skills; fabrication; and precision engineering. 47% of the workforce is employed as sheet metal workers. The largest industries in terms of employment are mechanical equipment, electronics and metal products. Engineering employment is geographically concentrated around Tewkesbury, Cheltenham, Stroud, South Gloucestershire, Bristol, Swindon, South Somerset, Poole and Plymouth.

West Midlands – There are an estimated 86,300 employees in the regional workforce, in 5,850 companies. There is a total requirement of 15,730 employees needed in the region between 2007 and 2014. Skills gaps in the region include: CNC machine operation; fabrication; Computer Aided Design (CAD); assembly line/production robotics; welding skills; general engineering skills; general machining; Materials Requirement Planning (MRP11); Statistical Process Control (SPC); tool setting; moulding skills; metal workers; grinding; plating; and pattern making. 67% of the workforce is employed as metal making and treating process operatives. The largest industries in terms of employment are metal products, mechanical equipment and automotive. Engineering employment is geographically concentrated around Birmingham, Sandwell, Walsall, Coventry, Dudley and Telford and Wrekin.

Yorkshire and the Humber – There are an estimated 57,900 employees in the regional workforce, in 3,580 companies. There is a total requirement of 13,595 employees needed in the region between 2007 and 2014. Skills gaps in the region include: CNC machine operation; Materials Requirement Planning (MRP11); general engineering skills; metal workers; Computer Aided Manufacture (CAM); assembly line/production robotics; tool setting; moulding skills; and manufacturing. 72% of the workforce is employed as metal making and treating process operatives. The largest industries in terms of employment are metal products, mechanical equipment and automotive. Engineering employment is geographically concentrated around Sheffield, Leeds, Bradford, Kirklees, Rotherham and Kingston upon Hull.

Northern Ireland – There are an estimated 8,800 employees in the metals workforce. There is a total requirement of 500 employees needed per year between 2005 and 2014. 39% of the workforce is employed in the welding trades. Skills gaps include: welding; CNC machine operations; mechanical engineering skills; metalworking; and electrical engineering skills. The largest industries in terms of employment are electrical and electronics industry and the metals industry.

Scotland – There are an estimated 28,500 employees in the workforce, in just over 2,000 companies. There is a total requirement of 7,140 employees needed between 2007 and 2014. Skills gaps in the region include: CNC machine operation; Materials Requirement Planning (MRP11); metal workers; Computer Aided design (CAD); Computer Aided Manufacture (CAM); Computer Aided Engineering (CAE); Statistical Process Control (SPC); assembly line/production robotics; tool setting; general engineering skills; craft skills; fabrication; mechanical engineering; and turners. 62% of the workforce is employed as smiths and forge workers. The largest industries in terms of employment are electronics, metal products and mechanical equipment. Engineering employment is geographically concentrated around the City of Glasgow, Fife, South Lanarkshire, the City of Aberdeen, North Lanarkshire and West Lothian.

Wales – There are an estimated 30,000 employees in the workforce, in just under 1,450 companies. There is a total requirement of 4,350 employees needed between 2007 and 2014. Skills gaps in the region include: Computer Aided design (CAD); fabrication; CNC machine operation; welding skills; general engineering skills; general machining; precision engineering; and machine operator (unspecified). 75% of the workforce is employed as metal making and treating process operatives. The largest industries in terms of employment are automotive, basic metals, mechanical equipment and aerospace. Engineering employment is geographically concentrated around Flintshire, Neath Port Talbot, Newport, Rhondda, Cynon and Taff, Bridgend and Wrexham.

[N.B. Data derived from Annual Business Inquiry, 2007, Census, 2001, and Northern Ireland Census of Employment, 2007.]


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