tion and changing trade patterns, the United States remains the world’s largest manufacturing economy and is gaining strength. A new threat is beginning to hinder


I


some of the growth. Recent estimates show 600,000 jobs are unfilled due to a lack of skilled applicants. Te industry is experiencing a shortage of workers that are qualified to fill the open jobs. Several factors contribute to the


shortage, including the net loss of manufacturing jobs and an educational system that places more emphasis on attending a four-year college than on promoting other options. Increasing automation and complexity in manu- facturing operations also means even interested workers may lack necessary job requirements. Te metalcasting industry is not


immune to these issues, it has been feeling the impact of a lack of required skills in the pool of applicants along with other manufacturing sectors.


Workforce Challenges: The Skills Gap


A survey of manufacturers con- ducted by Deloitte Consulting LLP


n recent decades, manufactur- ing has faced a number of challenges. Despite the impact of a shifting global economy, increasing offshore produc-


and the Manufacturing Institute found 67% of respondents indicated a moderate to severe shortage of avail- able, qualified workers to fill open jobs. Fifty-six percent anticipate the short- age to worsen in the next three to five years. Te survey also indicated 5% of manufacturing jobs remain unfilled due to a lack of qualified candidates, which translates to nearly 600,000 jobs at a time when U. S. unemployment totals more than 12 million (Fig. 1 and 2). Shortages are most prevalent


in skilled production jobs such as machinists, operators and technicians. Seventy-four percent of respondents indicated workforce shortages or skill deficiencies in production roles have a significant impact on their ability to expand operations or improve produc- tivity. Unfortunately, these jobs require the most training and are traditionally the hardest to find existing talent to fill. Te shortage of skilled workers is


the result of several factors building over several decades. Despite a resurgence of manufacturing, the industry has lost some four million jobs as work moved offshore, operations consolidated and automation improved efficiency.


The Metalcasting Situation Te metalcasting industry faces these


obstacles to attracting and training qualified workers. It has an additional


challenge, to overcome the common misconception of metalcasting as an unappealing work environment. Te metalcasting positions most in demand are CNC machinists, plant maintenance personnel and patternmakers. Needs vary by region and often


are dictated by plant location, local competition and the operation’s repu- tation in the community. For example, according to Joey Leonard, vice presi- dent of human resources for Waupaca Foundry, many children follow their parents’ footsteps into careers at Wau- paca Foundry, looking to the company for dependable and rewarding careers. Tis generational connection and the company’s standing within the com- munity make it easier to attract work- ers for operations in Waupaca, Wis., and Tell City, Ind. Yet when the company recently


restarted operations in Etowah, Tenn., it had difficulty finding 50 mainte- nance workers with skills suited to a start-up operation. Tese differences between the sites illustrate the chal- lenge to groom employees by having them work alongside experienced personnel versus starting from scratch.


Changing Skill Levels


Several metalcasting executives note that finding qualified workers to fill maintenance positions is complicated


Fig. 1. Shown are the Manufacturing Institute survey responses to the question, “For which employee segments have workforce shortages or skill deficiencies had a significant negative impact on your company’s ability to expand operations or improve productivity?”


April 2013 MODERN CASTING | 19


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