Engineering and manufacturing
Metal casting, foundry and patternmaking technician - Methods Development Technician
Casting is the process from which solid metal shapes (castings) are produced by filling voids in molds with liquid metal
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.
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
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.
K9:
All the relevant physical processes and characteristics of the production process in metal casting foundries
K10:
How to use simulation technology to predict (quantitatively) all properties relevant to meet customers’ specification and importantly, to produce a sound casting in the most economical way.
Technical Educational Products
- ST0566: Metal casting, foundry and patternmaking technician - Methods Development Technician (Level 3) Approved for delivery
- Reference:
- OCC0566F
- Status:
Approved occupation
- Average (median) salary:
- £30,544 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.
- 5212/01 Die casters
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.
S12:
Manually calculate and produce a complete simulation including, runner, gating design and feeding options to ensure a quality casting using the economical production method in various metals and production processes.
S13:
Evaluate and solve production issues and casting failures in various metals by using problem solving techniques related to the running, gating and feeding of castings.
Technical Educational Products
- ST0566: Metal casting, foundry and patternmaking technician - Methods Development Technician (Level 3) Approved for delivery
- Reference:
- OCC0566F
- Status:
- Approved occupation
- Average (median) salary:
- £30,544 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.
- 5212/01 Die casters
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.
Technical Educational Products
- ST0566: Metal casting, foundry and patternmaking technician - Methods Development Technician (Level 3) Approved for delivery
- Reference:
- OCC0566F
- Status:
- Approved occupation
- Average (median) salary:
- £30,544 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.
- 5212/01 Die casters
