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Metal casting, foundry and patternmaking technician - Foundry Material & Process Control Technician

Metal casting, foundry and patternmaking technician - Foundry Material & Process Control Technician

Engineering and manufacturing

Level 3 - Technical Occupation

Casting is the process from which solid metal shapes (castings) are produced by filling voids in molds with liquid metal

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Reference: OCC0566A

Status: assignment_turned_inApproved occupation

Average (median) salary: £27,030 per year

SOC 2020 code: 8115 Metal making and treating process operatives

SOC 2020 sub unit groups:

  • 8115/99 Metal making and treating process operatives n.e.c.
  • 5211/01 Metal fabricators and finishers
  • 5211/03 Whitesmiths
  • 5212/01 Die casters
  • 5212/03 Moulders, mould makers and core makers

Technical Education Products

ST0566:

Metal casting, foundry and patternmaking technician - Foundry Material & Process Control Technician

(Level 3)

Approved for delivery

Employers involved in creating the standard:

Alucast Limited, Archibald Young Limited, Bonds Foundry Limited, Boro Foundry Limited, Bradken Limited, Brafe Engineering, Castallum Limited, Casting Plc, CM Patternmaking, Cooper Roller Bearings Limited, Datum Patterns, DMT Limited, Durham Foundry, Finecast Limited, FSE Group, Hadleigh Castings Limited, HCM Engineering, Inductotherm Europe Ltd, J D Norman Industries, Lost Wax Developments Ltd, Maycast Nokes Precision Engineering Limited, Midas Patterns, MRT Castings, Newby, Foundries, Pheonix Patterns, R D Castings Limited, Saint Gobain, Sarginsons Limited, Sheffield Forgemasters Limited, South Lincs Foundry Limited, Stone Foundries, Summit Patterns, Taylors Foundry, Thomas, Dudley, W H Rowe Limited, Westfield Patterns Limited, Wier Minerals, William Cook Cast Products Limited

Summary

Metal Casting, Foundry and Patternmaking Technicians are involved in highly skilled, complex and important roles in the Cast Metals Industry. The UK industry is a modern and advanced sector, producing 530,000 tonnes of castings in all metals with an annual value of £2.2 Billion and the 400 foundries employ more than 17,000 Operatives, Technicians, Engineers, Supervisors, Managers and Staff. Castings may weigh less than a gramme or over 600 tonnes. The industry underpins and is a vital supplier to other industries (automotive, aerospace, rail, power and renewable energy, medical, pumps & valves, defence, petrochemical and marine). Technicians can be employed in all sizes of companies, working independently or as part of a team in a foundry, workshop or laboratory. An eye for detail is necessary and they will need to comply with safety requirements.

Employers involved in creating the standard:

Alucast Limited, Archibald Young Limited, Bonds Foundry Limited, Boro Foundry Limited, Bradken Limited, Brafe Engineering, Castallum Limited, Casting Plc, CM Patternmaking, Cooper Roller Bearings Limited, Datum Patterns, DMT Limited, Durham Foundry, Finecast Limited, FSE Group, Hadleigh Castings Limited, HCM Engineering, Inductotherm Europe Ltd, J D Norman Industries, Lost Wax Developments Ltd, Maycast Nokes Precision Engineering Limited, Midas Patterns, MRT Castings, Newby, Foundries, Pheonix Patterns, R D Castings Limited, Saint Gobain, Sarginsons Limited, Sheffield Forgemasters Limited, South Lincs Foundry Limited, Stone Foundries, Summit Patterns, Taylors Foundry, Thomas, Dudley, W H Rowe Limited, Westfield Patterns Limited, Wier Minerals, William Cook Cast Products Limited

Typical job titles include:

Foundry Material and Process Control Technician
Foundry Post Casting Technician
Foundry Production Technician
Inspection and Quality Assurance Technician
Metal Casting Furnace and Ladle Technician
Methods Development Technician
Pattern and Model Making Technician

Keywords:

Casting
Castings
Foundry
Foundry & Patternmaking Technician
Metal Casting
Patternmaking Technician

Knowledge, skills and behaviours (KSBs)

K1: Relevant statutory, quality, environmental compliance procedures and systems, organisational and health and safety regulations relating to manufacturing operations.
K2: Their individual roles and responsibilities within the organisation and the limits of their own authority and the implications of operating outside of this.
K3: How to interpret relevant engineering and manufacturing data and documentation to execute their job role, i.e., how to understand a 2-dimensional engineering drawing and use this to produce a 3-dimensional model.
K4: The general Metal Casting, Foundry and Patternmaking manufacturing mathematical and scientific principles, methods, techniques, graphical expressions, symbols formulae and calculations used by this engineering environment. i.e. how to understand contraction allowances in the calculation of technical drawings for specific pattern production or the temperature specifications of casting liquid metal.
K5: The structure, properties and characteristics of common materials used in the sector for example: Pattern Making materials like different woods, metals and plastics, Foundry Sand, Binders, Coatings, Feeding and Filtration Systems, Refractories, Various Metal Alloys, Additives, Waxes and Lubricants. Laboratory Testing including: Sand and Binder Properties, Chemical Composition and Mechanical Testing i.e.: Tensile and Hardness Testing.
K6: The full process of producing castings from a technical drawing to a finished casting and they must have knowledge of the manufacturing practices, processes and procedures.
K11: Analytical testing procedures and how to create informative reports.
K12: Must be able to refer to published ‘standards’ and understand their relevance to the materials and processes.

S1: Apply safe systems of work, complying with health and safety legislation, regulations, environmental compliance procedures and systems and other relevant guidelines.
S2: Demonstrate clear and effective communication skills which include oral, written, electronic and visual displays.
S3: Plan and obtain all the resources and documentation required to undertake the manufacturing process i.e. a technician would plan and prepare the process to produce prototype castings. All elements and steps would be required to be planned, resources would need to be briefed and all stages of production recorded.
S4: Undertake the work using the correct processes, procedures and equipment. i.e. the final inspection of a complete casting prior to despatch to ensure it complies with customer specifications.
S5: Perform safety, quality and compliance checks, using the correct processes, procedures and equipment. i.e.: ensuring the gravity die assembly is safe and ready to start production.
S6: Complete appropriate documentation in an accurate, efficient and legible way by using the correct terminology.
S7: Maintain a positive working relationship with a range of people working within the manufacturing environment.
S8: Deal promptly and effectively with Casting, Foundry or Patternmaking problems within the limits of their responsibility using approved diagnostic methods and techniques and report those which cannot be resolved.
S9: Work efficiently and effectively, maintaining workplace organisation and minimising waste.
S14: Organise, evaluate and report outcomes using the appropriate testing equipment to validate that materials and processes are to International and National specifications as well as the customer requirements.
S15: Be able to evaluate, monitor and manage technical specifications of production processes, casting alloy compositions and finished casting specifications.

B1: Personal responsibility and resilience – Comply with the health and safety guidance and procedures, be disciplined and have a responsible approach to risk. Work diligently regardless of the level of supervision, accept responsibility for managing time and workload and stay motivated and committed when facing challenges.
B2: Work effectively in teams – Integrate and contribute with the team, support other people, consider implications of their own actions on other people and the business whilst working effectively to get the task completed.
B3: Effective communication and interpersonal skills – An open and honest communicator, communicates clearly using appropriate methods, listens well to others and has a positive and respectful attitude.
B4: Focus on quality and problem solving – Follow instructions and guidance, demonstrate attention to detail, follow a logical approach to problem solving and seek opportunities to improve quality, speed and efficiency.
B5: Continuous personal development – Reflect on skills, knowledge, behaviours and seek opportunities to develop, adapt to different situations, environments or technologies and have a positive attitude to feedback and advice.

Occupational Progression

This occupational progression map shows technical occupations that have transferable knowledge and skills.

In this map, the focused occupation is highlighted in yellow. The arrows indicate where transferable knowledge and skills exist between two occupations. This map shows some of the strongest progression links between the focused occupation and other occupations.

It is anticipated that individuals would be required to undertake further learning or training to progress to and from occupations. To find out more about an occupation featured in the progression map, including the learning options available, click the occupation.

Progression decisions have been reached by comparing the knowledge and skills statements between occupational standards, combined with individualised learner movement data.

Technical Occupations

Levels 2-3

Higher Technical Occupations

Levels 4-5

Professional Occupations

Levels 6-7

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Level 3

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