Sample Scheme of Work and
Lesson Plan
Engineering
OCR Level 2 Principal Learning in Engineering H810
Unit F554: Maintenance
This Support Material booklet is designed to accompany the OCR Diploma in Engineering
specification for teaching from September 2008.
© OCR 2009
Contents
Contents
2
Sample Scheme of Work: OCR Level 2 Principal Learning in Engineering H810 Unit
F554: Maintenance
3
Sample Lesson Plan: OCR Level 2 Principal Learning in Engineering H810 Unit
F554: Maintenance
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9
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 2 Principal Learning in Engineering H810 Unit F554:
Maintenance
Suggested
teaching time
30 hours
Topic outline
Topic
Maintenance
Suggested teaching and homework
activities
Suggested resources
Points to note
Unit overview: This unit is externally assessed and will take the form of two assignments.
Assignment 1: a two-part report which contains:
a) Documented evidence of the routine maintenance of an engineered product or system including reference to the tools, information and procedures
used the learner should provide supporting evidence in the form of photographic evidence and supporting learner comments of the procedures
undertaken, together with the use of tools and equipment;
b) A learner-produced maintenance plan detailing the procedures for maintaining an engineered product or system identified by the learner the plan
should detail maintenance procedures, tools and equipment required together with appropriate safety considerations.
Assignment 2: a two-part report which contains:
a) An evaluation of the reliability of an engineered component from a different engineered product or system to that which the learner maintained in
Assignment 1, using statistical methods to analyse the failure trends supporting evidence of the method of analysis must be included;
b) Identify an engineering product.
The unit provides learners with the opportunity to learn basic principles and techniques of Engineering maintenance whilst working safely, learners will
= Innovative teaching idea
Engineering Diploma
= ICT opportunity
3 of 10
Sample Diploma Scheme of Work
OCR Level 2 Principal Learning in Engineering H810 Unit F554:
Maintenance
Suggested
teaching time
30 hours
Topic
Maintenance
Suggested teaching and homework
Suggested resources
Points to note
activities
experience carrying out maintenance and diagnostic procedures using manufacturers' information and data sheets.
Topic outline
Learners will also have the opportunity to learn about the methods used to analyse failure trends and develop knowledge and understanding of the
implications if products or equipment are not properly maintained.
There are many opportunities for learners to demonstrate their PLT’s capabilities in this unit.
Learners will be able to:
Use appropriate tools and
equipment safely

small group teaching lesson

old damaged/worn mountain bike

identify one safety issue with class and
show how to fill in worksheet with hazards,
potential risk and remedial action

modify to achieve the following:

and effectively
(Health and Safety
= Innovative teaching idea
4 of 10
worn brake pads
Learners in groups identify all potential risks
and discuss in whole class
loose ripped seat

Learners in groups to describe risk and
recommend remedial action
worn/flat tyre

class activity to discuss findings and
prioritise them
frayed exposed brake cable remove chain
guard

groups to produce a maintenance
schedule/manual
remove reflectors etc…
Issues with products)
1 hour
no hand grips
worn crank bearing


presenters may need to visit presenters
local recycling centre to get a suitable
mountain bikes

depending on group size presenters might
need several bikes

presenters may have to lead the learners
into identifying pinch points, bruise hazards
etc…

pre-population of a file with suitable
drawings of a mountain bikes
pre-populated worksheet risk assessment
= ICT opportunity
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 2 Principal Learning in Engineering H810 Unit F554:
Maintenance
Suggested
teaching time
30 hours
Topic outline
Topic
Maintenance
Suggested teaching and homework
activities
Use manuals, manufacturers’
information and

data to inform the correct
procedure for the
introduce the class to different types, styles
and formats of the various handbooks and
manuals

role play activity with a student describing to
another how to access, inspect and
diagnose a fault on a washing machine
routine maintenance of an
engineered
product or system
(Introduction to maintenance
manuals)
2 hours

using fault finding flow diagram Learners to
access, inspect and diagnose a fault

group discussion on activity

Learners to be demonstrated the following
on the visit:
inspection of cycle, use of maintenance
manuals, diagnosis of faults/wear, form
filling, parts acquisition
Suggested resources

computer workstation and suitable software

maintenance manuals for a range of
products and systems such as:
Points to note

these should be both customer handbooks
and service engineers maintenance
manuals

washing machines will have to be preprepared with a fault such as broken fan belt
washing machine, central
heating system, motor cycles,
fire safety equipment and
systems, burglar alarms

washing machine per group


local motor cycle dealership willing to
accept a visit
this task could be moved after the visit
lesson

some companies might restrict numbers so
more than one visit might have to be
arranged

pre-visit the dealership to discuss
requirements

clip board per student

worksheet with questions and blanks for
responses
Visit to motor cycle dealership
1 hour
= Innovative teaching idea
Engineering Diploma
= ICT opportunity
5 of 10
Sample Diploma Scheme of Work
OCR Level 2 Principal Learning in Engineering H810 Unit F554:
Maintenance
Suggested
teaching time
30 hours
Topic
Maintenance
Suggested teaching and homework
activities
Suggested resources
Points to note
Devise a maintenance
procedure for an


motor scooters


engineered product or system
Test the
following the visit to motor cycle dealership
Learners to produce a monthly maintenance
guide/manual for a motor scooter
handbooks and maintenance manuals for a
variety of products
presenters may need to direct the Learners
to sites with pictures diagrams of motor
scooters

Learners to undertake the tasks and
photograph actions

computer workstation and suitable software

procedure, make any
necessary modifications

Learners to produce a monthly maintenance
guide with annotated instructions

digital camera
encourage the Learners to make the check
list/handbook as visual as possible

encourage the Learners to demonstrate and
photograph the procedures

domestic goods engineer will give a
talk/demonstration on the following:

a set of washing machines


set of service and maintenance manuals
pre – determine with engineer what
presenters requirements are
using manuals to service an appliance,
using manuals to fault find an appliance,
tools and equipment used, safety
procedures and the use of test equipment

set of damaged worn components such as:


seals, motors and bearings…
It might be beneficial to copy the relevant
parts from the manuals to avoid confusion
Topic outline
and re-test
(Produce a monthly motor
scooter check list)
3 hours
Visit by domestic
goods engineer
1 hour
= Innovative teaching idea
6 of 10
= ICT opportunity
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 2 Principal Learning in Engineering H810 Unit F554:
Maintenance
Suggested
teaching time
30 hours
Topic outline
Carry out routine maintenance
operations
and/or diagnostic routines on
an engineered
product or system
(Assembling and dissembling
a washing machine)
3 hours
Research and investigate the
implications and impact for
both the user and
manufacturer if routine
maintenance procedures are
not followed Act on any
= Innovative teaching idea
Engineering Diploma
Topic
Maintenance
Suggested teaching and homework
activities
Suggested resources
Points to note

dissembling a washing machine using
service manual

set of washing machines


set of service and maintenance manuals
a visit to a local recycling centre to obtain a
washing machines

inspect using service manual

tools and equipment per workstation


fill in appropriate forms
a local domestic goods outlet might be able
to help

change motor


clean and service waste system

remove drum inspect and
Careful consideration of the health and
safety implications of letting the Learners
“live test” their washing machines after reassembly should be made

re-assemble

other activities could be added/substituted

replace drum seal


keep maintenance records
presenters may need to reset a local
recycling centre to obtain washing machines

Learners carry out a reliability study of an
engineered product

set of worn components for the Learners to
use such as:


Learners to use statistical methods to
analyse failure trends

set of statistics
presenters local washing machine supplies
could help with the supply of washing
machine

Learners should show by means of
calculations:
computer workstation with suitable
presentation software


presenters may need to source statistical
information from parts manufacturers as
retail outlets and repair centres are unlikely
to have this data
= ICT opportunity
7 of 10
Sample Diploma Scheme of Work
OCR Level 2 Principal Learning in Engineering H810 Unit F554:
Maintenance
Suggested
teaching time
30 hours
Topic
Maintenance
Topic outline
Suggested teaching and homework
activities
information gained

mean time to failure (MTTF)

mean time to repair (MTTR)
(Reliability Study of
components)

mean time between failure (MTBF)

Learners to produce a report that contains
an evaluation of the failure trends of
component and explain the implications of
this to the user and manufacturer
Parts and component
identification of a mobility
scooters

inductive teaching lesson as specimen
lesson plan
Suggested resources

as specimen lesson plan
Points to note

some centres have produced their own set
statistics and this is acceptable

this task is designed to prepare the
Learners for the model assignment
1 hour
= Innovative teaching idea
8 of 10
= ICT opportunity
Engineering Diploma
Sample Diploma Lesson Plan
OCR Level 2 Principal Learning in
Engineering H810 Unit F554: Maintenance
OCR recognises that the teaching of this qualification above will vary greatly from school to school
and from teacher to teacher. With that in mind this lesson plan is offered, as a possible approach
but will be subject to modifications by the individual teacher.
Lesson length is assumed to be one hour.
Learning Objectives for the Lesson
Objective 1
Learners can identify the main parts of a mobility scooter.
Objective 2
Learners can identify the main mechanical components of a mobility scooter.
Objective 3
Learners can identify what materials the parts and components are made from.
Recap of Previous Experience and Prior Knowledge
Resources
Pack of labels of parts components and materials of mobility scooter.
(Inductive
teaching
pack)
A3, laminated pictures of a mobility scooter – 1 per group
A2 picture of mobility scooter on whiteboard or actual mobility scooter
Set of individual mechanical components.
No previous experience is needed for this lesson.
Content
Time
4 minutes
6 minutes
5 minutes
5 minutes
6 minutes
6 minutes
6 minutes
6 minutes
Content
Put the Learners into mixed gender and ability groups of 3 or 4 Learners and
direct them to a table with worksheets and direct them to a table with worksheets
and access to a mobility scooter – appoint a group leader.
Describe the task explaining how they are to identify what parts, components
and materials are to be found on a mobility scooter Explain the difference
between a part and a mechanical component.
Group Activity – The Learners are to split the pack of labels into the three
categories parts, mechanical components and materials.
Class discussion – the Learners are to discuss their results and correct their
categories where necessary.
Group Activity – Learners are to identify the parts of mobility scooter by placing
the labels next to the mobility scooter.
Class Discussion – class discuss their findings and correct results written on
white board and/or placed on mobility scooter.
Group Activity – Learners are to identify the components of a mobility scooter by
placing the labels next to the item on the mobility scooter.
Class discussion – class to discuss their findings and correct results written on
the white board and/or placed on mobility scooter.
Engineering Diploma
9 of 10
Sample Diploma Lesson Plan
Time
6 minutes
where
necessary
Content
Individual Activity – Learners are to write the correct results onto their worksheet
and identify what materials the parts and components are made of.
Consolidation
Time
10 minutes
10 of 10
Content
Class discussion – go through the list of mechanical components and discuss
with the class how they are maintained.
Components/systems could include: Brakes, bearings, sprocket and chain,
grease, nipple, various clamping devices, electric motor, switching, 12v system.
Engineering Diploma