Ministry of Labor and Skill

Technical and Vocational Training Sector

OCCUPATIONAL STANDARD
Foundry Work
NTQF Level II-IV

Ministry of Labor and Skill

March 2023
 Introduction

Ethiopia has embarked on a process of reforming its Technical and Vocational Education and
Training (TVET) System. Within the policies and strategies of the Ethiopian Government,
technology transformation by using current international standards and international best
practices as the basis, and, adopting, adapting, and verifying them in the Ethiopian context –
is a pivotal element. TVET is given an important role with regard to technology transfer. The
new paradigm in the outcome-based TVET system is the orientation at the current and
anticipated future demand of the economy and the labor market.

The Ethiopian Occupational Standard (EOS) is the core element of the Ethiopian National
TVET Strategy and an important factor within the context of the Ethiopian TVET
Qualification Framework (EtQF). They are national Ethiopian standards, which define the
current and future occupational requirements and expected outcomes related to a specific
occupation using distinct Units of Competencies without taking TVET delivery into account.

The whole Package EOS document for an occupation s an integrated set of nationally
endorsed core generic Unit of Competences organized into different qualification levels built
one upon the other below or sidewise to make a full occupational profile.

This document details the mandatory format, sequencing, wording and layout for the Ethiopia
Occupational Standard which is comprised of Units of Competence.
A Unit of Competence describes a distinct work activity. It is documented in a standard
format that comprises:
 Occupational title and NTQF level
 Unit title
 Unit code
 Unit descriptor
 Elements and Performance criteria
 Range and Variables
 Evidence guide
Together all the parts of a Unit of Competency guide the assessor/curriculum developer in
determining the candidate training and assessment.
The ensuing sections of this EOS document comprise a description of the occupation with all
the key components of a Unit of Competence:
 Chart with an overview of all Units of Competence with their Unit Codes and Titles
 Detail contents of each Unit of Competence occupational map providing the TVET
providers with information and important requirements to consider when designing
training programs using this standard and show a career path.
Occupational Standard: Foundry Work Level II
Occupational Code: MIN FDW2
NTQF Level II

MIN FDW2 01 0323 MIN FDW2 02 0323 MIN FDW2 03 0323

Prepare Technical Perform Bench Work Perform Basic Foundry
Drawing Works

MIN FDW2 04 0323 MIN FDW2 05 0323 MIN FDW2 06 0323

Perform refractory lining Operate General Wood Operate Basic metal
and repair workshop Machinery Workshop Machinery

MIN FDW2 07 0323 MIN FDW2 08 0323 MIN FDW2 09 0323

Develop and manufacture Perform Metal Arc Welding Apply Basic Electrical
wood pattern. Practices

MIN FDW2 10 0323

Apply 5s Procedures
NTQF Level III

MIN FDW3 01 0323 MIN FDW3 02 0323 MIN FDW3 03 0323

Prepare basic Engineering Perform CAD Operation Develop and manufacture
detail Drawing. metal pattern.

MIN FDW3 04 0323 MIN FDW3 05 0323 MIN FDW3 06 0323

Operate Melting furnace Pour molten Metal Fettle and Trim Metal
Casting

MIN FDW3 07 0323 MIN FDW3 08 0323 MIN FDW3 09 0323

Carry out heat treatment Undertake test and inspect Perform Gravity Die
on foundry related Casting
materials

MIN FDW2 10 0323 MIN FDW3 11 0323

Perform oxy acetylene Prevent and Eliminate
welding and cutting MUDA
Occupational Standard: Foundry Works IV
Occupational Code: MIN FDW4
NTQF Level IV

MIN FDW4 01 0323 MIN FDW4 02 0323 MIN FDW4 03 0323

Develop and manufacturing Develop and manufacturing Perform Centrifugal and
gear and impeller pattern polystyrene patterns Investment Casting
Processes

MIN FDW4 04 0323 MIN FDW4 05 0323 MIN FDW4 06 0323

Maintain and Repair Tools, Supervise the Supervise CIM production
Equipment and mechanical manufacturing of Patterns Operations
machine drive and models

MIN FDW4 07 0323 MIN FDW4 08 0323 MIN FDW4 09 0323

Supervise Ferrous and Non- Manage Product Cost Perform process Planning
ferrous Melting and Casting Estimation and Bill of and Scheduling
Operations Materials
Occupational Standard: Foundry Works Level II
Unit Title Prepare Technical Drawing
Unit Code MIN FDW2 01 0323
Unit Descriptor This unit of competency defines the skills and knowledge required to
prepare and interpret technical drawings. Drawings are provided to
Ethiopian National standards as a Technical drawing or Graphical symbols
and their equivalents from the full range of engineering disciplines.

Elements Performance Criteria

1. Identify drawing 1.1. Manual drafting Tools and equipment appropriate to the drawing
requirements and method chosen are selected.
equipment 1.2. Standard operating procedures (SOPs) are properly followed
1.3. Job requirements are identified from specifications, job sheets or
associated work instructions
2.1. Orthographic and isometric drawing are identified
2. Identify and
Prepare Technical 2.2. Orthographic and isometric views are explained
drawing 2.3. Alphabet of lines are identified and used
2.4. Angles of projections are identified and explained
2.5. Codes and symbols are correctly identified and explained according
to drawing standards
2.6. Multi view drawings and product parts are drawn

3.1. Drawings and version are checked and validated against job
3. Interpret technical requirements
drawing
3.2. Components and assemblies or symbols used in the drawings are
recognized
3.3. Dimensions, instructions and material requirements are identified
3.4. List of required materials are compiled
3.5. Concepts of fit and tolerances considered

Variables Range
Drawing May include, but not limited to:
 Perspective
 Exploded view
 Hidden view technique
Projections May include, but not limited to:
 First angle projections
 Third angle projections
Tolerances May include, but not limited to:
 General tolerance
 Angular tolerance
 Geometric tolerance


Fit May include, but not limited to:

 Clearance fit
 Transition fit
 Interference fit
Tools and equipment May include, but not limited to:
 Set square, T-square, compass, divider
 Different types of drawing paper
 Pencil
 Drawing board and masking tape

Evidence Guide
Critical Aspects of Demonstrate knowledge and skills to:
Competence  Sketches and interpret technical drawings
 Interpreted symbols, dimensional tolerances and notations
Underpinning Demonstrate knowledge of:
Knowledge and  Alphabet of lines, drawing symbols & tolerances
Attitudes  Relationship between the views contained in the drawing
 Objects represented in the drawing
 Units of measurement used in the preparation of the drawing
 Dimensions of the key features of the objects depicted in the
drawing
 Conventions used in technical drawings
 Correct interpretation of instructions contained in drawings
 Materials from which drawing object(s) are made and their features
and manufacturing and assembly requirements.
 Units of measurement used in the preparation of the drawing
 Dimensions of the key features of the objects depicted in the
drawing
 Understanding of the instructions contained in the drawing
 The actions to be undertaken in response to those instructions
 The materials from which the object(s) are made any symbols used
in the drawing as described in range statement
 Hazard and control measures associated with interpreting technical
drawings, including housekeeping
 Safe work practices and procedures
Underpinning Skills Demonstrates skills of:
 Drawing technique
 Dimensioning techniques
 Checking the drawing against job requirements/related equipment
in accordance with standard operating procedures
 Confirming the drawing version as being current in accordance
with standard operating procedures
 Reading, interpreting information on the drawing, written job
instructions, specifications, standard operating procedures, charts,
 lists and other applicable reference documents
 Undertaking numerical operations, geometry and
calculations/formulae within the scope of this unit

Resources Implication Access is required to real or appropriately simulated situations,

including work areas, materials and equipment, and to information on
workplace practices and OHS practices.
Assessment Methods Competency may be assessed through:
 Interview/Written Test
 Observation / Demonstration with Oral Questioning
Context of Assessment Competency may be assessed in the work place or in a simulated work
place setting.
 Have vocational competency in interpreting technical drawings at
least to the level being assessed with relevant industry knowledge
and experience.
Occupational Standard: Foundry Works Level II
Unit Title Perform Bench work
Unit Code MIN FDW2 02 0323
Unit Descriptor This unit covers the competences required to determine job
requirements, perform basic bench work operations and check the
components for conformance to specifications.

Elements Performance Criteria

1.1. Measurement of dimensions and variables are completed
without causing damage to any instrument or components
1. Measure
1.2. Appropriate measuring instrument is selected
dimensions or
1.3. Relevant measuring techniques are used and results
variables using
appropriately recorded
appropriate
1.4. All measuring activities are carried out according to industry
instrument
regulations/guidelines OHS & requirements and
enterprise/procedures policies
2. Lay-out and 2.1. Materials are selected according to the requirements specified
mark in the drawing.
dimensions/ 2.2. Dimensions/features are laid out and marked in accordance with
features on work drawing specifications using bench work tools and equipment.
piece 2.3. Lay-outing and marking are performed applying safety
procedures and using personal protective devices.
3.1. Work pieces are clamped in work holding devices to avoid
3. Perform Cutting, damage and accidents.
chipping and 3.2. Work pieces are cut, chipped or filed using hand tools with in
filling tolerance specified in the drawing
3.3. Bench work operations (i.e. layout; cutting with hacksaw and
chisel; filing; drilling; tapping etc…) are performed applying
safety procedures and using personal protective devices.
3.4. Wooden components, Metal bars, pipes and other materials are
cut based on measurements
4. Drill and ream 4.1. Operations are performed applying safety procedures and using
holes personal protective devices
4.2. Proper tools and instruments are selected.
4.3. Drilling, and reaming of holes are performed according to
drawing specification and recommended sequence.
5. Cut threads 5.1. Thread cutting operations are performed applying safety
using tap, stock procedures and using personal protective devices
and die 5.2. Thread is cut to fit gage or mating screw, within tolerance
given in drawing.
5.3. Thread is cut in accordance with the recommended tapping
sequence.
6. Assemble 6.1. Mechanical fastening operations are performed by using rivets,
components screw as well as bolt and nuts
 mechanically 6.2. Worn-out screws and studs are removed by Extractor.
6.3. The assembled product being finalizes (Cleaning polishing
painting…...).

Variables Range
Materials May include but not limited to:
 Ferrous
 Non Ferrous
Measuring May include but not limited to:
instrument  Tap meter
 Steel rule
 Calliper
 Gages
 Square and bevels
Bench work Tools May include but not limited to:
and Equipment  Pedestal Grinder
 Surface plate
 Drill Press
 Layout and marking tools
 Cutting tools (hacksaw, chisel, files)
 Drills, reamers, laps
 Thread cutting tools (taps and stock and die)
 Chisels
- flat cold chisel
- cape chisel
- diamond-point chisel
- round nose chisel
Work holding May include but not limited to:
Devices  Clamps
 Vices
Thread May include but not limited to:
 Internal
 External
Extractor May include but not limited to:
 Screw extractor
 Stud extractors
Bench work May include but not limited to:
operations  Layout and marking
 Cutting
 Chipping and Filing
 Drilling
 Reaming
  Thread cutting
 Off-hand grinding

Evidence Guide
Critical Aspects of Assessment requires evidence that the candidate:
Competence  Laid-out and marked dimensions/features on the work-piece
 Hand sawed metal and wood materials
 Cut, chipped and filed work-piece
 Drilled, reamed and lapped holes
 Cut threads
 Performed off-hand grinding
Underpinning Demonstrate knowledge of:
Knowledge and  Shop Safety Practices
Attitudes - Safe working habits
- Identification of hazardous areas
- Use of protective clothing and devices
- Safe handling of tools, equipment and materials
- Housekeeping practices
- Application of first-aid treatment
- Use of fire extinguishers
 Shop Mathematics
- Basic arithmetic operations
- Percentages and ratios
- Conversion of units (English to metric)
- Trigonometric functions
- Computation of feed, cutting speed and machine rpm
 Drawing/Plans
- Standard drawing symbols
- Orthographic and isometric drawings
 Measurements
- Linear measuring tools (rules, Vernier, micrometer, height gage)
- Geometrical tolerances
 Materials and related science
- Classification and mechanical properties of engineering materials
 Use and care of bench work tools and equipment

Underpinning Skills Demonstrate skills of:

 Performing bench work operations
 Using bench work tools and equipment
 Using measuring instruments
 Operating drill press and grinders
 Perform layout, filing, cutting, drilling, tapping, scrapping, lapping
 Performing safety measures and procedures
 Laying-out and marking
  Sawing, cutting, chipping, filing, Drilling, reaming
 Cutting threads (internal &external)
 Scraping and honing
 Extracting fasteners
Resource The following resources must be provided:
Implications  Materials, tools, equipment and facilities appropriate to proposed
activity
 drawings, sketches or blueprint
Methods of Competence may be assessed through:
Assessment  Interview/ Oral Questions/ Written exam
 Demonstration/Observation
Competence may be assessed in the workplace or in simulated
Context of
workplace environment.
Assessment

Occupational Standard: Foundry Works Level II

Unit Title Perform Basic Foundry Works
Unit Code MIN FDW2 03 0323
Unit Descriptor This unit of competency covers sand preparation, sand moulds and
cores by hand and machine for metal casting typically in a working
foundry. Moulds are made by using single split patterns. Fabrication
from specifications, instructions or drawings.

Elements Performance Criteria

1. Identify job 1.1 Job requirements are correctly identified from drawings,
requirements instructions and specifications
1.2 Material is selected appropriate to job requirements
1.3 Sequence of operation including job set up is determined for
maximum safety, efficiency and to meet job specifications
2. Select and prepare 2.1. Pattern equipment is correctly identified.
patterns, hand tools 2.2. Pattern equipment is inspected to specifications, and damaged
and equipment patterns are identified for repair or replacement to standard
operating procedures
2.3. Patterns are assembled to specification
2.4. Pattern equipment is set up to specification according to
standard operating procedures
3. Prepare sand 3.1. Sand is mixed for correct time to specifications.
3.2. The performance of mixer and the condition of the sand is
monitored.
3.3. Material supply is maintained.
3.4. Faults are reported.
3.5. Sample is correctly extracted.
3.6. Test is applied in accordance with standard operating
procedures.
3.7. Test results are compared against specifications.
3.8. Adjustments to formula/mix are made as required in accordance
with standard operating procedures
3.9. Load is charged correctly according to standard operating
procedures.
3.10. Unwanted treated sand is disposed of according to standard
operating procedures.
4. Make mould and core 4.1. Appropriate moulding/core making equipment is selected and
positioned according to standard operating procedures
4.2. Appropriate moulding media is selected to produce mould and
core to specification
4.3. Mould is secured according to standard operating procedures
4.4. Mould is closed and checked for compliance to component
 specification in accordance with standard operating procedures
4.5. Core is positioned in prints utilising chaplets and chills as
required and vented to specification according to standard operating
procedures
4.6. Mould and cores are rammed up with joints and drawbacks as
required to standard operating procedures
4.7. Loose pieces, vents, risers and runners are positioned and
secured as required to standard operating procedures
4.8. Pattern and loose pieces are removed from mould and core box
in a safe manner least likely to cause damage to the pattern and in
accordance with standard operating procedures
4.9. Mould is inspected and repaired as required
4.10. Mould and core is cleaned and painted according to
specification using standard operating procedures
4.11. Pouring basin is selected or manufactured to specification and
positioned in accordance with standard operating procedures
4.12. Parting and stripping systems are utilised in accordance with
standard operating procedures
5. Perform simple metal 5.1. The right safety procedure is applied.
casting 5.2. The require metals and alloys are selected.
5.3. The right manufacture process is selected and used for making a
component of an important consideration at the early stages of
product design.
5.4. Metal that can melt and can have regular shape the designer
desires.
5.5. Finishing works are performed like, File and polish.
6. Clean and restore 6.1. All materials/debris is cleared and work site cleaned and left in
work area a safe state.
6.2. Unwanted treated sand is disposed of according to standard
operating procedures

Variables Range
May include but not limited to:
 Binders
Materials  Hardeners
 Sand additives
 Mould coatings
May include but not limited to:
Faults
 Chemical ratios - acid, binder, water
Test May include but not limited to:
 Clay content test
 Grain refinement test (sieve analysis)
 Moisture content test
 Shear test
  Permeability test
May include but not limited to:
 Flat back
Patterns
 Uneven
 Plated patterns
 Multi-joint
 Consumable
 Split patterns
 Loose piece patterns
 Patterns requiring odd sides
 Cored moulds
 Drag and cope mould
May include but not limited to:
Moulds  Flat back
 Uneven jointed
 Multi-part moulds
Cores May include but not limited to:
 Full
 Half and segment cores
Moulding media May include but not limited to:
 Green sand
 Shell sand and chemically bonded media
Pouring basins May include but not limited to:
 Hand and pattern formed
Parting and stripping May include but not limited to::
systems  Dry and wet

Evidence Guide
Critical Aspects of Must demonstrate knowledge and skills in:
Competence  Safety procedures Followed
 Checked/measured finish component
 Patterns, sands, moulds and cores, are well manipulated
 Matching of specifications, sketches and drawings to mould and core
requirements were recognised
 Positioning pattern. cores are ensured in accordance with job
specifications
 Moulding equipment and media to match a range of job requirements
were selected
 Moulds, cores and pouring basins for a range of jobs and metals
efficiently made.
Underpinning Demonstrate knowledge of:
Knowledge and  Variety of pattern types and their application in a casting process
Attitudes  Pattern assembly techniques
 Selection of a moulding box to match job and pattern
  Principles and processes for selection of ancillary components
 Sand types and their bonding systems
 Compaction processes
 Parting and stripping systems
 Mould requirements including vents, runners, risers and other
requirements
 Finishing and closing techniques
 Core placement
 Pouring requirements
 Securing systems
 Pattern care and storage
 Environmental requirements
 Use and application of personal protective equipment
 Foundry safe work practices and procedures
 Hazards and control measures associated with producing moulds and
cores by hand (jobbing)
Underpinning Skills Demonstrate skill of:
 Interpreting written instructions, sketches and drawings
 Assembling and positioning patterns in moulding boxes
 Preparing moulding media
 Filling and compacting mould assemblies
 Stripping patterns
 Inspecting moulds
 Finishing moulds
 Positioning cores in prints
 Closing moulds
 Placing pouring basins
 Securing moulds
 Following oral instructions
Resource The following resources must be provided:
implications  tools, equipment and facilities appropriate to the activities
 materials relevant to the proposed activity
 drawings, sketches or blueprint
Assessment Competency may be assessed through:
Methods  Interview/Written Test
 Observation/Demonstration with Oral Questioning
 The emphasis for assessment should be on jobbing ability, that is, the
ability to produce moulds and cores for a variety of job specifications
involving different metals, sands and patterns.
Context of Competency may be assessed in the work place or in a simulated work
Assessment place setting.
The competencies covered by this unit would be demonstrated by an
individual working alone or as part of a team. The assessment
environment should not disadvantage the candidate.
Occupational Standard: Foundry Works Level II
Unit Title Perform refractory lining and repair
Unit Code MIN FDW2 04 0323
Unit Descriptor This unit covers repairing and installing/replacing
refractory.

ELEMENT PERFORMANCE CRITERIA

1. Prepare refractory 1.1. Safety (OHS) requirement associated with installing /replacing
materials Refractory and workplace environment requirements are
adhered to throughout the work.
1.2. Appropriate refractory Materials are selected to meet
specifications.
1.3. Refractory media is mixed to specification.
2. Install refractory 2.1. Sequence of operations to install refractory is determined to
meet the job specification.
2.2. Refractory is installed using appropriate techniques and tools
and equipment to meet the job specification.
2.3. Refractory is cured to specifications using appropriate
Techniques and equipment to meet the job specification.
3. Inspect refractory 3.1.Specification is interpreted and understood.
3.2.Specific areas of the refractory are identified for repair or
replacement.
3.3. Determine refractory material to be repaired and installed
4. Knock out refractory 4.1. Sequence of operations to remove refractory is determined to
meet the job specification.
4.2. Appropriate Tools and Equipment are selected to safely
remove damaged refractory.
4.3. Damaged refractory is removed and disposed of safely.
4.4. OHS procedures and measures are implemented throughout the
knock out refractory.
4.5. Housekeeping procedures are performed in accordance.

Variable Range
Materials May include but not limited to:
 Bricks
 Quartz
 Asbestos
 Cements
Refractory May include but not limited to:
The heat insulating material used inside molten metal vessels
and includes material which can be machine rammed hand
 rammed forked or vibrated including refractory bricks and
fibreboard.

Tools and equipment May include, but not limited to:

 Paint brush
 Brooms
 Chisel
 Steel pipe and mixer
Install refractory May include but not limited to:
 Hand ramming,
 machine ramming,
 internal and external vibration

Evidence Guide
Critical Aspects of Assessment requires evidence that the candidate:
Competence  Able to repair and install/replace of all type of refractory
Underpinning Knowledge Demonstrate knowledge of:
and Attitudes  Repair or replacement requirements
 Inspection techniques
 Mixing, installing and curing techniques and equipment
 OH&S legislation and ISO regulations applying to working
with refractory
 Use and application of personal protective equipment
 Safe work practices and procedures
 Hazards and control measures associated with refractory
installation and repair
Underpinning Skills Demonstrate skills of:
 Interpreting job specifications and other applicable
reference documents
 Planning and sequencing operations
 Inspecting and identifying faults
 Removing damaged refractory safely
 Mixing refractory correctly
 Installing refractory correctly
 Curing refractory correctly
 Following oral instructions
Resource Implications The following resources must be provided:
 all manuals/catalogues relative to work activity
 tools and equipment as well as consumable materials
Methods of Assessment Competence may be assessed through:
 Interview / Written Test
 Observation / Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the work place or in a
 simulated work place setting.
Occupational Standard: Foundry Works Level II
Unit Title Operate General Wood Workshop Machinery
Unit Code MIN FDW2 05 0323
Unit Descriptor This unit covers the competence in setting up and operating
wood working machines to produce patterns.

Elements Performance Criteria

1. Determine work 1.1. Work requirements, instructions and specifications are
requirements and interpreted and understood.
select machines
1.2. Materials including consumables are identified / selected
and prepared following standard procedures
1.3. Appropriate wood working machines such as Wood lathe,
Router Jig saw, and Sander etc. are selected to meet
specifications.
2. Set up and Operate
2.1. Operations are performed applying safety procedures
machines and using personal protective devices
2.2. Tools/cutters are selected, sharpened and set up
appropriate to task requirements.
2.3. Guards/stops are set and adjusted as required.
2.4. Wood working machines are set-up in accordance with
company standard operating procedures and safety
requirements
2.5. Material to be machined is positioned and secured
effectively
2.6. Materials are machined to specification using standard
operating procedures.
3. Assure Quality of 3.1 . Machined component is evaluated against specifications
finished component and predetermined finish.
3.2 . Necessary rectification is done to meet specifications or
comply with predetermined finish.
3.3 . Machine and tools are cleaned and maintained following
workplace procedures and standards.

Variable Range
Work May include, but not limited to:
requirements  Sizing
 Appearance in terms of figure, grain or surface finish
 Allowance of imperfections such as twist, bow, bend,
 Sloping grain, knots, shakes, gum veins etc.
Woodworkin May include, but not limited to:
g  Band saws
machines  Buzzers
  Thicknesses
 Disk sander
 Bobbin sander
 Pattern mill
 Wood lathe
 Pedestal router and drill
Tools/Cutters May include, but not limited to:
 Blades
 Router bits
Guards/stops May include, but not limited to:
 Fixed guards and stops
 Variable guards and stops
Set up May include, but not limited to:
 Installation of the blades and cutters
 Settings for the job
 Adjustments for sizing and speed

Evidence Guide
Critical Aspects of Assessment requires evidences that the candidate:
Competence  Determined job requirements
 Had set up woodworking machines
 Operated woodworking machines
 Checked finished component
Underpinning Knowledge Demonstrate knowledge of:
and Attitude  Application & use of general wood working machines
 Procedure in interpreting instructions, drawings or sketches
 Numerical operations and calculations within the scope of
this unit
 Consequences of selecting inappropriate materials
 Different machines and machining processes and their
operations
 Various checking procedures and devices including
coordinate measuring and machine checking
 Procedures for recording deviation or modification to
original drawings or specifications
 Hazards and control measures associated with developing
and manufacturing precision models
Underpinning Skills Demonstrate skills of:
 Determining job requirements from job instructions,
 Specifications, standard operating procedures and other
applicable reference documents
 Checking and clarifying task-related information
 Selecting and setting machines
 Setting guards and stops
  Handling, machining and storing timber and wood
 Measuring materials and components to specified
sizes/tolerances
 Checking for conformance to specifications

Resource Implications Access is required to real or appropriately simulated situations,

including work areas, materials and equipment, and to
information on workplace practices and OHS practices.
Methods of Assessment Competence may be assessed through:
 Interview/ Written Test
 Observation/ Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the work place or in a simulated
work place setting. The competencies covered by this unit would
be demonstrated by an individual working alone or as part of a
team.
Occupational Standard: Foundry Works Level II
Unit Title Operate Basic Metal Workshop Machinery
Unit Code MIN FDW2 06 0323
Unit Descriptor This unit covers the knowledge, skills and attitudes required in
using workshop machines in fabrication and assembly of metals.

Elements Performance Criteria

1. Determine and plan 1.1. Work requirements are analyzed and selected from work
job requirements instructions and drawings/diagrams
1.2. Sequence of operations is determined for maximum
efficiency and to meet work requirements and
specifications.
1.3. Appropriate machine and tools are selected based on work
requirements
2. Set-up machine 2.1. Operations are performed applying safety procedures and
using personal protective devices
2.2. Routine maintenance and adjustments are carried out
based on machine inspection plan
2.3. Cutting Tools are inspected and if necessary sharpened
according to the work requirements
2.4. Tools are mounted and positioned within machine
specifications
2.5. Guards and accessories are set and adjusted as required
2.6. Speeds and feeds are calculated using appropriate
mathematical techniques and reference material.
2.7. Setup operations are performed following
correct/standard procedures and applying safety measures.
3. Perform machine 3.1. Materials to be machined is mounted and secured using
operations clamping devices appropriate to the work requirements
3.2. Machine is operated correctly to suit work and material
requirements.
4. Assure Quality of 4.1. Component is checked for conformance to specifications
finished and predetermined finish in accordance with given
components standards.
4.2. Appropriate techniques, measuring tools and equipment are
used in checking conformance.
4.3. Deviations are handled appropriately in accordance with
organization procedures and standard.

Variables Range
Machine May include, but not limited to:
 Lathe
  Radial arm drill
 Mills
 Horizontal metal band saws
 Pedestal grinder.
Accessories May include, but not limited to:
 Chucks
 Centres
 Clamps
 Vices and angle plates
Materials May include, but not limited to:
 Ferrous and non-ferrous metals
Clamping devices May include, but not limited to:
 Chucks
 Vices
 Clamps
 Bars and packing etc.
Measuring tools May include, but not limited to:
 Steel rule
 Venire calliper
 Micrometre calliper
Cutting tools May include, but not limited to:
 Lathe tools
 Milling cutters
 Drill, reamers
 Band saw blades etc.

Evidence Guide
Critical Aspects of Must demonstrate knowledge and skills in:
Competence  Determined job requirements
 Set-up machine
 Performed machine operation
 Checked/measured finish component
Underpinning Demonstrate knowledge of:
Knowledge and  Shop safety practices may include:
Attitudes - safe working habits
- identification of hazardous areas
- protective clothing and devices
- safe handling of tools, equipment and materials
- housekeeping
- first-aid
- fire extinguishers
 Drawing interpretation (within the scope of this unit) may
include:
 - standard drawing scales, symbols and abbreviations
- alphabet of lines
- orthographic and isometric drawings
- angle projections
- assembly and detail drawings
- interpreting tolerances, limits and fits
 Shop mathematics (within the scope of this unit) may
include:
- basic arithmetic operations
- fractions and decimals
- percentages and ratios
- conversion of units (English to metric)
- unit of measurement
- applying trigonometric functions
 Measurements (within the scope of this unit) may include:
- linear measuring tools (rules, Vernier, micrometer)
- angle measuring tools
- geometrical tolerances
- slip gages
- precision levels
 Materials and related science may include:
- classification and mechanical properties of engineering
materials
 Machine operations (within the scope of this unit) may
include:
- types and specifications
- parts and functions
- set-up procedures
- setting cutting speed, rpm, feed rate
- work holding and tool holding devices
- tools and tool geometry
- operating procedures
 Safe operation of tool sharpening equipment
 Consequences of incorrect speeds and feeds
Underpinning Skills Demonstrate skills of:
 Determining job requirements
 Reading, interpreting and following routine and familiar
information on written job instructions, standard operating
procedures and other applicable reference documents
 Verifying specifications
 Selecting and setting-up machine
 Computation of feed, cutting speed and machine rpm
 Selecting cutting tools
 Performing machine operations
 Measuring components to specifications
 Checking finished component
Resource implications The following resources must be provided:
  Tools, equipment and facilities appropriate to the activities
 Materials relevant to the proposed activity
 Drawings, sketches or blueprint
Assessment Methods Competency may be assessed through:
 Interview/Written Test
 Observation/Demonstration with Oral Questioning
Context of Assessment Competency may be assessed in the work place or in a simulated
work place setting.
Occupational Standard: Foundry Works Level II
Unit Title Develop and Manufacture Wood Pattern.
Unit Code MIN FDW2 07 0323
Unit Descriptor This unit covers developing and manufacturing wood patterns, both
regular shaped and split patterns, based on an understanding of casting
and moulding principles.

ELEMENT PERFORMANCE CRITERIA

1. Determine job 1.1. Safety (OHS) requirement associated with manufacturing wood
requirements pattern and workplace environment requirements are adhered to
throughout the work.
1.2. Job instructions and specifications are interpreted correctly.
1.3. Type of wood pattern required is determined through application
of moulding/casting techniques and foundry processes.
1.4. Appropriate timber/timber composites are selected to meet
specification.
2. Develop and 2.1. Pattern parameters are calculated to specification e.g. angles,
lay out wood tapers, clearances, contractions etc.
patterns 2.2. Pattern is laid out showing tapers, machining allowances, core
prints and method of construction to specification.
2.3. Jigs and fixtures are developed and manufactured to aid wood
pattern manufacture as required.
3. Manufacture 3.1. Materials are marked out and construction is developed to meet
wood patterns specification.
3.2. Using acceptable wood pattern making techniques and procedures,
and utilising appropriate hand, handheld power tools and
appropriate machines for wood proceeding. Pattern or pattern
component parts are produced to size and shape and checked for
conformance to specifications.
3.3. Using acceptable wood pattern making techniques and procedures,
pattern component parts are joined or fixed as required and
checked for conformance to specification.
3.4. Pattern is correctly marked, colour coded or tagged to
specifications or standard operating procedures.
3.5. OHS procedures and measures are observed throughout the
process
3.6. Housekeeping procedures are performed in accordance with
workplace standard procedures
Variable Range
Timber/timber May include, but not limited to:
composites  Hardwood
 Softwood
 Laminates
 Plywood
 Veneers and bonded fibber board
Handheld power tools May include, but not limited to:
 Circular saw
 Power drill
 Jigsaw
 Random orbital sander
 Router
Appropriate machines for May include, but not limited to:
wood proceeding  Wood Lathes
 Grinders
 Pedestal drills
 Pantographs and other machines as needed, like CNC
wood pattern making machines
Joining and fixing May include, but not limited to:
 Glued
 Screwed
 Nailed
 Stapled

Evidence Guide
Critical Aspects of Assessment requires evidence that the candidate:
Competence  determined job requirements
 developed and lay out wood patterns
 manufactured wood patterns
Underpinning Knowledge Demonstrate knowledge of:
and Attitudes  Kinds of timber products including features, characteristics
and applications
 Moulding and casting techniques
 Tools required for casting/moulding
 Jigs and fixtures methods of construction
 Formulas and mathematical techniques required for
necessary manufacturing of patterns/core boxes i.e.
contraction, taper, clearances, machining allowances etc.
 Identification of coding and numbering
 Pattern checking techniques
 Mould ability (i.e. surface finish, face taper, convex or
 concave perspectives, undercuts, etc.)
 Types of personal protective equipment
 Safe work practices and procedures
Underpinning Skills Demonstrate skills of:
 Reading/interpreting/following information on written
 job instructions, specifications, standard operating
 procedures, charts, lists, drawings and other documents
 Performing computation on different numerical
operations, geometry and formulas within the scope of this
unit
 Selecting appropriate timber to suit the moulding/ casting
techniques and foundry process
 Laying out the pattern/core boxes
 Constructing patterns/core boxes
 Joining and fixing component parts
Resource Implications The following resources must be provided:
 all manuals/catalogues relative to work activity
 tools and equipment as well as consumable materials
Methods of Assessment Competence may be assessed through:
 Interview / Written Test
 Observation / Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the work place or in a
simulated work place setting.
Occupational Standard: Foundry Works Level II
Unit Title Perform Metal Arc Welding
Unit Code MIN FDW2 08 0323
Unit Descriptor This unit covers the skills, attitudes and knowledge required in
preparing the materials and carrying out routine Manual Metal Arc
Welding (MMAW).

Elements Performance Criteria

1. Plan and prepare 1.1. OHS measures are followed and applied throughout welding
welding work activities
1.2. Welding requirements are identified from work instructions and
drawing
1.3. Materials and appropriate welding equipment are selected based
on norms and regulations
2. Perform welding 2.1. Welding currency is set up correctly according to standard
Practices
2.2. Electrodes are selected to suit application and standard settings
2.3. Materials are cleaned and prepared based on procedures
2.4. Materials are welded to job requirements and instructions
2.5. Welding seams are cleaned in accordance with operating
procedures
3. Assure quality and 3.1. Welding seams are cleaned and inspected in accordance with
clean up operating procedures
3.2. Feedback on performance provided by others in the team is
encouraged, acknowledged and acted upon
3.3. Joins are measured according to specification
3.4. Welding equipment and work area are cleaned and maintained
after welding activity

Variable Range
Materials Low and mild carbon steel or similar
Equipment Welding leads, welding machines, electrode holder etc.
Preparation Cleaning, setting up jigs, fixtures, clamps, joint preparation
Cleaning Slag and spatter, cleaning, using files and grinders

Evidence Guide
Critical Aspects of The candidate can:
Competence  plan and prepare welding work
 perform routine welding
 assure quality and clean up
Underpinning Knowledge Must demonstrate knowledge of:
 material and equipment preparation
 properties and characteristics of materials and consumables
 weld characteristics
  equipment set-up and settings
 MMAW processes and properties
 post-welding treatments
 safe welding practices
 use and application of personal protective equipment
Underpinning Skills Must demonstrate skills in:
 preparing materials and electrodes
 setting up welding equipment
 welding with MMAW
 reading and interpreting routine information on written job
instructions, specifications and standard operating procedures
 performing measurements for joint preparation and routine MMAW
Resources Implication Access is required to real or appropriately simulated situations,
including work areas, materials and equipment, and to information on
workplace practices and OHS practices.
Assessment Methods Competency may be assessed through:
 Interview/Written Test
 Observation/Demonstration with Oral Questioning
Context of Assessment Competency may be assessed in the work place or in a simulated work
place setting.
Occupational Standard: Foundry Works Level II
Unit Title Apply Basic Electrical Practices
Unit Code MIN FDW2 09 0323
Unit Descriptor The unit covers skills and knowledge required to apply
minor/basic handling and maintenance practices associated with
a range of electrical equipment at the metal engineering
workplace.
Elements Performance Criteria
1. Prepare for work 1.1. Occupational Health and Safety standards, codes of practice,
manufacturers' specifications, environmental regulations and
enterprise procedures are identified, applied and monitored
according to regulations throughout the work process
1.2. Work requirements are identified from relevant work orders
or equivalent
1.3. Resources (material and equipment) required to perform the
tasks are selected for compliance with the work
specifications
1.4. Relevant plans, drawings and texts are identified and
interpreted in accordance with the work plan
1.5. Potential hazards are identified and prevention and/or
control measures are selected in accordance with regulations
1.6. Work area is prepared in accordance with work requirements
and site specifications
2. Conduct minor 2.1. Minor maintenance is conducted in accordance with the
handling and work plan and site requirements
maintenance
2.2. Minor adjustments are undertaken in accordance with
prescribed procedures and schedules and site requirements
2.3. Faults are reported to the relevant and responsible
parties in accordance with site/enterprise procedures
3. Notify the 3.1. Work is completed and responsible personnel notified in
completion of accordance with site/enterprise requirements and regulations
quality work
3.2. Plant, tools and equipment are maintained and stored in
accordance with site/enterprise procedures
3.3. Work area is cleared of waste, cleaned, restored and secured
in accordance with site/enterprise regulations
3.4. Final checks with supervisor are made to ensure the
work conforms with instructions and regulation

Variable Range
Maintenance May include, but not limited to:
 Changing globes and starters
 Switchboard indicator lenses
  Checking transformer oil levels
 Recording of cell voltages and specific gravity;
 Cleaning
 Minor fabrication tasks, e.g. brackets, cable supports, gaskets
and similar
Completion May include but not limited to:
 Plant and maintenance records,
 Job cards
 Check sheets
 On device labelling updates
 Reporting and/or documenting equipment defects
 Supervisor acceptance
Tools and May include but not limited to:
equipment  General hand tools,
 Portable electrical tools,
 Measuring tools
 Specialist tools.
 Lubricants,
 Cleaning agents,
 Contact cleaners,
 Emery paper
 Filters
 Battery cells
 Air conditioners
 Cooling plant
 Transformers
 Switchboards
 Control panels

Evidence Guide
Critical Aspects of Demonstrate knowledge and skills in:
Competence  basic handling and maintenance of electrical machinery and
equipment
Underpinning Demonstrate knowledge of:
Knowledge and  Occupational Health and Safety standards and statutory and
Attitudes regulatory requirements associated with the handling and
maintenance of electrical equipment
 Support and/or protection requirements and specifications
 Maintenance procedures and associated manufacturer
requirements
 Marking, tagging and labelling requirements for cables,
wires, conductors and connections
 Performing basic maintenance
  Data to be recorded/reported and the frequency of
recording/reporting
 Requirements for approval to work
 Use and application of personal protective equipment for
terminating and isolating electrical wiring
Underpinning Skills Demonstrate skills of:
 Safe working practices of:
- Occupational Health and Safety standards
- Relevant statutory requirements and codes of practice
- Relevant Ethiopian standards
- Equipment and material required to perform the work
- Isolation procedures
- Layout of plant/work site and operation of its equipment
- Maintenance techniques
 Use hand and portable power tools
 Checking materials for conformance to specifications
 Checking existing and new installation site for correct
location and specification
 Marking, tagging and labelling cables, wires, conductors and
connections to specification
 Reading and interpreting routine information on written
work
 Instructions, specifications and standard operating
procedures and may include drawings
Resources Implication Access is required to real or appropriately simulated situations,
including work areas, materials and equipment, and to
information on workplace practices and OHS practices.
Assessment Methods Competency may be assessed through:
 Interview/Written Test
 Observation/Demonstration with Oral Questioning
Context of Assessment Competency may be assessed in the work place or in a simulated
work place setting.
Occupational Standard: Foundry Work Level II
Unit Title Apply 5S Procedures
Unit Code MIN FDW2 10 0323
Unit Descriptor This unit covers the knowledge, skills and attitude required to
apply 5S techniques to his/her workplace. It covers
responsibility for the day-to-day operations of the workplace
and ensuring that continuous improvements of Kaizen elements
are initiated and institutionalized.

Elements Performance Criteria

1. Prepare for work. 1.1. Work instructions are used to determine job requirements,
including method, material and equipment.
1.2. Job specifications are read and interpreted following
working manual.
1.3. OHS requirements, including dust and fume collection,
breathing apparatus and eye and ear personal protection
needs are observed throughout the work.
1.4. Tools and equipment are prepared and used to implement
5S.
1.5. Safety equipment and tools are identified and checked for
safe and effective operation.
1.6. Kaizen Board (Visual Management Board) is prepared and
used in harmony with different workplace contexts.
2. Sort items. 2.1. Plan is prepared to implement sorting activities.
2.2. Cleaning activities are performed.
2.3. All items in the workplace are identified following the
appropriate procedures.
2.4. Necessary and unnecessary items are listed using the
appropriate format.
2.5. Red tag strategy is used for unnecessary items.
2.6. Unnecessary items are evaluated and placed in an
appropriate place other than the workplace.
2.7. Necessary items are recorded and quantified using
appropriate format.
2.8. Performance results are reported using appropriate formats.
 2.9. Necessary items are regularly checked in the workplace.
3. Set all items in 3.1. Plan is prepared to implement set in order activities.
order. 3.2. General cleaning activities are performed.
3.3. Location/Layout, storage and indication methods for items
are decided.
3.4. Necessary tools and equipment are prepared and used for
setting in order activities.
3.5. Items are placed in their assigned locations.
3.6. After use, the items are immediately returned to their
assigned locations.
3.7. Performance results are reported using appropriate formats.
3.8. Each item is regularly checked in its assigned location and
order.
4. Perform shine 4.1 Plan is prepared to implement shine activities.
activities. 4.2 Necessary tools and equipment are prepared and used for
shinning activities.
4.3 Shine activity is implemented using appropriate
procedures.
4.4 Performance results are reported using appropriate formats.
4.5 Regular shining activities are conducted.
5. Standardize 5S. 5.1. Plan is prepared and used to standardize 5S activities.
5.2. Tools and techniques to standardize 5S are prepared and
implemented based on relevant procedures.
5.3. Check lists are followed for standardize activities and
reported to relevant personnel.
5.4. The workplace is kept to the specified standard.
5.5. Problems are avoided by standardizing activities.
6. Sustain 5S. 6.1. Plan is prepared and followed to sustain 5S activities.
6.2. Tools and techniques to sustain 5S are discussed, prepared
and implemented based on relevant procedures.
6.3. Workplace is inspected regularly for compliance to
specified standard and sustainability of 5S techniques.
6.4. Workplace is cleaned up after completion of job and before
 commencing next job or end of shift.
6.5. Situations are identified where compliance to standards is
unlikely and actions specified in procedures are taken.
6.6. Improvements are recommended to lift the level of
compliance in the workplace.
6.7. Checklists are followed to sustain activities and report to
relevant personnel.
6.8. Problems are avoided by sustaining activities.

Variable Range
OHS requirements May include but not limited to:
 Legislation/Regulations/Codes of practice and enterprise
safety policies and procedures. This may include protective
clothing and equipment, use of tooling and equipment,
workplace environment and safety, handling of material, use
of fire-fighting equipment, enterprise first aid, hazard
control and hazardous materials and substances.
 Personal protective equipment is to include that prescribed
under legislation/regulations/codes of practice and
workplace policies and practices.
 Safe operating procedures are to include, but are not limited
to the conduct of operational risk assessment and treatments
associated with workplace organization.
 Emergency procedures related to this unit are to include but
may not be limited to emergency shutdown and stopping of
equipment, extinguishing fires, enterprise first aid
requirements and site evacuation.
Tools and equipment May include but not limited to:
 Paint
 Hook
 Sticker
 Signboard
 Nails
 Shelves
 Chip wood
 Sponge
 Broom
 Pencil
 Shadow board/Tools board
Safety equipment and May include but not limited to:
tools  Dust masks/goggles
 Glove
  Working cloth
 First aid and safety shoes
Items May include but not limited to:
 Tools
 Jigs/Fixtures
 Materials/components
 Machine and equipment
 Manuals
 Documents
 Personal items (e.g. Bags, lunch boxes and posters)
 Safety equipment and personal protective equipment
 Other items which happen to be in the work area
The appropriate May include but not limited to:
procedures  Steps for implementing 5S (sort, set in order and shine)
activities.
 Written, verbal and computer based or in some other format.
Unnecessary items May include but not limited to:
 Defective or excess quantities of small parts and inventory
 Out-dated or broken jigs and dies
 Worn-out bits
 Out-dated or broken tools and inspection gear
 Old rags and other cleaning supplies
 Electrical equipment with broken cords
 Out-dated posters, signs, notices and memos
 Some locations where unneeded items tend to accumulate
 In rooms or areas not designated for any particular purpose
 In corners next to entrances or exists
 Along interior and exterior walls
 Next to partitions and behind pillars
 Under the eaves of warehouses
 Under desks and shelves and in desk and cabinet drawers
 Near the bottom of tall stacks of items
 On unused management and production schedule boards
 In tools boxes that are not clearly sorted
Appropriate format May include but not limited to:
 All items, necessary and unnecessary items.
Red tag May include but not limited to:
 A format prepared with a red colour paper or card which is
filled and attached temporarily on the unnecessary items
until decision is made. The red tag catch people’s attention
because red is a colour that stands out. So to fill and attach
red tag on items, asks the following three questions:
 Is this item needed?
  If it is needed, is it needed in this quantity?
 If it is needed, does it need to be located here?
Necessary items May include but not limited to:
Are required in the workplace for current production or
administrative operation in the amount needed.
Shine activity May include, but not limited to:
 Inspection
 Cleaning
 Minor maintenance May include, but not limited to:
- Tightening bolts
- Lubrication and Replacing missing parts
Tools and techniques to May include but not limited to:
standardize 5S  5S Job Cycle Charts
 Visual 5S
 The Five Minute 5S
 Standardization level checklist
 5S checklist
 The five Whys and one How approach(5W1H)
 Suspension
 Incorporation and Use Elimination
 5S slogans
 5S posters
 5S photo exhibits and storyboards
 5S newsletter
 5S maps
 5S pocket manuals
 5S department/benchmarking tours
 5S months
 5S audit
 Awarding system
 Big cleaning day
 Patrolling system May include, but not limited to:
- Top management Patrol
- 5S Committee members and Promotion office Patrol
- Mutual patrol
- Self-patrol
 Checklist and Camera patrols
Relevant procedures May include but not limited to:
 Assign 5S responsibilities
 Integrate 5S duties into regular work duties
 Check on 5S maintenance level
 OHS measures such as signage, symbols / coding and
labelling of workplace and equipment
 Creating conditions to sustain your plans
  Roles in implementation
Reporting May include but not limited to:
 Verbal responses
 Data entry into enterprise database
 Brief written reports using enterprise report formats
Relevant personnel May include but not limited to:
 Supervisors, managers and quality managers
 Administrative, laboratory and production personnel
 Internal/external contractors, customers and suppliers

Evidence Guide
Critical Aspects of Demonstrates skills and knowledge to:
Competence  Discuss how to organize KPT.
 Describe the pillars of 5S.
 Discuss the relationship between Kaizen elements.
 Implement 5S in own workplace by following appropriate
procedures and techniques.
Underpinning Demonstrates knowledge of:
Knowledge and  Kaizen principle, pillars and concept
Attitudes  Key characteristic of Kaizen
 Elements of Kaizen
 Basics of KPT
 Aims, benefits and principles of KPT
 Stages of KPT
 Structure and role of the components of Junior KPT
 Concept and parts of Kaizen board
 Concept and benefits of 5S
 The pillars of 5S
 Three stages of5S application
 Benefits and procedure of sorting activities
 The concept and application of Red Tag strategy
 Relevant Occupational Health and Safety (OHS) and
environment requirements
 Benefits and procedure of set in order activities
 Set in order methods/techniques
 Benefits and procedure of shine activities
 Inspection methods
 Planning and reporting methods
 Method of Communication
 Benefits of standardizing and sustaining 5S
 Tools and techniques to sustain 5S
 Ways to improve Kaizen elements
 Benefits of improving kaizen elements
 Relationship between Kaizen elements
Underpinning Skills Demonstrates skills of:
 Participating actively in KPT
 Technical drawing
 Communication skills
 Planning and reporting own tasks in implementation of 5S
 Following procedures to implement 5S in own workplace
 Using sorting formats to identify necessary and unnecessary
items
 Improving workplace layout following work procedures
 Preparing labels, slogans, etc.
 Reading and interpreting documents
 Observing situations
 Gathering evidence by using different means
 Recording activities and results using prescribed formats
 Working with others
 Solving problems by applying 5S
 Preparing and using kaizen board
 Preparing and using tools and equipment to implement and
sustain 5S
 Improving Kaizen elements by applying 5S
 Standardizing and sustaining procedures and techniques to
avoid problems
 Procedures to standardizing 5S activities
 Analysing and preparing shop layout of the workplace
 Standardizing and sustaining checklists
Resources Implication Access is required to real or appropriately simulated situations,
including work areas, materials and equipment, and to
information on workplace practices and OHS practices.
Methods of Assessment Competence may be assessed through:
 Interview/Written Test
 Observation/Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the work place or in a
simulated work place setting.
NTQ
F
Occupational Standard: Foundry Works Level III
Unit Title Prepare Basic Engineering Detail Drawings
Unit Code MIN FDW3 01 0323
Unit Descriptor This unit of competency covers the skills and knowledge required to
identify drawing requirements, preparing engineering drawings and
an engineering parts list, and issuing the drawings.

ELEMENT PERFORMANCE CRITERIA

1. Determine 1.1 Scope and information requirements for drawing purpose are
drawing checked drawings include 2-D drawings to international
requirements. Standard organization (ISO) 128-1:2003 Technical drawing –
General principles.
1.2 Available information relevant to project and work requirements,
and identified and interpreted
1.3 Equipment required to complete work are identified and
prepared
1.4 Requirements for presentation of drawings examined
1.5 Communication requirements during project work are Confirmed
2. Produce detail 2.1 Drawings in plane orthogonal, or equivalent Prepared
drawing 2.2 Standard drawing conventions, including dimensions, required
method of projection, and full notation applied
2.3 Drawing techniques according to work requirements are used.
2.4 Industry standards and symbols are ensured as well as presented
and applied
3. Prepare 3.1. Components or parts are Identified and organised in accordance
engineering with organisation/customer requirements
parts list 3.2. Parts list are prepared in accordance with organisation/customer
requirements
4. Complete 4.1 Dimensions, angles and proportions checked and confirmed
drawing task 4.2 Drawing is presented and ensured relevant and accurate
information according to organisational requirements.
4.3 All drawings are Issued and filed according to workplace
procedures
4.4 Areas of improvement are identified and work is evaluated
4.5 Final drawing to a standard scale is plotted or printed

Variable Range
Standard drawing May include but not limited to:
conventions  Use of correct sectioning technique
 Identification of cutting plane
 Accurate line types
 Appropriate view positions
- use of correct symbols
- use of correct dimensioning technique
- provision of suitable number of views
 Use of correct scales
 Neat presentation
Drawing techniques May include but not limited to:
 Orthogonal projection:
- first angle projection
- third angle projection
- projection symbol
- preferred system of projection in Australia
- number of views
- relationship of views
 Sheet format:
- borders and title blocks
- application of projection symbol
- drawing sheets and sizes
- lettering styles
- Australian Standards
 Dimensioning:
- unidirectional dimensioning
- aligned dimensioning
- projection and dimension lines
- arrow heads
- dimension placement
 Scale drawing:
- recommended scales
- reduction scales
- enlargement scales
- multiple scales
- dimensioning techniques of scale drawings
 Sectioning:
- types of sections
- required section views
- placement of views
- cutting planes
- labeling of cutting planes and section views
- general notes

Evidence Guide
Critical Aspects of Assessment requires evidence that the candidate:
Competence  Able to perform advanced structural detail drafting.
Underpinning Demonstrate knowledge of:
Knowledge and
Attitudes  General knowledge of different approaches to drawing
 Awareness of copyright and intellectual property issues and
legislation in relation to drawing
 Environmental and occupational health and safety (OHS) issues
associated with the tools and materials used for drawing
 Quality assurance procedures
 Principles of plane geometry:
- geometric shapes
- plane geometry
- geometric construction
- line types during construction
 Drawing construction:
- four center method
- ordinate method
- sectioning isometric shapes
- dimensions and notations
 Requirements and purpose of the drawing to be produced
 Requirements and purpose of the engineering parts list
 Sources of relevant data/information
 Timeframe for completion of drawings
persons who can confirm drawing requirements
Underpinning Skills Demonstrate skills of:
 Literacy skills sufficient to read and interpret instructions and
specifications for drawing work
 Obtaining all relevant job requirements, data/information and
specifications necessary to produce the drawing in accordance
with workplace procedures
 Planning and sequencing operations
 Checking and clarifying task-related information
 Numeracy skills sufficient to interpret technical information
and conduct mathematical problem solving as required in the
scope of this unit
 Applying spatial principles to achieve scale and proportion
 using drafting equipment appropriate to the drawing method
chosen
 Recording completed drawings and/or parts lists in accordance
with standard operating procedures
 Handling and storing the approved drawings and/or parts lists
in accordance with standard operating procedures
Resource The following resources must be provided:
Implications  all manuals/catalogues relative to work activity
 tools and equipment as well as consumable materials
Methods of Competence may be assessed through:
Assessment
  Interview / Written Test
 Observation / Demonstration with Oral Questioning
Context of Competence may be assessed in the work place or in a simulated
Assessment work place setting.
Occupational Standard: Foundry Works Level II
Unit Title Perform CAD Operation
Unit Code MIN FDW3 02 0323
Unit Descriptor This unit covers the skills and knowledge required to create
drawings with the use of Computer Aided Design (CAD)
software.

Elements Performance Criteria

1. Confirm drawing 1.1 Purpose, scope, information and presentation requirements
requirements for drawing are confirmed
1.2 Review available information relevant to project and work
requirements are identified and addressed further
information needs
1.3 Computing equipment and software used in the
organization are identified.
2. Identify key 2.1 Types of CAD software are described and used for detail
features of CAD drafting, their key features and suitability for producing
software specific drawing outcomes
2.2 Differences in CAD process to generate 2-D drawings, 3-D
models, and reasons for each presentation are identified
2.3 CAD software used in the organization and confirms
compatibility with other software programs and peripheral
equipment is identified.
3. Access software 3.1 Open software and navigate organizational filing and
and set up for library system
drawing work 3.2 Organizational and software templates are identified and
determined uses
3.3 Identify organizational symbols, codes and standards to be
applied in drafting work and how these are accessed and
applied
4. Produce basic 4.1 CAD functions to produce basic drawing elements are
drawing elements used
4.2 Editing and transfer tools and methods to modify
drawing elements are used
4.3 Dimensions, text and symbols to drawing elements are
applied
4.4 Import and export files into/out of working space
 4.5 Different views and perspectives are generated
5. Complete CAD 5.1 Drawing elements are saved and filed according to
operations organizational procedures
5.2 Drawing elements are printed and evaluated presentations

Variables Range
CAD software May include but not limited to:
 AutoCAD
 Inventor
 Revit
 Solid works
 Pro-Steel
 X-Steel
Key features May include but not limited to:
 2-D
 3-D modeling
 Built-in specifications
 File import/export
 Save
 Undo
 Scale
Specific drawing May include but not limited to:
outcomes  2-D
 3-D modeling
 Drawings for specific engineering applications
 Orthographic/isometric/perspectives/schematics
Basic drawing May include but not limited to:
elements  Points, line angles, circles, arcs, planes, figures and solids
 Squares, rectangles and triangles
 Bisected lines and dividing lines
 Polygon, ellipse, spline, dimension and hatch
Editing and transfer May include but not limited to:
tools and methods  Delete, fillet, chamfer, erase, trim/extend, break, undo and
redo commands
 Zooming and panning
 Moving, copying, rotating and mirroring
 Polar and rectangular duplication
 Object snaps
 Dimensions
 Selecting entities
  Dividing
 Scaling
 Measuring
 Grouping

Evidence Guide
Critical aspect of Assessment requires evidence that the candidate:
Competency  Determined job requirements
 Prepared CAD environment
 Created 3D CAD drawings
 Observed safety practices in accordance with OSH standards
 Communicated effectively with others to ensure effective work
operation
Underpinnin Demonstrates knowledge of:
g Knowledge  CAD / CAM system and its application
and Attitudes  Standard engineering drawing symbols, references and
terminology
 Projection and projection lines
 Specifications and/or requirements of the part to be drawn
 All appropriate lineal, diametric and geometric tolerances
 Procedures for determining tolerances including numerical
operations, geometry and calculations/formulae within the scope of
this unit
Underpinnin Demonstrates skill of:
g Skills  Read, interpret and follow information on written job instructions,
specifications, standard operating procedures
 Check drawings to ensure that assembly/fabrication is possible
 Produce drawings in accordance with acceptable standard and
required specifications by using CAD/CAM system
 Plan and sequence operations
 Create2D and 3D CAD drawings
Resource The following resources should be provided:
implications  Product sample
 Product drawing
 Reference books
 Computers
 Work instruction
 Manuals
 CAD software
 Tutorials and workstation
Method of Competency in this unit may be assessed through:
assessment  Written examination
 Direct observation/ demonstration with oral questioning
Context for  Competency may be assessed in the work place or in a simulated
Assessment work place setting
Occupational Standard: Foundry Works Level III
Unit Title Develop and manufacturing metal pattern.
Unit Code MIN FDW3 03 0323
Unit Descriptor This unit covers the competence required in developing and
manufacturing metal patterns and core boxes.

Elements Performance Criteria

1.Determine work 1.1. Drawings, instructions and specifications are interpreted and
requirements understood.
1.2. Pattern type and design are conceptualised and planned with
reference to customer's specification (written or verbal) for
number, layout, and runner system and core box design.
1.3. Type of metals pattern, required is determined through
application of molding /casting techniques and foundry
processes
1.4. A plan is developed for sequence of manufacture for either a
high or low volume foundry production pattern.
2. Develop metal 2.1. Applicable materials and tools are selected to meet
pattern specification
2.2. Appropriate materials are selected and obtained to meet
requirements of strength, durability and component finish etc.
2.3. Calculations appropriate to establishing pattern parameters,
including angles, tapers, contraction, etc. Are performed,
where applicable.
3. Produce metal 3.1. Appropriate machines and machining process are selected to
patterns and core shape/produce metal patterns and core boxes to specification.
boxes
3.2. Selected hand and hand held power tools are used to produce
metal patterns and core boxes to specification.
3.3. Metal patterns and core boxes are checked to specification and
surface finish and are checked for mould ability.

Variables Range
materials May include, but not limited to:
 A range of ferrous
 Non-ferrous and alloy materials
machines May include but not limited to lathes, milling machines,
grinders, pedestal drills, pantographs and other machines as
 needed, like CNC, lathe and milling machines
Tools May include but not limited
 Straight pins
 Scissors
 Pencils’
 Rulers
 Chisel
 Lath cutters
 End mills

Elements Performance Criteria

Critical Aspects of Demonstrates skills and knowledge to:
Competence  Determine job requirements
 Develop pattern equipment
 Manufacture production patterns and core boxes
Underpinning Knowledge Demonstrate knowledge of:
and Attitudes  characteristics of metals and alloys and their application in
the development/manufacture of production patterns
 tolerances and contraction rates typically used in the
manufacture of production patterns
 production moulding and casting techniques
 tooling required for casting/moulding
 technical method
 the use and application of jigs and fixtures
 methods of construction including machining provision
and clamping arrangements
 appropriate techniques, tools and equipment to measure,
mark out and produce production patterns
 The formula and mathematical techniques required for
manufacturing production patterns/core boxes i.e.
contraction, taper, clearances, machining allowances etc.
 identification coding and numbering
 pattern checking techniques
 Mould ability i.e. surface finish, face taper, convex or
concave perspectives, undercuts, etc.
 use and application of personal protective equipment
 safe work practices and procedures
 hazards and control measures associated with developing
and manufacturing production patterns
Underpinning Skills Demonstrate skills of:
 determining job requirements from written instructions,
sketches and drawings
 planning and sequencing manufacturing operations
 checking and clarifying task-related information
 selecting appropriate metals to suit the moulding/casting
techniques and foundry process
 laying out/constructing production pattern/core boxes
 joining and fixing component parts
 checking pattern for conformance to specifications
  measuring components to specified tolerances
 calculating shrinkage, draft, machine allowances

Resources Implication Access is required to real or appropriately simulated situations,

including work areas, materials and equipment, and to
information on workplace practices and OHS practices.
Methods of Competence may be assessed through:
Assessment  Interview/ Written Test
 Observation/ Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the work place or in a simulated
work place setting.
 Occupational Standard: Foundry Works Level III
Unit Title Operate Melting Furnace
Unit Code MIN FDW3 04 0323
Unit Descriptor This unit covers Prepare furnace, Charged material analysis and
operating melting furnace.

Elements Performance Criteria

1. Select 1.1. Storage area for raw materials -scrap, other metallic feed
and prepare raw material, flux etc. are properly shown
materials
1.2. furnace is positioned in proper way and flow of melt is marked
1.3. Requisitions are completed as required according to standard
operating procedures.
1.4. Charge material analysis is undertaken in accordance with
standard operating procedures.
1.5. The charge analysis is converted to furnace charge weight using
standard operating procedures
1.6. Charge is weighed according to standard operating procedures

2. Furnace 2.1. Type of the furnace, heat source and its melting capacity is
design: described
2.2. Schematic sketch of the furnace and sectional drawing is shown
2.3. Proper quantity of material is charged per ton of melt
2.4. Furnace refractory lining is used.
3. Start-up 3.1. Furnace is inspected for any defects or damage.
furnace 3.2. Faults are reported according to standard operating procedures
3.3. Routine operational maintenance of furnace is undertaken to
standard operating procedures.
3.4. Furnace is started-up to standard operating procedures.
4. Charge furnace 4.1. Emergency/safety procedures are identified and followed as
necessary.
4.2. Materials are pre-heated if required according to standard
operating procedures.
4.3. Materials are charged into furnace using standard operating
procedures.
4.4. Suitable areas for emergency unloading of molten metal are
 identified and kept available
5. Monitor 5.1. Furnace is maintained at optimum operating condition to standard
furnace
operating procedures.
5.2. Sample for chemical analysis is taken and remedial action is applied
as required to correct composition using standard operating
procedures.
5.3. Dross or slag is removed from furnace per standard operating
procedures.
5.4. Metal in the furnace is de-gassed to standard operating procedures.
5.5. Temperature of metal is checked and adjustment made if necessary
according to operating procedures
6. Tap or unload 6.1. Quantity of the required metal is identified.
the furnace
6.2. Tap rate is carried out to standard operating procedures.
6.3. Tapping or unloading is undertaken and completed safely according
to standard operating procedures.
7. Shut down 7.1. Shut-down of furnace is completed to standard operating
furnace
procedures.
7.2. Routine operational maintenance of furnace is undertaken to
standard operating procedures.
7.3. OHS procedures and measures are observed and applied
throughout the process (from element 1 to 8)
Variable Range
Charge material May include, but limited to,
Type of alloy to be melted not limited.
 Gray cast iron and its alloys
 Low /medium carbon steel
 High alloy carbon steel
 Stainless steel
 Aluminum and its alloy
 Copper alloy
Furnace May include, but limited to,
 Singular or multi oil, gas fired or electric induction, arc and
resistance furnace
Routine May include, but not limited to:
operational  Routine repair
maintenance  lubrication
  Cleaning
 Repairing of refractory lining
 Patching of refractory
Faults May include, but not limited to:
 Leaks in crucible
 Clogged burner
 Damage crucible
Furnace May include but limited
refractory  Alumina bricks
 Silica bricks
 Magnesia carbon bricks etc

Emergency/ May include, but not limited to:

safety procedures  Tapped out
 Cleaning of burner
 Repair
Evidence Guide
Critical Aspects of Assessment criteria :
Competence  Detailed layout sketch of the melting section
 Select materials
 Furnace design: Describe the furnace mentioning the
following points
- Start-up furnace
- Charge furnace
- Monitor furnace
- Tap or unload the furnace
- Shut down furnace
Underpinning Demonstrate knowledge of:
Knowledge and  Types of manual used in the foundry industry
Attitudes  Identification of symbol used in the manuals forms and
standing operating
 Identification of unit of measuring and unit of conversion
 refractory conditions, faults, and routine repair
 condition of cooling water supply for induction furnace
 starting procedures for different types of furnaces
 metallic charge materials and alloying elements
 weighing procedures and scale types
 correct order of loading of different charge materials
 thermocouple condition monitoring and adjustment
mechanism for furnace
 interpretation of carbon equivalent and wedge test results
 degassing procedures including tablet, lance and other
procedures
 coagulant agents, application procedures and slag removal
procedures
 close-down procedures
  use and application of personal protective equipment
 safe work practices and procedures
 hazards and control measures associated with operating
melting furnaces
Underpinning Skills Demonstrate skills in:
 Reading and interpreting routine information on written job
instructions, specifications, standard operating procedures
relevant test data sheets and other standard workplace forms
including drawings for furnace operation
 Following oral instruction and entering routine and familiar
information onto pro forma and standard workplace forms.
 Identifying faults and areas for routine repair of the furnace and
performing routine maintenance as necessary.
 Following procedures for starting and closing down furnace
 Deciding on charge materials, weighing them and feeding the
charge materials into the furnace.
 Measuring and correcting metal temperature
 Sampling for chemical analysis, carbon equivalent and chill
wedge tests
 De-gassing using tablets or lance and other methods
 De-slagging or dross removal
 Tapping temperature and procedure of the molten metal
 Weighing procedures using different scale types
 Correct order of loading of different charge materials
 Thermocouple condition monitoring instruments and
adjustment mechanism for furnaces
 Repair lining of furnace lining refractory
 Operating re lining of furnaces lining refractory
Resource implications The following resources must be provided:
 all manuals/catalogues relative to melting/casting
 job order, requisitions slip for materials
 materials, tools and equipment relevant to the activity
 actual furnace
Methods of Competence may be assessed through:
Assessment  Interview/ Written Test
 Observation/ Demonstration with Oral Questioning
Context of Competence may be assessed in the work place or in a simulated
Assessment work place setting.
Occupational Standard: Foundry Works Level III
Unit Title Pour Molten Metal
Unit Code MIN FDW3 05 0323
Unit Descriptor This unit covers knowledge and skill manually pouring
molten metal

Elements Performance Criteria

1. Prepare for pouring 1.1. The condition of the mould is checked according to
molten metal standard operating procedures.
1.2. The condition of the ladle is checked according to
standard operating procedures (Ladle is
preheated/prepared and transferred to receive molten
metal and Additives are determined from specification
and added to molten metal as required.)
1.3. The temperature of molten metal is checked for
conformance to specification, and pouring method is
sequenced to standard operating procedures.
1.4. The capacity of the required pour is identified against
specification according to standard operating
procedures.
2. Maintain quality of 2.1. Slag/dross is removed where necessary according to
metal as required standard operational procedures.
2.2. The temperature is monitored as required.
2.3. Chemical analysis is undertaken and remedial action
applied as required and in accordance with standard
operating procedures.
3. Setup ladle position 3.1. Safety clips are checked according to standard
operating procedures.
3.2. The ladle is filled and transferred to the pouring area in
accordance with standard operating procedures.
3.3. Additives are determined from specification and added
to molten metal as required.
4. Pour molten metal 4.1. Personnel in the immediate area of the metal pour are
informed that pour is to take place and appropriate
safety clothing and equipment is used as specified in
standard operating procedures.
4.2. Metal is poured safely to specification and in accordance
with standard operating procedures.
4.3. Metal is poured at an appropriate and continuous rate.
4.4. A test bar is poured in accordance with standard
operating procedures as required
4.5. The ladle is emptied, cleaned and maintained according to
standard operating procedures
Variable Range
Ladle May include, but not limited to:
 Lip pour
 Tea pot
 Bottom pour
 Barrel
 Bull ladles of varying capacity
Additives materials May include, but not limited to:
 Alloys
 Inoculants
 Spheroidisers
 Coagulants

Evidence Guide
Critical Aspects of Assessment requires evidence that the candidate:
Competence  Prepared for pouring molten metal
 Preheated or prepared ladle
 Transferred ladle to furnace
 Poured molten metal and maintained quality of metal as
required
Underpinning Knowledge Demonstrate knowledge of:
and Attitude  Types and pouring characteristics of metals
 Types and characteristics of ladles
 Procedures for maintaining condition and integrity of
ladle
 Procedure on safe handling and transfer of molten metal
 Metal treatments procedures for making additions to
molten metal
 Slag and dross removing procedures
 Techniques for sampling/testing molten metal pouring
 Metal identification and tagging procedures
 Use and application of personal protective equipment
 Safe work practices and procedures
 Hazards and control measures on pouring molten metal
Underpinning Skills Demonstrate skills of:
 Reading and following written instructions, standard
operating procedures, specifications and standard test
 Data sheets
 Selecting and checking ladle
 Preparing ladle for pouring
 Treating metal
 Removing slag and dross
 Sampling and testing molten metal
 Pouring molten metal into moulds and pigs
 Tagging pig metal
Resources Implication Access is required to real or appropriately simulated
situations, including work areas, materials and equipment,
and to information on workplace practices and OHS
 practices.
Methods of Assessment Competence may be assessed through:
 Interview/ Written Test
 Observation/ Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the work place or in a
simulated work place setting.

Unit Title Fettle and Trim Metal Castings

Unit Code MIN FDW3 06 0323
Unit Descriptor This unit covers fettling and trimming metal castings and assessing
the quality of the casting.

Elements Performance Criteria

1. Determine job 1.1.Personal protective equipment are selected and used correctly.
requirements
1.2.Manual or mechanical handling methods are applied
appropriate to the work requirements
1.3.Job requirements are correctly determined from instructions and
specifications.
1.4.Correct mouldings and/or castings are located and arranged for
efficient processing.
2. Identify excess 2.1. Casting is removed from mould and/or sand media is removed
material for
from casting as required.
removal
2.2. Castings are stored or positioned in a safe manner
2.3. Castings are visually checked as suitable for further processing,
and excess metal is correctly identified according to standard
operating procedures
3. Select tools and 3.1. Cleaning method is selected appropriate to casting and job
equipment requirements.
3.2. Rumbling/shot blast/sand blast equipment is set to specification
and used in accordance with standard operating procedures as
required.
3.3. Appropriate hand tools are correct selected and used for the
given task.
3.4. Appropriate power tools and accessories are selected and used
for the given task.
4. Remove excess 4.1. Excess metal (e.g. runners, risers and flashing) is removed
material
using methods and equipment appropriate to the task and to
standard operating procedures.
4.2. Excess metal suitable for recycling is identified according to
standard operating procedures.
 4.3. Excess metallic materials are identified from specifications
and isolated as required according to standard operating
procedures.
5. Quality assess 5.1. Castings are visually checked for conformance with
castings
specifications to standard operating procedures.
5.2. Non-conforming castings are rejected or set aside and identified
for further consideration or remedial action according to
standard operating procedures.
5.3. Faults are reported/recorded as required according to standard
operating procedures.
Variable Range
Personal protective May include, but not limited to:
equipment  Safety goggles
 Apron
 Gloves and Safety shoes
Hand tools May include, but not limited to:
 Files
 Chisels
 Hammers, etc.
Power tools and May include, but not limited to:
accessories  Saws
 Croppers
 Grinding disks/belts (including grades)
 Swing grinder
 Pedestal grinders etc.
 Hanger type blast machine
 Shot thumb blast machine
 Table type shot blasting machine
Evidence Guide
Critical Aspects of Assessment requires evidence that the candidate:
Competence  Performed fettling and trimming metal castings.
 Operated grinding machines and cutting equipment.
 Operated shot blasting machines.
Underpinning Demonstrate knowledge of:
Knowledge  Characteristic of quality fettling standards for metal
casting/forging
 Fettling requirements
 Different fettling tools and their usage
 Handling procedure and storage requirements of materials tools
and equipment
 Use and application of personal protective equipment
 Safe work practices and procedures
 Hazards and control measures associated with fettling and
trimming metal castings
Underpinning Skills Demonstrate skills of:
 Interpreting written instruction sketches and drawings
 Identifying castings
 Visually inspecting castings
 Fettling and trimming metal castings
 Conducting a final inspection
 Recording and reporting associated with fettling and trimming
metal castings
 Handling materials, tools and equipment
Resource The following resources must be provided:
Implications  all manuals/catalogues relative to coreless induction furnace or ,
job order, requisitions slip of materials
 tools, equipment and consumable materials
 actual furnace and operations
Methods of Competence may be assessed through:
Assessment  Observation/ Demonstration with Oral Questioning
 interview
 portfolio
Context of Competence may be assessed in the work place or in a simulated
Assessment work place setting.
Occupational Standard: Foundry Works Level II
Unit Title Carry out Heat Treatment
Unit Code MIN FDW3 07 0323
Unit Descriptor This unit covers the competence in performing heat
treatment of ferrous and non-ferrous metals, selecting the
appropriate process to achieve the desired result using a
variety of equipment.
Elements Performance Criteria
1 Determine job 1.1. Personal protective equipment/devices are used in
requirements and accordance with Occupational Health and Safety (OHS)
select heat requirements
treatment
equipment 1.2. Work requirements are determined from engineering
drawing, work sheet or verbal instruction from
metallurgist and other concerned personnel.
1.3. Heating equipment and material are selected according
to standard operating procedures for the required heat
treatment process.
2 Work safely with 2.1 Safety clothing and personal protective equipment is
hot metals used correctly according to standard operating
procedures.
2.2 Emergency procedures are demonstrated according to
approved safety instructions.
2.3 Safety signs and symbols are identified and understood.
2.4 Equipment is used according to specifications and
standard operating procedures.
3 Set up equipment 3.1 Hazards are identified and control measures implemented
to maintain a safe work environment.
3.2 Equipment is set up according to standard operating
procedures and manufacturers' instructions.
3.3 Information related with equipment and process are
recorded as per standard procedures.
3.4 Required heating temperature, soaking time and cooling
time are applied and maintained according to standard
operating procedure.
3.5 Optimum furnace operation requirement is maintained as
per standard operating procedures.
3.6 Furnace atmosphere is maintained as per standard
operating procedures
3.7 Temperature distribution inside the furnace is monitored
 and adjusted, if necessary, in accordance with standard
operating procedures
4 Heat treat material 4.1 Material is treated to achieve required result and may
include preparation processes.
4.2 Material is piece or batch loaded and unloaded using
equipment appropriate to the situation, according to
standard operating procedures.
4.3 Correct temperature is maintained according to standard
operating procedures
5.3
Variable Range
Heating equipment May include, but not limited to:
 Gas, oil fired and electric furnaces, such as:
- pit furnace
- box type furnace
- boggie (car type) furnace or
- muffle furnace
Heat treatment process May include, but not limited to:
 Stress relieving
 Annealing
 Normalizing
 Quenching (air, water, oil)
 Tempering
Materials May include, but not limited to:
 Carbon steels
 Alloy steels
 Aluminum alloys.
 Non-ferrous
Evidence Guide
Critical Aspects of Assessment requires evidence that the candidate:
Competence  Determined job requirements
 Set-up heat treatment equipment
 Loaded/ arranged the materials
 Operated and monitored heating equipment
 Heat treated materials
 Shut down furnace
Underpinning Knowledge Demonstrate knowledge of:
and Attitudes  work specifications
 material characteristics
 heat treatment applications, equipment and processes
 emergency procedures
 material preparation, quenching, preheating
requirements
 material condition during heat treating process
 batch and/or piece loading of furnaces
 safe loading of furnaces
 hazards and control measures associated with heat
 treatment, including housekeeping
 use and application of personal protective equipment
Underpinning Skills Demonstrate skills of:
 setting up and operating heat treatment equipment
 applying heat treatment
 safely loading furnace
Resource implications The following resources must be provided:
 manuals/catalogues relative to heat treatment
 job order, requisitions slip for materials
 materials, tools and equipment relevant to the activity
Methods of Assessment Competence may be assessed through:
 Interview/ Written Test
 Observation/ Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the work place or in a
simulated work place setting.
Occupational Standard: Foundry Works Level III
Undertake Test And Inspect On Foundry Related
Unit Title
Materials
Unit Code MIN FDW3 08 0323
Unit Descriptor This unit covers the competence required in Undertake
prescribed tests on foundry related materials
Elements Performance Criteria
1. Test and inspect 1.1. Appropriate and certified laboratory/test equipment are
materials used
1.2. Appropriate procedures/standards for the requirements
of the test are selected
1.3. Samples are prepared according to appropriate
procedures
1.4. Dimensional and Visual inspection ,as well as testing
is done on foundry materials
1.5. Standard samples are tested (calibrated)
1.6. External and relevant tests are applied

2. Undertake prescribed 2.1.Test instruments are employed as required by

tests procedures
2.2. samples are tested
2.3.Test results are recorded and checked
2.4. Quality check and quality standard is accomplished

3. Report result of tests 3.1.Report as per quality parameter is prepared

3.2.Tests are conducted and reporting requirements are
identified
3.3. Implications of test results for product is determined
3.4. Recommend actions to be taken based on test results
and enterprise procedures are undertaken
3.5. Final report is prepared and circulated in accordance
with enterprise requirements.

Variable Range
Quality check May include, but not limited to:
 Visual inspection ,
 dimensional inspection ,
 examination of surfaces sound test ,
 tensile test
 hardness testing (Brunel test or Rockwell test)
 fracture test
 impact test
 creep test
Quality standards May include, but not limited to:
 Materials
 Components
 Process
 Procedures
Quality parameters May include, but not limited to:
 Standard Design / Specifications
 Material Specification
Evidence Guide
Critical Aspects of Demonstrates skills and knowledge to:
Competence  Check completed work continuously against organization
standard
 Identify and isolate faulty or poor service
 Check service delivered against organization standards
 Identify and apply corrective actions on the causes of
identified faults or error
 Record basic information regarding quality performance
 Investigate causes of deviations of services against
standard
 Recommend suitable preventive actions
Underpinning Knowledge Demonstrates knowledge of:
and Attitude  Relevant quality standards, policies and procedures
 Characteristics of services
 Safety environment aspects of service processes
  Evaluation techniques and quality checking procedures
 Workplace procedures and reporting procedures
Underpinning Skills Demonstrates skills to:
 interpret work instructions, specifications and standards
appropriate to the required work or service
 carry out relevant performance evaluation
 maintain accurate work records
 meet work specifications and requirements
 communicate effectively within defined workplace
procedures
Resource Implications Access is required to real or appropriately simulated
situations, including work areas, materials and equipment,
and to information on workplace practices and OHS
practices.
Methods of Assessment Competence may be assessed through:
 Interview / Written Test
 Observation / Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the work place or in a
simulated work place setting.
Occupational Standard: Foundry Works Level III
Unit Title Perform Gravity Die Casting
Unit Code MIN FDW3 09 0323
Unit This unit covers prepare mould for die casting, manually pouring the metal,
Descriptor removing the material and cleaning the die. Metals used in this area may
include aluminum, aluminum alloys and other ferrous metals.

Elements Performance Criteria

1. Prepare and 1.1 . Appropriate safety clothing and apparatus is used.
Identify work 1.2 Product drawings, instruction and specifications are interpreted
requirement and fully understand.

1.3 Appropriate mould materials are selected as per method of

moulding and specifications.

1.4 Mould fabrication technique, moulding of components, casting

technique and foundry process are identified to determine the
type of mould required.
1.5 Die coat is mixed & applied in correct proportion and
sequence and in a safe manner according to standard operating
procedures.
1.6 . Die temperatures are lifted to, or maintained, at the correct
level.
2. Prepare mould 2.1. Samples for aesthetic inspection are produced and
construction dimensional inspection is performed as per specification
requirement.

2.2. Mould is prepared for application of appropriate mould

coating as per standard operating procedures.

2.3. Mould is mounted and secured to casting machine as per

standard operating procedures.

2.4. Mould/ machine is prepared for pouring of molten metal as

per standard operating procedures.
 2.5. Mould is inspected for related defects as per standard
operating procedures.

2.6. Dimensions are checked and mould is rectified, if needed,

as per standard operating procedures.
3. Carry out 3.1. Pour is made in manner to reduce porosity and lamination.
manual pouring 3.2. Conditions are identified that contribute to inferior castings or
rejects.
3.3. Allowance is made for adequate cooling time.
3.4. Pour is made at a continuous and appropriate rate during
filling.
3.5. Monitoring of die coating condition is carried out and re-
spraying occurs as required.
4. Remove 4.1. Necessary safety precautions should be followed in removal of
materials cast parts.
4.2. Parts are removed and stored in a manner that minimises
damage.
4.3. Any flash is removed from the die surface
5. Clean die 5.1. Shot blaster is operated in a safe manner and according to
standard operating procedures.
5.2. Furnace is dressed and/or degassed to standard operating
procedures
5.3. The ladle is cleaned and maintained according to standard
operating procedures.
5.4. Work area is cleaned of coating and shot residue to appropriate
standard.

Variable Range
Appropriate safety Aluminum Association safety status sheet recommendations,
clothing and glasses, aluminized suits, masks, gloves, gauntlet, etc.
apparatus
Mould material May include, but not limited to:
 Gary cast iron for the halves or quadrants
  Tool steel for bottom mould
 Gary cast iron for center mould
Type of mould May include, but not limited to:
 center pouring mould
 side pouring mould
 semi-permanent mould with sand core
 with loose piece
Mould coating May include, but not limited to:
 Preheating of mould (110° – 150°C)
 Coating application/ technique (spraying)
 Coating type
 Insulating type
 Lubricating type
Evidence Guide
Critical Aspects of Assessment requires evidence that the candidate:
Competence  Identified job requirement
 Prepared mould construction plan
 Fabricated mould
 Inspection mould
 performed machine operation
 checked/measured finish component
Underpinning Demonstrate knowledge of:
Knowledge and  Casting process of non-ferrous alloys
Attitudes  Metal, resin, and composite product knowledge including
characteristics and application
 Moulding and casting techniques for ferrous metal
 Machining and tool / die making process
 Principles of permanent mould coating and application
 Method and technique of permanent mould fabrication
 Use of jig / fixture
 Mould checking technique
 Casting inspection technique
 Casting defect, cause and countermeasure
  Use and application of personal protective equipment
 Safe work practice and procedures
 Hazards and control measures associated with developing
and manufacturing permanent mould
 Observant/Attentive to details
 relevant written instructions
 die coat function(s) in die casting
 correct proportions and consistency of die coats
 correct identification of die coat materials
 procedures for raising the temperature of the die to the
correct level and maintaining the required temperature
 procedures to be followed when pouring molten metal to
produce sound castings
 curing times for castings of various volumes and materials
 correct procedures for removing castings from the die and
storing of castings
 die condition and need for shot blasting
 shot blaster operating procedures
Underpinning Skills Demonstrate skills of:
 Determining job requirements from written instructions,
standard operating procedures, sketches, drawings and
other applicable reference documents
 Planning and sequencing operations
 Checking and clarifying task related information
 Selecting appropriate materials to suit the moulding/casting
techniques and foundry process
 Joining and fixing component parts
 Checking moulds
 Calculating contraction rates/pitch/proportions/profiles
 Calculating gating/riser system
 Preparation of mould coating
 Application of mould coating
  mixing of die coats in the correct proportions in accordance
with standard operating procedures
 maintaining of die at correct temperatures
 pouring of molten metal
 assessing correct curing times
 applying die coats
 removing of casting from die
 operating shot blaster
 using measurement skills needed to meet the requirements
of this unit
Resource The following resources must be provided:
implications  Manuals/catalogues relative to mould making
 Job order, requisitions slip for materials
 Materials, tools and equipment relevant to the activity
 Incoming material receiving effort
 Quality handbook procedure for melting
Methods of Competence may be assessed through:
Assessment  Interview/ Written Test
 Observation/ Demonstration with Oral Questioning
Context of Competence may be assessed in the work place or in a simulated
Assessment work place setting.
 Occupational Standard: Foundry Works Level III
Unit Title Perform oxy acetylene welding and cutting
Unit Code MIN FDW2 10 0323
Unit Descriptor This unit covers the necessary competence in performing oxyacetylene
cutting and welding in fabrication and assembly of metals.

Elements Performance Criteria

1.1 Personnel Protective Equipment (PPE) issues are raised with

1. Prepare designated personnel in accordance with Oxyacetylene cutting
Oxyacetylene workplace procedures and relevant OHS legislation.
welding and 1.2 Preventative OHS procedures are demonstrated throughout all
cutting scope of Oxyacetylene cutting work, and with regards to
equipment’s and Oxyacetylene cutting workplace standards and regulations
apply OHS in
work shop 1.3 Welding and Cutting equipment and consumables are selected
and prepared according to job requirements

2. Set up 2.1. Instructions, symbols, specifications including bead size,

oxyacetylene bead placement, reinforcement etc. are interpreted correctly
welding and cutting in accordance with cutting procedure sheet, if available, and
outfit standard operating procedures.
2.2. Cutting equipment including cylinders, regulators, hoses,
torches and tips are assembled and set up safely in
accordance with standard operating procedures.
2.3. Welding and cutting equipment, including cylinders,
regulators, hoses, torches and tips are assembled and set up
safely in accordance with standard operating procedures
2.4. Materials are prepared to achieve required weld
specification
3. Weld and Cut 3.1. Cutting and welding procedures are followed according to
materials with regulations.
Oxy acetylene 3.2. Materials are welded and cut in all positions according to
standards.
3.3. Cut components are quality inspected and released due to
standard and procedures.
4. Clean up 4.1. Work area is cleared and material disposed.
4.2. Tools and equipment’s are cleaned, checked, maintained and
stored in accordance with manufacturer recommendations and
work place procedures.
Variable Range
Equipment and May include but not limited to:
consumables  Fuel gases including oxyacetylene and oxyacetylene
 Generator
 LPG
 Hydrogen etc., cylinders, regulators, hoses, cutting torches, tips
Materials May include but not limited to:
 Low carbon steel
 Plate
 Pipe
 Tube and round bar
Occupational May include but not limited to:
Health and  Protective clothing and equipment,
Safety (OHS)  Use of tools and equipment,
 Workplace environment and safety, handling of materials,
 Use of firefighting equipment
 Use of first aid equipment,
 Hazard control and hazardous materials and substances
 Personal protective equipment is to include that prescribed under
legislation, regulation and workplace policies and practices
Tools and May include but not limited to:
equipment  Hand and power tools,
 Measuring equipment,
 Oxyacetylene and accessories

Evidence Guide
Critical Aspects Demonstrate knowledge and skills of:
of Competence  Preparatory requirements
 purpose and examples of cutting
 appropriate settings for the given task and the selected
equipment/consumables
 Fuel gas properties and applications
 Safe cutting practices
 Use and application of personal protective equipment for
oxyacetylene cutting
 Relevant hazards and control measures related to the competence
Underpinning Demonstrate knowledge of:
knowledge  Preparatory requirements
 Material and consumable properties and characteristics
 Relevant hazards and control measures related to the competence
Underpinning Demonstrate skills of:
skills  Proper adjustments of cutting flame
 Fuel gas properties and applications
  Safe cutting practices
 Use and application of personal protective equipment for
oxyacetylene cutting
Resources Access is required to real or appropriately simulated situations,
Implication including work areas, materials and equipment, and to information on
workplace practices and OHS practices.
Assessment Competency may be assessed through:
Methods  Interview/Written Test
 Observation/Demonstration with Oral Questioning
Context of Competency may be assessed in the work place or in a simulated work
Assessment place setting.
Occupational Standard: Foundry Work Level III
Unit Title Prevent and Eliminate MUDA
Unit Code MIN FDW3 10 0323
Unit Descriptor This unit covers the knowledge, skills and attitude required by a worker to
prevent and eliminate MUDA/wastes in his/her workplace by applying
scientific problem-solving techniques and tools to enhance quality,
productivity and other kaizen elements on continual basis. It covers
responsibility for the day-to-day operation of the work and ensures Kaizen
Elements are continuously improved and institutionalized.

Element Performance Criteria

1. Prepare for 1.1. Work instructions are used to determine job requirements, including
work. method, material and equipment.
1.2. Job specifications are read and interpreted following working
manual.
1.3. OHS requirements, including dust and fume collection, breathing
apparatus and eye and ear personal protection needs are observed
throughout the work.
1.4. Appropriate material is selected for work.
1.5. Safety equipment and tools are identified and checked for safe and
effective operation.
2. Identify 2.1 Plan of MUDA and problem identification is prepared and
MUDA and implemented.
problem 2.2 Causes and effects of MUDA are discussed.
2.3 All possible problems related to the process /Kaizen elements are
listed using statistical tools and techniques.
2.4 All possible problems related to kaizen elements are identified and
listed on Visual Management Board/Kaizen Board.
2.5 Tools and techniques are used to draw and analyze current situation
of the work place.
 2.6 Wastes/MUDA are identified and measured based on relevant
procedures.
2.7 Identified and measured wastes are reported to relevant personnel.
3. Analyze causes 3.1 All possible causes of a problem are listed.
of a problem. 3.2 Cause relationships are analyzed using 4M1E.
3.3 Causes of the problems are identified.
3.4 The root cause which is most directly related to the problem is
selected.
3.5 All possible ways are listed using creative idea generation to
eliminate the most critical root cause.
3.6 The suggested solutions are carefully tested and evaluated for
potential complications.
3.7 Detailed summaries of the action plan are prepared to implement the
suggested solution.
4. Eliminate 4.1. Plan of MUDA elimination is prepared and implemented by medium
MUDA and KPT members.
Assess 4.2. Necessary attitude and the ten basic principles for improvement are
effectiveness adopted to eliminate waste/MUDA.
of the solution. 4.3. Tools and techniques are used to eliminate wastes/MUDA based on
the procedures and OHS.
4.4. Wastes/MUDA are reduced and eliminated in accordance with OHS
and organizational requirements.
4.5. Tangible and intangible results are identified.
4.6. Tangible results are compared with targets using various types of
diagrams.
4.7. Improvements gained by elimination of waste/MUDA are reported to
relevant bodies.
5. Prevent 5.1. Plan of MUDA prevention is prepared and implemented.
occurrence of 5.2. Standards required for machines, operations, defining normal and
wastes and abnormal conditions, clerical procedures and procurement are
sustain discussed and prepared.
operation. 5.3. Occurrences of wastes/MUDA are prevented by using visual and
auditory control methods.
 5.4. Waste-free workplace is created using 5W and 1Hsheet.
5.5. The completion of required operation is done in accordance with
standard procedures and practices.
5.6. The updating of standard procedures and practices is facilitated.
5.7. The capability of the work team that aligns with the requirements of
the procedure is ensured and trained on the new Standard Operating
Procedures (SOPs).

Variable Range
OHS requirements May include, but not limited to:
 Are to be in accordance with legislation/ regulations/codes of practice
and enterprise safety policies and procedures. This may include
protective clothing and equipment, use of tooling and equipment,
workplace environment and safety, handling of material, use of fire-
fighting equipment, enterprise first aid, hazard control and hazardous
materials and substances.
 PPE are to include that prescribed under legislation/regulations/codes
of practice and workplace policies and practices.
 Safe operating procedures are to include, but are not limited to the
conduct of operational risk assessment and treatments associated with
workplace organization.
 Emergency procedures related to this unit are to include but may not be
limited to emergency shutdown and stopping of equipment,
extinguishing fires, enterprise first aid requirements and site
evacuation.
Safety equipment May include but not limited to:
and tools  Dust masks/goggles
 Glove
 Working cloth
 First aid and
 Safety shoes
Statistical tools and May include but not limited to:
techniques
  7 QC tools May include, but not limited to:
- Stratification
- Pareto Diagram
- Cause and Effect Diagram
- Check Sheet
- Control Chart/Graph
- Histogram and Scatter Diagram
 QC techniques May include, but not limited to:
- Brain storming
- Why analysis
- What if analysis
- 5W1H
Tools and May include but not limited to:
techniques  Plant Layout
 Process flow
 Other Analysis tools
 Do time study by work element
 Measure Travel distance
 Take a photo of workplace
 Measure Total steps
 Make list of items/products, who produces them and who uses them &
those in warehouses, storages etc.
 Focal points to Check and find out existing problems
 5S
 Layout improvement
 Brainstorming
 U-line
 In-lining
 Unification
 Multi-process handling &Multi-skilled operators
 A.B. control (Two point control)
  Cell production line
 TPM (Total Productive Maintenance)
Relevant May include but not limited to:
procedures  Make waste visible
 Be conscious of the waste
 Be accountable for the waste and measure the waste.
4M1E May include but not limited to:
 Man
 Machine
 Method
 Material and Environment
Creative idea May include but not limited to:
generation  Brainstorming
 Exploring and examining ideas in varied ways
 Elaborating and extrapolating
 Conceptualizing
Medium KPT May include but not limited to:
 5S
 4M (Machine, Method, Material and Man)
 4p (Policy, Procedures, People and Plant)
 PDCA cycle
Basics of IE tools and techniques
The ten basic May include, but not limited to:
principles for  Throw out all of your fixed ideas about how to do things.
improvement  Think of how the new method will work- not how it won.
 Don’t accept excuses. Totally deny the status quo.
 Don’t seek perfection. A five precent implementation rate is fine as
long as it’s done on the spot.
 Correct mistakes the moment they are found.
 Don’t spend a lot of money on improvements.
  Problems give you a chance to use your brain.
 Ask “why?” At least five times until you find the ultimate cause.
 Ten people’s ideas are better than one person’s.
 Improvement knows no limits.
Tangible and May include, but not limited to:
intangible results  Tangible result may include quantifiable data
 Intangible result may include qualitative data
Various types of May include, but not limited to:
diagrams.  Line graph
 Bar graph
 Pie-chart
 Scatter diagrams
 Affinity diagrams
Visual and auditory May include, but not limited to:
control methods  Red Tagging
 Sign boards
 Outlining e.t.c.
5W and 1H May include, but not limited to:
 Who
 What
 Where
 When
 Why and
 How
Standard Operating May include, but not limited to:
Procedures (SOPs).  The customer demands
 The most efficient work routine (steps)
 The cycle times required to complete work elements
 All process quality checks required to minimize defects/errors
 The exact amount of work in process required
Evidence Guide
Critical Aspects of Demonstrate knowledge and skills to:
Competence  Discuss why wastes occur in the workplace
 Discuss causes and effects of wastes/MUDA in the workplace
 Analyze the current situation of the workplace by using appropriate
tools and techniques
 Identify, measure, eliminate and prevent occurrence of wastes by using
appropriate tools and techniques
 Detect non-conforming products/services in the work area
 Apply effective problem-solving approaches/strategies.
 Implement and monitor improved practices and procedures
 Apply statistical quality control tools and techniques.
Underpinning Demonstrate knowledge of:
Knowledge and  Targets of customers and manufacturer/service provider
Attitude  Traditional and kaizen thinking of price setting
 Kaizen thinking in relation to targets of manufacturer/service provider
and customer
 value
 The three categories of operations
 the 3“MU”
 wastes occur in the workplace
 The 7 types of MUDA
 QC story/PDCA cycle/
 QC story/ Problem solving steps
 QCC techniques
 7 QC tools
 The Benefits of identifying and eliminating waste
 Causes and effects of 7 MUDA
 Procedures to identify MUDA
 Necessary attitude and the ten basic principles for improvement
  Procedures to eliminate MUDA
 Prevention of wastes
 Methods of waste prevention
 Definition and purpose of standardization
 Standards required for machines, operations, defining normal and
abnormal conditions, clerical procedures and procurement
 Methods of visual and auditory control
 TPM concept and its pillars.
 Relevant OHS and environment requirements
 Method and Lines of communication
 Methods of making/recommending improvements.
 Reporting procedures
 Workplace procedures associated with the candidate's regular technical
duties
 organizational structure of the enterprise
Underpinning Demonstrate skills to:
Skills  Draw & analyse current situation of the work place
 Use measurement apparatus (stop watch, tape, etc.)
 Calculate volume and area
 Apply statistical analysis tools
 Use and follow checklists to identify, measure and eliminate
wastes/MUDA
 Identify and measure wastes/MUDA in accordance with OHS and
procedures
 Use tools and techniques to eliminate wastes/MUDA in accordance
with OHS procedure.
 Apply 5W and 1H sheet
 Update and use standard procedures for completion of required
operation
 Apply Visual Management Board/Kaizen Board.
 Detect non-conforming products or services in the work area
  Work with others
 Read and interpret documents
 Observe situations
 Solve problems
 Communicate information
 Gather evidence by using different means
 Report activities and results using report formats
 Implement and monitor improved practices and procedures
Resources Access is required to real or appropriately simulated situations, including
Implication work areas, materials and equipment, and to information on workplace
practices and OHS practices.
Methods of Competence may be assessed through:
Assessment  Interview/Written Test
 Observation/Demonstration with Oral Questioning
Context of Competence may be assessed in the work place or in a simulated work
Assessment place setting.
NTQF LEVEL IV
Occupational Standard: Foundry Works Level IV
Unit Title Develop manufacture gear and impeller pattern
Unit Code MIN FDW4 01 0323
Unit Descriptor
This unit covers laying out and manufacturing gear, impeller patterns
with predetermined thicknesses
Elements Performance Criteria
1. Determine job 1.1. Drawings, instructions and specifications are interpreted and understood.
requirements
1.2. Appropriate material is selected to specifications.

1.3. Molding, cast techniques and foundry processes are applied in

determining the type of pattern required.
2. Lay out gear 2.1. Pattern parameters are calculated.
and impeller
2.2. Pattern is laid out showing tapers, machining allowances, core prints and
pattern
method of construction etc. to specification.

2.3. Jigs and fixtures are developed and manufactured to aid the manufacture
of the pattern form as required.
3. Manufacture 3.1. Materials are marked out and construction is developed to meet
gear and specifications.
impeller
3.2. Pattern or pattern component parts are produced to size and shape and
pattern
checked for compliance with specifications using acceptable wood
pattern making techniques, procedures and utilizing appropriate hand and
hand held power tools.

3.3. Pattern component parts are joined or fixed as required, according to

specifications, using pattern making techniques and procedures.

3.4. Pattern is correctly marked, color-coded and/or tagged in compliance

with specifications or standard operating procedures.
Variable Range
Pattern parameters May include, but not limited to:
 Pitch circles, pressure angles, tooth form, left and right hand flight
helix, pitch axial dimensions, angles, tapers, clearances, contraction
allowances appropriate to developing various types of gear, and
impeller forms
Calculated May include, but not limited to:
 The determination of contraction rates, pitch, proportions, profiles as well
as general engineering calculations.
May include, but not limited to:
Material
Hardwood, softwood, epoxy resins, composites

Wood, metal or plastics .wax and plaster of Paris are also used
Evidence Guide
Critical Aspects of Demonstrate knowledge and skills to:
Competence  Develop and manufacture
 Gear,
 Impeller
 Patterns.
Underpinning Demonstrate knowledge of:
Knowledge and  Timber, epoxy resin and composite product knowledge including
Attitudes features, characteristics and applications
 Moulding and casting techniques for cast gears and impeller
propellers
 Tooling required for casting/moulding
 Method techniques
 The use and application of jigs and fixtures
 Methods of construction
 Techniques, tools and equipment to measure, mark out & produce
gear and impeller patterns
 Mathematical calculations and formulae required to manufacture
patterns/core boxes - contraction, taper, pitch, profiles, clearances,
machining allowances
 Identification coding and numbering
 Pattern checking techniques
 Mould ability i.e. Surface finish, face taper, convex or concave
perspectives, undercuts, etc.
 Use and application of personal protective equipment
 Safe work practices and procedures
  Hazards and control measures associated with developing and
manufacturing gear and impeller propeller patterns
Underpinning Skills Demonstrate skills of:
 Determining job requirements from written instructions,
standard operating procedures, sketches, drawings and other
applicable reference documents
 Planning and sequencing operations
 Checking and clarifying task-related information
 Selecting appropriate materials to suit the moulding/casting
techniques and foundry process
 Selecting and applying adhesives
 Laying out the pattern/core boxes
 Constructing patterns/core boxes
 Joining and fixing component parts
 Checking patterns
 Calculating contraction rates/pitch/proportions/profiles
 Undertaking relevant engineering calculations
Resources Implication Access is required to real or appropriately simulated situations,
including work areas, materials and equipment, and to information on
workplace practices and OHS practices.
Methods of Assessment Competence may be assessed through:
 Interview/ Written Test
 Observation/Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the work place or in a simulated work
place setting.
Occupational Standard: Foundry Works Level IV
Unit Title Develop and manufacture polystyrene patterns
Unit Code MIN FDW4 02 0323
Unit Descriptor This unit covers all patterns using polystyrene, including patterns for
the lost foam process and for those areas on a wood pattern and core
box where polystyrene is required

Elements Performance Criteria

1. Determine job 1.1. Comply with work health and safety (WHS) requirements at all
requirements times
1.2. Drawings, instructions and specifications are interpreted and
understood.
1.3. The appropriate grade/type of polystyrene is selected to meet
specifications.
1.4. Follow standard operating procedure
2. Mark out 2.1. Calculations are performed to determine contraction allowance etc.
polystyrene 2.2. Pattern/pattern components are marked out to specifications.
pattern
3. Manufacture 3.1. Appropriate tools are selected and techniques are used to manufacture
polystyrene polystyrene patterns to specification.
pattern
3.2. Pattern components are correctly jointed and secured using adhesives
appropriate to the task.
3.3. Pattern is checked for conformance to specifications and correctly
marked for identification.
3.4. Patterns are handled and stored in a safe manner.

Variable Range
Polystyrene Polystyrene is made by stringing together or polymerizing styrene, a
building block chemical used in the manufacture of many products.

Evidence Guide
Critical Aspects of Demonstrates skills and knowledge to:
Competence  Types and applications of polystyrene for pattern making
 Pattern checking techniques
 Planning and sequencing tasks/operations
 Checking patterns for compliance
 Handling finished polystyrene products
Underpinning Demonstrate knowledge of:
Knowledge and  The formulae and mathematical techniques required for
Attitudes manufacturing patterns/core boxes i.e. contraction, taper,
clearances, machining allowances etc.
 Marking out techniques for polystyrene patterns
 Undercuts and holes
 Types and applications of adhesives
 Tools and their uses in the manufacture of polystyrene patterns
 Handling and storage techniques
 Use and application of personal protective equipment
 Safe work practices and procedures
 Hazards and control measures associated with developing and
manufacturing polystyrene patterns
Underpinning skills Demonstrate skills of:
 Determining job requirements from written instructions,
sketches and drawings
 Checking and clarifying task-related information
 Selecting polystyrene appropriate for pattern or foundry process
 Marking out in relation to polystyrene patterns
 Selecting and applying adhesives
 Manufacturing polystyrene patterns
 Checking patterns for compliance
 Handling finished polystyrene products
 Using calculations to determine contraction allowances

Resource Access is required to real or appropriately simulated situations, including

Implications work areas, materials and equipment, and to information on workplace
practices and OHS practices.
Methods of Competence may be assessed through:
Assessment
 Interview / Written Test
 Observation / Demonstration with Oral Questioning
Context of Competence may be assessed in the work place or in a simulated work
Assessment place setting.
Occupational Standard: Foundry Works Level IV
Unit Title Perform Centrifugal and Investment Casting Processes
Unit Code MIN FDW4 03 0323
Unit Descriptor This unit covers competence in performing centrifugal and investment
casting processes.

Elements Performance Criteria

1. Prepare 1.1. OHS and environmental protection measures are applied based
materials on working procedure
1.2. Spruce/tree materials are prepared/built according to
operational specifications
1.3. Assembled tree/materials are checked, if necessary
1.4. Casting methods and equipment are selected appropriate to
task.
1.5. The quantity of alloy required is calculated and weighed
according to industry standards
1.6. Tools and equipment are selected for the investment process
according to the required casting specifications
1.7. High grade material is melted in appropriate furnaces
according to casting requirements
1.8. Spin casting machines are prepared with the mould based on
operational standards
2. Invest flask 2.1. Flask is assembled according to the required casting
specifications
2.2. Investment is mixed according to manufacturers’ specifications
2.3. Curing stage is applied according to site-specific requirements
3. Operate ‘lost 3.1. ‘Low melt’ wax is evacuated by steam process according to
wax’ sequence requirements
3.2. Investment flask is positioned/stored correctly due to casting
requirements
3.3. ‘Burnout’ cycle is selected and applied due to industry standard
4. Perform 4.1. Casting steps is selected appropriate to task.
Centrifugal 4.2. Shell metal is poured under correct temperature in the mould
casting
 according to manufactures’ specification
4.3. The core metal, if needed, is poured after appropriate time in the
mould to achieve fine grained structure base standard requirements
4.4. Heat treatment is applied , if necessary, according to specification
5. Assure quality 5.1. Casted components are tested according to engineering
and clean site requirements
5.2. Cast is measured and results are documented according to
organizational specifications
5.3. Tools and equipment are properly cleaned and stored
5.4. Work area/site area is thoroughly cleaned and decontaminated
in accordance with enterprise standard procedures

Variable Range
Machines May include, but not limited to:
 High speed centrifugal vertical and horizontal spin casting
machines
 Various furnaces
Associated tools May include, but not limited to:
and equipment  Flasks and base
 Investment Scales
 Mixers
 Bowls
 Vacuum
 Centrifugal moulds

Evidence Guide
Critical Aspects Assessment requires evidence that the candidate:
of Competence  Select materials
 Produce wax pattern
 Make moulds
Underpinning Demonstrate the knowledge of:
Knowledge and  Curing/set stage requirements
Attitudes  Setting sequence and values for time, temperature, and/or
cam settings steamer process
 Determining suitability of flask/investment for burnout
 Setting sequence, procedures, adjustments for variables
 Setting up centrifugal casting processes
 Following procedures for storage and positioning of the
important for cleaning, storage and/or removal of materials
 Necessary recording procedures
 Safe work practices and procedures
Underpinning Demonstrate skills of:
Skills  Applying routine task-related information
 Checking pre-assembled wax for security, size, and weight
selecting/checking/cleaning spruce and investment materials
 Selecting appropriate components
 Recording weights
 Selecting and assembling appropriate flask size
 Calculating and weighing out proportions of investment
material and water
 Performing mixing, vibrating and vacuum procedures
 Operating steamer and process
 Inspecting flasks for residue prior to burn-out
 Selecting appropriate burn-out procedure/equipment
positioning/storing flask
 Inspecting and adjusting oven/kiln cavity
 Cleaning working area, and all tools and investing
equipment of investment residue
 Disposing of residue and material
 Operating centrifugal casting machines
 Installing centrifugal moulds
Resource Access is required to real or appropriately simulated situations,
Implications including work areas, materials and equipment, and to information on
workplace practices and OHS practices
Methods of Competence may be assessed through:
Assessment  Interview / Written Test
 Observation / Demonstration with Oral Questioning
Context of Competence may be assessed in the work place or in a simulated work
Assessment place setting.

Occupational Standard: Foundry work Level IV

 Unit Title Maintain and repair tools, equipment and mechanical
machine
Unit Code MIN FDW4 04 0323
Unit Descriptor The unit covers the skill, knowledge and attitudes required in
carrying out compulsory and routine safety and maintenance
checks on machines and equipment, calibrate measuring
instruments and tools in a manufacturing setting.

Elements Performance Criteria

1. Undertake 1.1. Tools and machines/equipment are inspected and checked
programmed safety according to workplace routine.
and maintenance 1.2. Measuring instruments are checked and calibrated in
checks accordance with manufacturer’s instructions.
1.3. Non-functional tools, instruments and equipment are
segregated and labeled according to classification.
1.4. Status/report is recorded on pro-forma or reported orally
based on operational processes.
2. Undertake basic 2.1. Machines/equipment are cleaned and lubricated using
programmed appropriate lubricant, according to preventive maintenance
maintenance schedule or manufacturer’s specifications/instructions
following standard procedures
2.2. Removal/replacement of consumable components is
undertaken to prescribed procedure and instructions
2.3. Fluids and lubricants are replaced and/or topped up to
prescribed schedule and according to manufacturer’s
instructions
2.4. Minor machine repairs are performed according to manual
instruction or workplace procedures
2.5. Machine moving parts are adjusted to manufacturer’s
specifications.
3. Perform basic 3.1. Tools and machines/equipment are cleaned using
preventive appropriate cleaning materials and according to standard
maintenance procedures
3.2. Tools and machines/equipment are lubricated and stored
 according to prescribed procedures
3.3. Necessary reports are accomplished in accordance with
workplace procedures

4. Inventory tools and 4.1. Inventory of tools, instruments and equipment is performed in
equipment accordance with workplace procedures
4.2. Inventory results are documented/recorded in appropriate
forms as per company regulations
4.3. Tools and equipment are stored safely in appropriate locations
in accordance with manufacturer’s specifications or company
policy

Variable Range
Machine/equipment May include, but not limited to:
 Manual, semi-automatic and automatic machines of a
stand-alone continuous production or process nature
Checked May include, but not limited to:
 Programmed safety and maintenance checks
 Adjustments of a limited nature including safety guards,
stops, wear pads and tool holders, nipping up glands and
adjustment of scrapers and aprons
Consumable May include, but not limited to:
components  Air filters
 Oil wipers
 Grease containers
 Tool tips
 Indicator globes
 Fluids and lubricants
 Guides and limit switch actuators
Tools May include, but not limited to:
 Cutting tools - hacksaw, crosscut saw, rip saw
 Boring tools - auger, brace, gimlet, hand drill
 Holding tools - vice grip, C-clamp, bench vice
 Threading tools - die and stock, taps
 Measuring instruments
Cleaning materials May include, but not limited to:
 Rust remover
 Lubricants
 Rugs, etc.
Evidence Guide
Critical Aspects Demonstrate knowledge and Skill of:
of Competence  Performed operational maintenance of machines/equipment and
tools
 Selected and used appropriate processes, tools and equipment to
carry out task
 Identified functional and non-functional tools and equipment
 Checked, lubricated and calibrated tools, equipment and
instruments according to manufacturer’s specifications
 Replaced defective tools, equipment and their accessories
 Observed and applied safe handling of tools and equipment and
safety work practices
 Prepared and submitted inventory report, where applicable
 Maintained workplace in accordance with OHS regulations
 Stored tools and equipment safely in appropriate locations and in
accordance with company practices
Underpinning Demonstrate knowledge of:
Knowledge and  Programmed maintenance and safety check procedures for the
Attitude specified machine/equipment
 Common defects of machines/equipment and hand tools
 Hand tools maintenance procedures
 Recording/reporting requirements
 Types and uses of lubricants and cleaning materials
 Types and uses of measuring instruments
 Safe work practices and procedures
 Hazards and control measures associated with operational
maintenance of machines/equipment
 Good housekeeping
Underpinning Demonstrate skills of:
Skills  Undertaking programmed safety and maintenance checks
 Undertaking programmed operational maintenance
 Entering routine and familiar information onto proformas and
standard workplace forms
 Maintaining hand tools
 Following routine information on written procedures
 Following oral instructions
 Orally reporting routine information
Resource Access is required to real or appropriately simulated situations,
Implications including work areas, materials and equipment, and to information on
workplace practices and OHS practices.
Methods of Competence may be assessed through:
Assessment  Interview/Written Test
  Observation/Demonstration with Oral Questioning
Context of Competence may be assessed in the work place or in a simulated work
Assessment place setting.
Occupational Standard: Foundry Works Level IV
Unit Title Supervise the Manufacturing of Patterns and Models
Unit Code MIN FDW4 05 0323
Unit Descriptor This unit covers competence required supervising the lay - out and
manufacturing of advanced patterns and models. It includes flow models,
viewing models, prototype and development models, and applying a wide
range of model materials e.g. timber, metal plastic, fiberglass composites
and processes.
Elements Performance Criteria
1. Determine and 1.1. Drawings, instructions and specifications are interpreted and
prepare work understood according to standards
1.2. Appropriate material is selected and prepared to meet specifications
1.3. Finished model design is conceptualized and planned with reference
to customer's specifications applying standardized operational
processes
1.4. Contractions allowances, clearances, tapers are calculated to establish
model parameters according to standards
1.5. Datum boards, jigs and fixtures are designed and manufactured due to
requirements
2. Manufacture 2.1. Sequence of manufacture is determined according to machine
model processes
2.2. Appropriate machines and machining processes are selected to
shape/produce model to specifications.
2.3. Suitable hand and hand held power tools are used by ensuring the
required finish according to specifications,
2.4. Where necessary, all deviations or modifications to original tooling
design, prints or plans, are recorded and reported consistent with
standard operating procedures
3. Assure quality 3.1. Adequate advanced measurement/ calculations are undertaken to
model check final specifications
3.2. If possible a 3D scanning is performed for documentation
compliant with organizational regulations
 Variables Range
Material May include, but not limited to:
 Timber
 Metal
 Plastic
 Fiberglass and composites etc.
Processes May include, but not limited to:
 High volume foundry tooling
 Injection moulding
 Pressure die casting etc.

Evidence Guide
Critical Aspects of Assessment requires evidence that the candidate:
Competence  Determine and prepare work
 Manufacture model
 Quality assure model
Underpinning Demonstrate knowledge of:
Knowledge and  Consequences of selecting inappropriate materials
Attitudes  Various processes requiring models
 Calculus, engineering calculations and formulae relating to
developing and manufacturing precision models
 Properties and uses of datum boards, datum holes or datum faces
 Reasons for developing the sequence of manufacture
 The range of machines and machining processes and their
operations
 The various checking procedures and devices including coordinate
measuring and machine checking
 Procedures for recording deviation or modification to original
drawings or specifications
 Hazards and control measures associated with developing and
manufacturing precision models
 Safe work practices and procedures
Underpinning Demonstrate skills of:
Skills  Reading, interpreting and following information on written work
 instructions, specifications, standard operating procedures, charts,
lists, drawings and other applicable reference documents
 Selecting appropriate materials
 Conceptualizing and determining type of model required to meet
specifications
 Performing calculations necessary for manufacture
 Developing and manufacturing datum boards, datum holes or
datum faces, jigs and fixtures etc. Required for accurate
manufacture
 Developing a planned sequence of manufacture
 Identifying areas required to be accurately manufactured by
NC/CNC
 Selecting and operating the appropriate range of machines and
machining processes for manufacturing the model accurately to
size, tolerance and specifications
 using required hand and hand held power tools
 measuring components to specified tolerances inclusive 3D
scanning
 carrying out checking procedures for checking to the
predetermined accuracy and fine tolerances
 recording and orally reporting routine information
Resource Access is required to real or appropriately simulated situations,
Implications including work areas, materials and equipment, and to information
on workplace practices and OHS practices
Methods of Competence may be assessed through:
Assessment  Interview / Written Test
 Observation / Demonstration with Oral Questioning

Context of Competence may be assessed in the work place or in a simulated

Assessment work place setting

Occupational Standard: Foundry Works Level IV

Unit Title Supervise and CIM production Operations
Unit Code MIN FDW4 06 0323
Unit Descriptor This unit covers the competency required of supervising and guiding production
operations including control of machine and processes and the capture of
manufacturing data through conventional or Computer-integrated
Manufacturing (CIM) processes.
Elements Performance Criteria
1. Interpret the design 1.1. Required features and extent of integration of the CIM system are
brief established in consultation with the client based on applicable operational
regulations
1.2. Technical, commercial and environmental parameters are established to the
scope of work in accordance with organizational procedures
1.3. Technical managers and senior design engineers are consulted in
determining a production process in compliance with engineering
standards
1.4. OHS, regulatory requirements and enterprise procedures relevant to scope
of work are considered.
1.5. Preliminary advice on feasibility of manual or possible CIM project are
collected and presented to client based on engineering environment.
2. Prepare production 2.1. Investigations and measurements are performed based on scope of work
process and operational standards
2.2. Required modelling and calculations are carried out using appropriate
software and validation techniques according to production specifications
2.3. A range of conventional and CIM manufacturing solutions are generated
using appropriate innovative and creative engineering specifications
2.4. Feasibility and evaluate solutions are checked against design criteria
ensuring conformity to standards and codes, technical, economic and OHS
requirements
2.5. Social and sustainability implications of solutions are determined
according to organizational specifications
2.6. Concept proposals is reviewed with client and identify preferred solution
according to operational procedures
3.Perform supervision of 3.1. Conventional manufacturing processes are planned in comparison to
conventional CIM design based on results of external feasibility study and organizational
 requirements
3.2. Documentation, drawings, specifications and instructions are provided in
accordance with industry standards
3.3. Client and stakeholders are consulted in accordance with company
procedures
3.4. Approved drafted production process is prepared for implementation
according to operational requirements and standards
Variable Range
Appropriate software and May include, but not limited to:
validation techniques  Comparison of traditional solutions for simple design problems with
software solutions to the same design problems
 Review of previously implemented design challenges which were
completed using the software.
Conventional May include, but not limited to:
manufacturing Limited use of ICT’s and the conventional part
 Analysis
 Planning
 Purchasing
 Materials handling and management
 Providing direct control
 Supervision of operations.
CIM manufacturing May include, but not limited to:
Using ICTs ’to control the entire production process. It may include:
 Computer-aided Design/Computer-aided Manufacturing (CAD/CAM)
 Computer-aided Process Planning (CAPP)
 Computer Numerical Control (CNC) machine tools
 Direct Numerical Control (DNC) machine tools
 Flexible Machining Systems (FMS)
 Automated Storage and Retrieval Systems (ASRS)
 Automated Guided Vehicles (AGV)
 use of robotics and automated conveyance
 computerised scheduling
 production and inventory control
  a business system integrated by a common database
OHS, regulatory May include, but not limited to:
requirements  OHS Acts and regulations
 Relevant standards
 Industry codes of practice
 Risk assessments
 Registration requirements
 Safe work practices
 Minimising ecological and environmental footprint of process, plant and
product
 Maximising economic benefit of process plant and product to the
organisation and the community
Evidence Guide
Critical Aspects of Must demonstrate knowledge and skills to:
Competence  Interpret features of plant and equipment and parameters to the brief or
contract
 Advise client based on discipline knowledge and OHS and regulatory
standards
 Research sustainability implications and current industrial design
techniques
 Determine OHS, regulatory and risk management requirements
 Investigate and measure
 Model and calculate using appropriate software and validation techniques
 Generate and evaluate a range of solutions for feasibility against design
criteria
 Sketch a conventional and CIM system solution
 Communicate, negotiate and review with stakeholders and client throughout
process to obtain agreement on proposal and sign-off on design
 Document design with drawings, specifications and instructions.
Underpinning Knowledge Demonstrate knowledge of:
and Attitudes  Current CIM design knowledge, skills and techniques, including
mechanical, electrical, fluid, electronic and information technologies,
sensor/transducers, controllers, interfacing and signal conditioning,
networking, software, data sharing and control functions
  Techniques for:
 continuous improvement
 problem solving and decision making
 Root Cause Analysis (RCA) or Failure Mode and Effects Analysis (FMEA)
or Design Review Based on Failure Mode (DRBFM), and Pareto analysis
 Features and capability of plant, equipment, controllers, software, network
and communication systems
 OHS and regulatory requirements, codes of practice, standards, risk
management and registration requirements
 Contemporary engineering design methods
 Software options for control and data sharing
 Hardware options and capabilities to suit processes and products
 Documentation, drawings, specifications, instructions required, process
information and programming
Underpinning Skills Demonstrate skills in:
 Determining features of CIM system, including OHS, regulatory and risk
management requirements
 Interpreting parameters to the brief or contract
 Investigating and presenting options
 Investigating faults in existing designs and arriving at solutions
 Selecting and using software and validation techniques
 Creating design solutions to match client expectations of innovation as well
as fitness for purpose
 Supervising services, maintainability, cost, manufacturability and assembly,
and ease of operation
 Evaluating solutions for feasibility against design criteria, including
relevant engineering and financial calculations and analysis
 Communicating, negotiating and reviewing with stakeholders and client
throughout process to obtain agreement on proposal and sign-off on design
 Documenting design with drawings, specifications and instructions
Resources Implication Access is required to real or appropriately simulated situations, including work
areas, materials and equipment, and to information on workplace practices and
OHS practices.
Methods of Assessment Competence may be accessed through:
 Interview/Written test
 Observation/Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the workplace or in a simulated workplace
setting.

Occupational Standard: Foundry Works Level IV

Unit Title Supervise Ferrous and Non-ferrous Melting and Casting Operations
Unit Code MIN FDW4 07 0323
Unit This unit of competency covers the skills and knowledge required to
Descriptor technically supervise an individual ferrous and non-ferrous melting and
casting operation in a foundry to ensure specifications are met and safety
 procedures maintained

Elements Performance Criteria

1. Identify 1.1. Required material specification are identified based on mold
specificatio requirements
ns for 1.2. Any special melting and casting requirements for the job are
required specified
casting 1.3. Safety procedures for the required melting and casting operation
are recognized
1.4. Identify Regulations and codes of practice relevant to foundry and
individual melting, pouring and casting operation are followed.
2. Assure 2.1. Hazards in the metal melting/pouring process are identified
hazard 2.2. Risks arising from those hazards are assessed
control 2.3. Controlling mechanisms in hazards in line with safety procedures and
means duty of care are implemented.
3. Verify 3.1. Required components to give the required metal specification are
metal Selected
charges to 3.2. The charge amount of each component and recommend
melting charges/additives to the charge are calculated
3.3. Preparation of the charge including checking for contaminants is
monitored.
4. Monitor 4.1. Hazards in the metal melting/pouring process are identified and
pouring of checked in accordance with operational regulations
molten 4.2. Pouring area is secured and all non-essential personnel are excluded
metal due to operational regulations
4.3. Ensure escape routes are known by crew involved and visually
marked due to safety and hazard regulations
4.4. Check emergency pour out pit is made operational and other safety
measures are in place based on safety requirements
4.5. Ensure molds are made ready to receive liquid metal, and spaces are
appropriate between each mould in accordance with operational
requirements
4.6. Check pouring is undertaken at correct temperature and in efficient
order based on operational standards
 4.7. If required heat treatment for engineering non-ferrous and ferrous
material is applied in compliance with the standards
4.8. Basic properties and characteristics of Non-ferrous metals are
understood.
5. Assure 5.1. Required samples are transmitted for analysis and tests in
quality accordance with organizational quality standards
casting 5.2. Casting report is documented against organizational regulations

Variables Range
Mold May include, but not limited to:
 Sand
 Die and investment moulds
Material May include, but not limited to:
 Non-ferrous metals:
- Aluminum
- Tin
- Magnesium
- Nickel
- Titanium
- Beryllium
- Lead
 Non-ferrous alloys:
- Aluminum alloys
- Brasses, Bronzes
- Copper alloys
- Nickel alloys
- Magnesium alloys
- Zinc-Tin alloys
Non- ferrous May include, but not limited to: physical and mechanical
properties of all the bellow alloys
 Non- ferrous metals, Introduction to metals --Aluminum
-Copper
-Zinc
-Lead
-Tin
-Nickel and magnesium and their alloys;.
Ferrous Physical and mechanical properties viz.
 Strength
 Elasticity
 Ductility
 Toughness
 Malleability
 Brittleness
 Hardness
 Stiffness
 Fatigue
  Classification of iron and steel;
- pig iron
- cast iron
- wrought iron
- steel
- alloy steel
- Stainless steel and carbon steels.

Evidence Guide
Critical Aspects of Demonstrates skills and knowledge to:
Competence  Supervise the safe operation of a melting furnace for non-
ferrous metals
 Supervise casting operation and equipment for non-ferrous
metals handled by utilized personnel
Underpinning Demonstrate knowledge of:
Knowledge and  Charge calculations:
Attitudes  Non-ferrous metals and alloys with the focus on casting
processes
 Types of furnaces and their relative advantages and
disadvantages for non-ferrous metals melt:
 Selection of appropriate refractories for non-ferrous metals
melting:
 Selection of the form of linings for non-ferrous melts
 Selection of the appropriate ladles/crucibles
 Supervision of other staff in melting and casting safety
 Furnace operation
 Use of lifting and handling equipment
 Types of test and control equipment
 Quality control and procedures
 Types of defects and prevention
 Tapping and pouring operations
 Importance of composition control methods used to calculate
for additions.
 Types of alloy additions and their effects on casting behavior
and finished product induction furnace melting, principles,
refractories suitable for steelmaking and their characteristics.
  arc furnace melting; acid, basic, single slag, double slag,
deoxidization and hydrogen control
 Ladle refining
 Cast iron:
 Types of cast iron
 Influence of carbon and silicon contents
 Carbon equivalent and effect of cooling rate
 Microstructure and classification of graphite
Underpinning Skills Demonstrate skills of:
 Applying appropriate calculations to determine charges
 Checking visually furnaces for operational condition and safety
risks
 Supervising and leading personnel
 Taking samples
 Applying safety and quality procedures
 Applying quality assurance standards
Resource Implications Access is required to real or appropriately simulated situations,
including work areas, materials and equipment, and to
information on workplace practices and OHS practices.
Methods of Competence may be assessed through:
Assessment  Interview / Written Test
 Observation / Demonstration with Oral Questioning
Context of Assessment Competence may be assessed in the work place or in a simulated
work place setting.

Occupational Standard: Foundry Works Level IV

Unit Title Manage Product Cost Estimation and Bill of Materials
Unit Code MIN FDW4 08 0323
Unit This unit covers the competency required to manage the estimated
Descriptor manufacturing cost of products or projects and needed bill of materials.

Elements Performance Criteria

1. Plan and 1.1. The work to be performed and managed is identified and clarified
prepare for
according to work requirements and/or tender
work
1.2. Essential time scheduling , sequences of work and labor are prepared
based on available resources and specifications

1.3. Format (take off sheet) and materials bill of quantities are prepared based
on technical specifications

1.4. Cost centers of all required resources in all respect of fields are determined
according to operational specifications

1.5. Information regarding remarks is supplied due to operational procedures

2. Develop 2.1. Appropriate labor rates and material costs are selected and applied based on
estimated
operational specifications
product /
2.2. Estimates of unit costs, as appropriate, are determined and applied based
project costs
on company reference data

2.3. Costs to the project of work cover, environmental protection agency

requirements, seeking approvals, waste management fees and other
statutory or additional costs are identified and applied due to requirements

2.4. Overhead recovery and margins are applied according to company policy

2.5. Completed estimated project costs for inclusion in tender or bill are
calculated based on organizational computer supported cost calculation
formats
3.Measure and
3.1. Measurements are quantified item by item according to technical
check correct
specifications
quantities of
work 3.2. Computation of the work to prepare the bill of quantities is done based on
company policies

3.3. Incorrect data and size of parameters are checked as per accepted
standards

3.4. Corrections and adjustment are made within standard formats

3.5. Bill of quantities is finalized and documented based on organizational

requirements
4.Maintain
4.1. The administration system through which resources are procured and
administrative
acquired is monitored for its effectiveness due to organizational regulations
control over
resource 4.2. Financial responsibility is exercised over the procurement and acquisition
acquisition system and its maintenance based on the cooperate procedures

process 4.3. Procurement reports are evaluated in preparation for management team
meetings due to requirements

4.4. Regular meetings are facilitated and conducted between team members and
the client to report on progress based on organizational regulations
5.Supervise the 5.1. A system for the effective supply and withdrawal of resources is
provision established and maintained based on company procedures
and
5.2. Strategic information on the usage and movement of resources within the
withdrawal
production area is managed and monitored based on company regulations
of resources
5.3. Communications principles and policies between on-site personnel and
providers of physical resources are established and maintained according to
policies

5.4. Feedback from the operators and production staff is obtained and
monitored at commencement, during and on completion of the project
based on organizational guidelines
6. Assure 6.1. Completed estimated production or project costs for inclusion in a tender or
quality and bill are verified in compliance with a computer supported cost calculation
verify all format
data 6.2. Actual costs are compared with estimated cost to identify deviations
according to operational regulations and standards

6.3. Deviations are motivated or rectified according to established organizational

framework, procedures and routines.

6.4. Assistance/ approval from management is obtained based on company

policies
Variables Range
Bill of Is an itemized list of materials required in constructing / producing, maintaining
quantities or repairing a specific structure
Information May include, but not limited to:
 Estimate relates to a discrete product with a limited number of operations
 to manufacture
 Verbal or written and graphical instructions, work schedules,
plans/specifications, memos, maps, Material Safety Data Sheets (MSDS),
diagrams or sketches and graphics, reference data
 Regulatory /legislative requirements pertaining to operations and the
environment
 Relevant specifications and instructions
 Organization work specifications and requirements
 Instructions issued by authorized personnel
Project May include, but not limited to:
costs  Organizational and subcontract labor hours
 Project administration costs
 Overheads
 Consumable and production materials
 Cost of meeting statutory requirements
 Waste removal fees
 Utilities/resource consumption
 Communications costs
Evidence Guide
Critical Aspects The competence is observed through:
of Competence  Identifying the materials required for a product/project
 Gathering all information required to deliver the product/project
 Interpreting measurements and calculating quantities and costs
 Planning and allocating human resources
 Identifying and costing other related costs such as those required to meet
statutory and regulatory processes
 Producing documentation which meets the timeframe sand quality standards
established by the organization
 Communicating effectively, both verbally and in writing
Underpinning Demonstrate knowledge of
knowledge and  Computation inclusive data organization and systematic analysis
attitude  Technical specification reading
 Effective administration and monitoring of the procurement system and
processes
 Sequence of production operations
 Types, scope and usage of labor through the employee and subcontractor
 systems
 Operation and structure of organizational costing and contracting system
 Ethiopian standards relevant to the industry sector
 Government regulations/legislations and standards
Underpinning Demonstrate skills in:
skills  Technological applications to facilitate use of the organization’s software
and office technology including appropriate procurement and costing
software programs
 Carry out numerical operations, geometry and calculations /formulae within
the scope of this unit
 Extrapolate labor and materials costs from written information
 Read drawings and technical specifications
 Plan and sequence operations
 Overview the impact on cost estimates
 Using preform estimate sheets
Resource Access is required to real or appropriately simulated situations, including work
Implication areas, materials and equipment, and to information on workplace practices and
OHS practices.
Methods of Competence may be assessed through:
Assessment  Interview / Written Test
 Observation/Demonstration with Oral Questioning
Context of Competence may be assessed in the workplace or in a simulated workplace
Assessment setting.

Occupational Standard: Foundry Works Level IV

Unit Title Perform Process Planning and Scheduling
Unit Code MIN FDW4 09 0323
Unit Descriptor This unit covers the knowledge, skills and attitude required to determine
production sequence, identify production requirements and capacities, and
prepare production schedules of component / part. It includes the review of
 process specifications and continuous production improvements.
Elements Performance Criteria
1. Determine 1.1. Steps required for the process are identified and flow charts are produced
production where required in accordance with standard operating procedures
sequence 1.2. Material and parts lists are prepared manually or with CAD in accordance
with standard operating procedures
1.3. Tooling and/or equipment requirements are documented in accordance
with standard operating procedures.
1.4. Process steps are documented and clearly represented in accordance with
standard operating procedures.
2. Identify and 2.1. Engineering production data are identified and obtained in accordance
analyze with workplace procedures.
production 2.2. Inventory capacities and requirements are identified and obtained in
requirements accordance with workplace procedures.
and capacities 2.3. Procurement and supply requirements and constraints are analyzed and
carried out in accordance with workplace procedures.
2.4. Production capacity and constraints are analyzed and applied in
accordance with workplace procedures.
2.5. Standard times are identified and obtained in accordance with workplace
procedures.
2.6. Production requirements are obtained with the existing resources and
strategies are evolved to fit with it based on technical specifications
3. Prepare 3.1. Production meetings of component is scheduled in accordance with
schedule for production, inventory, procurements, time constraints, supply and labour
production of capacities according to operational requirements
a 3.2. Schedule is documented in accordance with accepted organization
component/pa procedures and quality management.
rt
4.Review process 4.1. Supporting engineering and production data are analyzed and reviewed
specifications where required according to organizational procedures
4.2. The new production processes to be used are determined applying
organizational guidelines
4.3. Specifications are obtained and examined in accordance with operational
procedures
5. Assure quality 5.1. Overall enterprise goals and quality assurance Operations in the
workplace workplace are assured
operations 5.2. Quality problems and issues are promptly identified and adjustments are
made accordingly to company regulations
5.3. Production management and systems are improved in consultation with
colleagues to enhance constantly efficiency and effectiveness based on
Kaizen
5.4. Input is provided to appropriate management regarding staffing needs
according to labour laws
5.5. Workplace challenges are promptly identified and addressed accordingly
to operational and customer service regulations
5.6. Follow up action is taken to monitor the effectiveness of solutions in the
workplace based on company policies and standards

Variable Range
Production May include, but not limited to:
 Work planned over a timeframe,
processes
 Available resources
 Company data

Production May include, but not limited to:

meetings  Performance evaluation
 Work inspection
 Maintenance and repair scheduling
 Register equipment maintenance
 Location of potential hazards
 Pre-tour safety meetings
 Assist with supervision of teams
Production May include, but not limited to:
management  Steps / activities
 Milestones
 Targets and kPI against which progress can be monitored
and evaluated

Evidence Guide
Critical Aspects of Assessment requires evidence that the candidate:
Competence  Determine production sequence
 Identified production requirements and capacities
 Prepared schedule for production of a component/part
 Reviewed process specifications
Underpinning Demonstrate knowledge of:
Knowledge and  Production processes outside and within the organization
Attitudes  Tooling and/or equipment requirements for workplace processes
 Safe workplace practices and procedures
 Scheduling techniques
 Production methods
 Inventory policies
 Procurement, supply requirements and constraints
 General staffing levels, capabilities and application of standard times
 Machine set-up, capability and application of standard times
 Enterprise safety requirements and directives
 Quality assurance requirements
Underpinning skills Demonstrate skills to:
 Determine schedules and resources
 Match personnel to tasks and roles
 Facilitate problem solving associated with process variations
 Analyze process parameters
 Monitor process requirements
 Communicate effectively within the workplace
 Document, assess and transfer information
 Read, interpret and follow information on work specifications,
standard operating procedures and work instructions and other
reference material
 Maintain accurate records
 Implement sequence of operations
 Clarify and check task-related information
 Carry-out work according to OHS practices
Resource Access is required to real or appropriately simulated situations, including
Implications work areas, materials and equipment, and to information on workplace
practices and OHS practices.
Method of Competence may be assessed through:
Assessment  Interview / Oral Questions / Written exam
  Observation/Demonstration with Oral Questioning
Context of Competence may be assessed in the workplace or in a simulated workplace
Assessment setting.