Most commonly reported Work Activities

•   Controlling Machines and Processes Using either control mechanisms or direct physical activity to operate machines or processes (not including computers or vehicles).
•   Handling and Moving Objects Using hands and arms in handling, installing, positioning, and moving materials, and manipulating things.
•   Inspecting Equipment, Structures, or Material Inspecting equipment, structures, or materials to identify the cause of errors or other problems or defects.
•   Getting Information Observing, receiving, and otherwise obtaining information from all relevant sources.
•   Communicating with Supervisors, Peers, or Subordinates Providing information to supervisors, co-workers, and subordinates by telephone, in written form, e-mail, or in person.
•   Identifying Objects, Actions, and Events Identifying information by categorising, estimating, recognising differences or similarities, and detecting changes in circumstances or events.
•   Monitor Processes, Materials, or Surroundings Monitoring and reviewing information from materials, events, or the environment, to detect or assess problems.
•   Performing General Physical Activities Performing physical activities that require considerable use of your arms and legs and moving your whole body, such as climbing, lifting, balancing, walking, stooping, and handling of materials.
•   Making Decisions and Solving Problems Analysing information and evaluating results to choose the best solution and solve problems.
•   Judging the Qualities of Things, Services, or People Assessing the value, importance, or quality of things or people.

Working Life

Foundry workers produce cast metal products, ranging from car parts to ships' propellers or church bells. Metal is melted in a furnace and the molten metal is poured into moulds made out of sand or metal. Once the metal casting has set, the mould is removed.  
 
There are a number of different occupations within the foundry industry, because there are so many different processes involved.  
 
Sand mixers or sand mill operators mix the sand mixture used for moulding, or operate sand mixing machinery. Machine moulders operate automated or hand operated moulding machinery, check moulds for faults and carry out repairs. Furnace operators load up different kinds of furnaces with a metal mixture. They check temperatures and supervise the melting process.  
 
Casters then pour the molten metal into moulds. The metal is poured using large ladles suspended from cranes or small hand-held containers known as shanks. Knock-out operators use a variety of techniques to remove the mould once the casting has cooled. Finally, fettlers, grinders and shot blasters use a variety of techniques to remove any surplus metal from the casting.  
 
Many processes are automated, so much of the heavy physical labour is rapidly disappearing.  
 
Foundry workers may have to work in hot and noisy, and sometimes dark and dirty conditions.

Most commonly reported Work Tasks

• Measure and visually inspect products for surface and dimension defects to ensure conformance to specifications, using precision measuring instruments.
• Observe continuous operation of automatic machines to ensure that products meet specifications and to detect jams or malfunctions, making adjustments as necessary.
• Set up, operate, or tend metal or plastic molding, casting, or coremaking machines to mold or cast metal or thermoplastic parts or products.
• Turn valves and dials of machines to regulate pressure, temperature, and speed and feed rates, and to set cycle times.
• Read specifications, blueprints, and work orders to determine setups, temperatures, and time settings required to mold, form, or cast plastic materials, as well as to plan production sequences.
• Observe meters and gauges to verify and record temperatures, pressures, and press-cycle times.
• Connect water hoses to cooling systems of dies, using hand tools.
• Remove parts, such as dies, from machines after production runs are finished.
• Perform maintenance work such as cleaning and oiling machines.
• Smooth and clean inner surfaces of molds, using brushes, scrapers, air hoses, or grinding wheels, and fill imperfections with refractory material.

Further Information

• Foundry Moulder- from: N.C.S. [UK]
• Foundry Patternmaker- from: N.C.S. [UK]
• Foundry Process Operator- from: N.C.S. [UK]

This occupation is typically suited for people with the following Career Interests:

 Realist

Realists are usually interested in 'things' - such as buildings, mechanics, equipment, tools, electronics etc. Their primary focus is dealing with these - as in building, fixing, operating or designing them. Involvement in these areas leads to high manual skills, or a fine aptitude for practical design - as found in the various forms of engineering.

Realists like to find practical solutions to problems using tools, technology and skilled work. Realists usually prefer to be active in their work environment, often do most of their work alone, and enjoy taking decisive action with a minimum amount of discussion and paperwork.

 Administrative

Administrative people are interested in work that offers security and a sense of being part of a larger process. They may be at their most productive under supervisors who give clear guidelines and while performing routine tasks in a methodical and reliable way.

They tend to enjoy clerical and most forms of office work, where they perform essential administrative duties. They often form the backbone of large and small organisations alike. They may enjoy being in charge of office filing systems, and using computers and other office equipment to keep things running smoothly. They usually like routine work hours and prefer comfortable indoor workplaces.

 Investigative

The Investigative person will usually find a particular area of science to be of interest. They are inclined toward intellectual and analytical activities and enjoy observation and theory. They may prefer thought to action, and enjoy the challenge of solving problems with sophiscticated technology. These types prefer mentally stimulating environments and often pay close attention to developments in their chosen field.

Training can be provided on-the-job by experienced staff. Specialized training in this field is varied. Pathways into Foundary work can be to small & medium enterprises, seeking employment. Likewise larger engineering based employment and careers in the Engineering, Manufacturing, and Energy sector

Key Skills Certs: 

Manual Handling 

SafePass 

Key Skill Certs may be available at low or no costs Search our FET CourseFinder

Sample Education and Training Pathways
A number of courses are available throughout the country that focus on learning and skills that may be useful for this career. The examples and links below may guide you in your research. 

Further Education (FET)
Further Education & Training (FET) Courses are delivered by local ETBs, ranging in duration from several weeks up to 20 months. Courses are designed to meet the labour market needs and often include a large element of work experience.

Example search terms include: manufacturing, engineering operations.

Search for FET Courses

PLC Courses (FET)
PLC courses are full-time courses, one or two years duration, with awards at Level 5 and 6 on the NFQ. They are offered nationally in Schools and Colleges of Further Education.

Example search terms include: engineering.

Search for PLC Courses

Apprenticeships: 
Apprenticeships are structured work-based training programs that combine on-the-job training with classroom instruction. They run from 2 – 4 years and are open to individuals of all ages, including school leavers, those seeking a career change, and existing employees who wish to upskill.

Examples: Metal Fabricator, Original Equipment Manufacturing.

There are up to 33 Apprenticeships in Science, Technology, Engineering.

Search for Apprenticeships

Salary Range (thousands per year)* €26k - €44k

Salaries vary by employer, location, experience, and duties.

Data Source(s):
Morgan McKinley/ Sigmar/ CPL/ Indeed

Last Updated: February, 2024

Note: The following information relates to occupations that include: Paper and wood machine operatives; Coal mine operatives; Quarry workers and related operatives; Energy plant operatives; Metal working machine operatives; Water and sewerage plant operatives; Printing machine assistants; Plant and machine operatives n.e.c.

This information has been derived from the Solas National Skills Bulletin (2023).

Despite the strong employment growth rate for this occupation over the five-year period, employment only returned to pre-COVID-19 levels in 2022.

Although the green transition may result in an increased demand for elementary workers in energy and sewerage plant operations, the small numbers employed across the various roles in this occupation do not allow for detailed demand analysis.

• Engineers Ireland

  • 22 Clyde Road, Ballsbridge Dublin 4
  • (01) 665 1300
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• Irish Manufacturing research

  • Irish Manufacturing Research Unit A, Aerodrome Business Park Rathcoole, Co. Dublin D24 WCO4
  • (0) 1 5675000
  • [email protected]
  • Click Here