Foundry Engineering Apprentice

Summary

To train in the full technical and operational aspects of a large highly automated iron foundry. The departments you will spend time in are Quality, Core Making, Pattern Shop, Melting, Foundry and Process.

Annual wage: £12,646.40 a year
Minimum wage rates (opens in new tab)
Training course: Metal casting, foundry and patternmaking technician (level 3)
Hours: Monday to Thursday, 7.30am to 4.00pm. Friday, 7.30am to 1.30pm.
38 hours a week
Possible start date: Monday 6 January
Duration: 2 years 3 months
Positions available: 2

Work

As an apprentice, you’ll work at a company and get hands-on experience. You’ll gain new skills and work alongside experienced staff.

What you’ll do at work

Health and Safety, you will receive training to understand your responsibilities and to help us continually improve
Quality, you will have an overview of all aspects, from inspection, scanning, trials and how this is applied through our quality systems. This is to ensure we meet and deliver customer requirements
All aspects of core making, from the raw materials to the different processes they go through
All aspects of melting and pouring iron from the raw material, quality checks and ensuring the correct temperature for the iron
All aspects of pattern shop from making sure runner systems and feeders are in good order, to repairing patterns and core boxes
All aspects of foundry, including sand testing, pattern prep, placing a core into the mould and machine settings
All aspects of process, including loading a robot cell, loading a Koyama, correct packaging of castings and meeting the required quality standards for customers
The laying of cores into green sand moulds and those duties associated in line with production and quality standards.
To carry out any other duties within reason which are commensurate with your duties
To report any issues to your line manager immediately and to actively pursue improvement ideas to increase quality and productivity efficiencies using Lean Manufacturing techniques

Health, Safety & Environment

Ensure compliance with the company’s health and safety and environmental policies, ensuring these are understood and upheld
Ensure that you are always equipped with the correct personal protective equipment and is properly looked after and maintained.
Ensure that all accidents are reported and recorded in the accident book
Ensure any spillages are cleared up immediately and the correct emergency equipment is always available

Where you’ll work

Callywhite Lane

Dronfield

Derbyshire

S18 2XU

Training

An apprenticeship includes regular training with a college or other training organisation. At least 20% of your working hours will be spent training or studying.

College or training organisation

SHEFFIELD COLLEGE, THE

Your training course

Metal casting, foundry and patternmaking technician (level 3)

Equal to A level

Course contents

Your training plan

Metal casting, foundry and patternmaking technician apprenticeship leve 3 standard to be deliverd in the work place & day release at Sheffield College.

More training information

The course will be delivered in partnership with our training provider, Sheffield College and you will be studying towards a level 3 apprenticeship as a Metal Casting, Foundry and Patternmaking Technician. You will receive full training in the technical and operational aspects of a large highly automated iron foundry.

This is a two-year course and in the first year you will spend two months in each of the following departments: Quality, Core Making, Pattern Shop, Melting, Foundry and Process. In the second year you will specialise in one of the area’s most suitable to your attributes. This will be done in line with company health & safety, quality, and production standards. To live and uphold the Wm Lee culture and values.

Requirements

Essential qualifications

GCSE or equivalent in:

English (grade 3)
Maths (grade 3)

Let the company know about other relevant qualifications and industry experience you have. They can adjust the apprenticeship to reflect what you already know.

Skills

Communication skills
Attention to detail
Problem solving skills
Team working

About this company

William Lee has existed as an iron foundry for over 100 years and spent the majority of its time on Callywhite Lane. It has deep history since it began in 1860 as a family business at Montrose Works, Sheffield. The company moved to Callywhite Lane in 1901 and in 1924 the business was no longer owned by the Lee family. The foundry specialised in the production of malleable iron castings under various owners, such as William Prestwich and Sons in 1924, Tarmac in 1963 and Parkfield Group in 1986. During the Parkfield years the foundry started the move away from Malleable iron to spheroidal graphite iron (SG iron) as the business moved more towards truck and automotive iron castings. In 1991 the company was acquired by Castings PLC, and since that time the business has seen significant investment in new buildings, plant and equipment heading towards £50M. Today William Lee is one of the largest foundries left in the UK, following the demise of the UK foundry industry due to lack of investment, productivity and intense Worldwide competition. It is continual investment in plant, processes and a dedicated workforce that has enabled the company to remain in business. The company’s old 4 tonne ladles mark the entrance to Dronfield in two strategic places. These ladles where used for the production of malleable iron produced through cupola melting. Iron being transferred from the cupola receiving drum into these ladles for transferring into a large holding furnace.

After this apprenticeship

Upon completion of apprenticeship, potential of gaining full time position

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