Sample Schemes of Work and
Lesson Plans
Engineering
OCR Level 3 Principal Learning in Engineering H811
Unit F560: Maintaining engineering systems
This Support Material booklet is designed to accompany the OCR Engineering Diploma
specification for teaching from September 2008.
© OCR 2009
Contents
Contents
2
Sample Scheme of Work: OCR Level 3 Principal Learning in Engineering H811 Unit
F560: Maintaining engineering systems
3
Sample Lesson Plan: OCR Level 3 Principal Learning in Engineering H811 Unit F560
Maintaining engineering systems
10
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Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F560:
Maintaining engineering systems
Unit size 30 GLH
Unit level Level 3
Unit overview: This unit will be assessed by the learner producing a series of detailed wall charts and accompanying research folder which
could be used to present a specific engineering maintenance system to an employer.
The evidence should include:

Diagrams, photographs and detailed explanations of an engineering system and its failure modes and the predictive methods that would be

used on the system

An accompanying research folder outlining the method of data collection and analysis

Spreadsheet analysis of the data structures and analysis of the applied formulae

Sequential and hierarchical flow charts showing the correlation between the maintenance plan and its effects

Costs benefits calculations with appropriate explanations of the procedure and justification

Evidence of undertaking a maintenance procedure.
This unit will enable the learners to understand about the maintenance of engineered systems.
Through this study the learners will develop an understanding of the importance of determining appropriate maintenance strategies on plant and
processes, and the effect that this has in terms of efficiency, cost, quality, sustainability of resources, impact on environment and corporate
image.
= Innovative teaching idea
Engineering Diploma
= ICT opportunity
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Sample Diploma Scheme of Work
This unit builds on the knowledge of Level 2 Unit F554 Maintenance.
This unit is about strategy and application and could equally well be applied to the study of products or systems.
= Innovative teaching idea
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= ICT opportunity
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F560:
Maintaining engineering systems
Suggested
teaching
time
10 hours
Topic
Maintenance schedules and activity
Topic outline
Suggested teaching and
homework activities
Suggested resources
Points to note
The learner can:

To the group, present the main
acronyms used in engineering
manufacturing. As a pop quiz in small
groups learners write out the terms in
full and define.

Actual data on reliability could be obtained from an
engaged employer.

The acronyms should include:

MTTF, MTTR, MTBF, SPC, RTF

Manufacturers have product data sheets with predicted
life details for some products.


http://www.gelighting.com/na/ is the link for GE Lighting
in North America, details of lighting can be obtained
here.
Present real data to group containing
this data. Debate the choices to be
made and justify final selection.

A specific WRL employer activity can be centred on
maintenance.
The key debating points will be on
preventative maintenance vs run to
failure. Cost, resources and implications
of each should be covered. Link back to
the Risk Assessment element of unit
F556.

The acronyms activity and initial work on
data handling should take one lesson,
with preparation for the strategies debate
to be carried out as homework.

One lesson should be used for the final
preparation and the carrying out of the
debate.

Research should be completed as
homework.
Apply statistical
mathematical methods to
production and
maintenance data.
Analyse data trends for a
complex engineering
system.
Determine appropriate
maintenance strategies to
include a risk assessment
for a system or product
(IE4, CT1) (Maths)


Group debate on maintenance
strategies.

Learners research the maintenance
activities of a complex system,
preferably the system of an engaged
= Innovative teaching idea
Engineering Diploma

Employer or college based equipment could be used for
the maintenance activity. Lawn mowers, mopeds, cars
or similar are suitable.

Employer maintenance schedules can provide a
valuable resource.

http://www.spinlife.com/spintips/details/k/ManualWheelchair-Maintenance/a/116/c/2 is a link detailing the
maintenance of a wheelchair.
= ICT opportunity
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Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F560:
Maintaining engineering systems
Suggested
teaching
time
10 hours
Topic outline
Carry out a maintenance
activity (SM3)
Topic
Suggested teaching and
homework activities

Suggested resources
Points to note
employer.

http://www.ehow.com/video_4426968_check-beltsriding-lawn-mower.html a site containing videos
demonstrating lawn mower maintenance.

Individuals use the previous activities
to create and justify a maintenance
schedule for a piece of equipment.

A camera and/or video camera would support the
recording of the practical activities.


Learners then individually carry out the
maintenance activity detailed.

Details of the schedule, the activity,
reflection on the activity and any
changes that would be made to the
schedule in light of the activity should
be recorded in the learner work book.
= Innovative teaching idea
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Maintenance schedules and activity
The remaining teaching time should be
taken up with employer activities and the
practical maintenance activities.

A range of maintenance strategies could
be presented and used as the basis of a
balloon debate.

The equipment selected for this activity
needs to be sufficiently complex to
provide stretch and challenge to the
learner.
= ICT opportunity
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F560:
Maintaining engineering systems
Suggested
teaching time
5 hours
Topic
System failure
Topic outline
Suggested teaching and
homework activities
Suggested resources
Points to note
The learner can:

A group activity to identify causes of
failure.



Using an established report into a
major failure, students identify as
many of the causes as possible and
create a Root Cause Analysis
diagram for the major failure.
Identify and explain the
various types of system
failure and their
consequences
Explain methods used to
predict systems failure
(Eng)



= Innovative teaching idea
Engineering Diploma
Explore the concept of Cost Benefit
Analysis that will be revisited later.
Learners will individually research a
range of failures and identify the
causes of the failure and the range
of consequences arising from the
failures.
The group will compile a combined
report of the causes and
Try a reversal technique, ask the learners to design a system
that will fail, leading to the identification of the causes listed in
the next box.

There are reports available on the internet that can be used
for this purpose.

http://www.railwaysarchive.co.uk/documents/HSE_Hatf_IntRep002.pdf

This is the link to the report into the Hatfield rail crash.

Library, internet and employer research can all be employed
here. Local disasters should be avoided as examples because
of the potential for personal involvement.

A list of exemplar methods is included in the next box.
Methods used by engaged employers, methods suggested in
maintenance manuals and promotional literature from
companies offering reliability monitoring are all suitable
resources to help research.

Cost, complexity and business interruption are all factors that
need to be considered in these methods. A matrix of methods
could be created by the learners to show these attributes.

Main causes of failure:

Maladjustment

Maloperation

Run to failure

Stress fracture, fatigue, wear,
embrittlement

Overloading, seizure

Anodic and chemical corrosion

Lubrication failure, fouling, vibration

Poor training

Consequences should include:

Financial, political, social, personal
and technological factors.
Methods of predicting failure:

Condition monitoring

Visual inspection
= ICT opportunity
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Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F560:
Maintaining engineering systems
Suggested
teaching time
5 hours
Topic outline
Topic
Suggested teaching and
homework activities

The learner can:

Evaluate the effects of
different approaches to
maintenance on
operational and strategic
efficiency (Eng)
= Innovative teaching idea
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System failure
Suggested resources
Points to note
consequences of failure.

Shock pulse metering
Learners will use the combined
report to determine possible
methods of predicting failure. For
each method they should identify a
real example and evaluate the cost
implications of the method.

Vibration analysis

Oil debris analysis

Electrical current monitoring

Tool wear

Infra-red thermography

Ultrasonic testing
Taking a given complex system,
learners will individually apply the
different approaches to
maintenance. For each scenario they
will evaluate the potential effects of
that scenario in terms of operational
efficiency and strategic impact. The
evaluation will include both the
methods of predicting failure and the
maintenance activity.

This activity will be most effective if the resource is provided
by an employer willing to back up the material with interactive
workshops.

http://www.stemnet.org.uk/home.cfm is a link to the STEMNET
website. STEMNET run the STEM Ambassadors scheme and
can provide assistance in resourcing this activity.

http://www.hse.gov.uk/risk/theory/alarpcba.htm is a link to the
HSE site explaining CBA, this is in the context of risk reduction
but the principles are the same. An internet search for CBA
Template will reveal a number of downloadable forms that can
be utilised.

When evaluating effects the learners
should explore:

operator safety

scrap and rework

poor product quality

lost production

difficulty in planning production

failure to deliver

loss of competitiveness
= ICT opportunity
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F560:
Maintaining engineering systems
Suggested
teaching time
5 hours
Topic outline
Carry out a cost benefits
analysis of a
maintenance
programme (Maths)
Topic
Suggested teaching and
homework activities
Suggested resources
Points to note

Learners will recommend and justify
an appropriate maintenance plan.

loss of business

corporate image

For the recommended plan, learners
will estimate the costs of
implementing the plan and the
benefits the plan delivers. Leading
to a cost benefit analysis of the
maintenance plan.

reduction of waste

energy savings

improved product reliability

= Innovative teaching idea
Engineering Diploma
System failure
Learners will use the maintenance
plan and cost benefit analysis to
create a proposal for implementing
the maintenance plan.

The issues for consideration in the CBA
include:

financial value of time

materials and equipment against
financial values of reduced costs and
increased business

correct stock level of spares
= ICT opportunity
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Sample Diploma Lesson Plan
OCR Level 3 Principal Learning in
Engineering H811 Unit F560 Maintaining
engineering systems
System Failure
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
Using real data from an accident investigation learners see the “real life context
“of systems failure
Objective 2
Learners are able to interpret and apply official reports.
Objective 3
Learners apply the concepts learned to a specified engineering system
Recap of Previous Experience and Prior Knowledge

Learners were introduced to Risk Assessment in unit F556 and are revisiting the concept of
severity in terms of consequences.

Learners should be presented with the case study in advance to study as home work. In this
case a simplified version of the full report is used containing Executive Summary,
Photographs and investigation data.
Content
Time
Content
Pre-work
Download an official report into an accident. This example uses the investigation
into the Hatfield Rail crash.
http://www.railwaysarchive.co.uk/eventsummary.php?eventID=143 is the website
where the full report and other media can be downloaded. The Executive
Summary and key data from the final report are used to create a case study
students study for home work before the lesson.
5 minutes
Group review of the case study.
20 minutes
Group activity Using the case study the group create a fault tree to highlight the
possible causes of the accident.
10 minutes
Group activity: compare the Fault Tree outcomes with the list of possible list of
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Engineering Diploma
Sample Diploma Lesson Plan
causes of failure (pre-prepared handout).
10 minutes
Group activity: identify all the consequences associated with the failure in the
case study
Consolidation
Time
Content
5 minutes
Teacher reads out a number of examples of engineering systems that this
analysis can be applied to and learners select the system they will study for
homework.
Class discussion followed by Learning Log entry – What are the similarities and
differences between the failure in the case study and an investigation in an
engineering system?
Learners research the engineering system they chose from the list and for that
system they create a Fault Tree, and create a risk assessment matrix based on
the fault tree, suggesting contingencies for the failures determined to have the
highest risk.
10 minutes
Homework
Engineering Diploma
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