Sample Schemes of Work and
Lesson Plans
Engineering
OCR Level 3 Principal Learning in Engineering H811
Unit F561: Production and manufacturing
This Support Material booklet is designed to accompany the OCR Engineering Diploma
specification for teaching from September 2008.
© OCR 2009
Contents
Contents
2
Overview: OCR Level 3 Principal Learning in Engineering H811 Unit F561:
Production and manufacturing
3
Sample Scheme of Work: OCR Level 3 Principal Learning In Engineering H811 Unit
F561: Production And manufacturing
4
Sample Lesson Plan: OCR Level 3 Principal Learning in Engineering H811 Unit
F561: Production and Manufacturing
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Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F561:
Production and manufacturing
Unit size 60 GLH
Unit level Level 3
Unit overview: This unit is assessed by the undertaking a case study and evidenced in the form of a report covering the following aspects of a
production plan for the manufacture of an engineering product:
 Research and investigation of different types of manufacturing processes and systems

Identification of the application of CAE, CAM and CNC within a manufacturing system

Selection an appropriate manufacturing system for further study

Investigation and research of assembly systems and techniques, quality control and quality assurance requirements and statistical process
control

Production a production plan taking into account the above considerations.
The learners will have the opportunity to look at and study the different types and methods employed for engineering production and
manufacturing.
The learners will investigate different manufacturing systems and will develop a knowledge and understanding of different types of manufacturing
processes, assembly systems and finishing techniques. These will include, for example, prototyping, mass production, lean manufacturing, flexible
manufacturing and just in time (JIT) systems.
The learners will apply their understanding of manufacturing and production systems to develop a production plan, taking into consideration all the
influencing factors, including implications of quality control and quality assurance.
The unit outcome will take the form of a case study based upon an appropriate context.
= Innovative teaching idea
Engineering Diploma
= ICT opportunity
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Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F561:
Production and manufacturing
Suggested
teaching time
20 hours
Topic outline
Research and investigate
different types of
manufacturing processes and
systems
Topic
Investigating processes and quality
Suggested teaching and homework
activities
Suggested resources
Points to note

Group exercise on the differences between
manufacturing processes and
manufacturing systems.


For homework learners research a range of
manufacturers and systems and processes
used. During this research learners highlight
the use of computers in the systems and
processes.

(ii) Manufacturing Advisory Service with
specific resources on Manufacturing
Processes

Employer engagement and learning visits
can be incorporated in this research.



Identify the application of
= Innovative teaching idea
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
The learners produce a matrix showing
processes, systems and computer
techniques, the contexts in which they are
used, advantages and limitations.
Using the research learners create a flow
chart showing how a specific manufacturer
(i) Comprehensive list of manufacturing
processes from an American government
procurement site.
(iii) Free resource produced by the Open
University. This unit looks at technology and
section 3 focuses on manufacturing
processes in the context of innovation.
Including videos.

Manufacturing systems include:

one-off

batch

mass production

lean manufacture

flexible manufacturing

just in time systems
Types of rapid prototyping:

Selective laser sintering

Fused Deposition Modelling

Stereolithography

(iv) Free online CAD tutorial


Multi Jet Modelling
(v) CAD in Schools, educational resources,
including links to DCSF recommended
software.

Laminated Object Manufacture

Electron Beam Melting

3D Printing
= ICT opportunity
Engineering Diploma
Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F561:
Production and manufacturing
Suggested
teaching time
20 hours
Topic outline
Topic
Suggested teaching and homework
activities



Produce a production plan
taking into account the above
= Innovative teaching idea
Engineering Diploma
Suggested resources
uses computer technology in production.
CAE, CAM and CNC within a
manufacturing system (IE2)
(Eng)
Investigate and research
assembly systems and
techniques, quality control and
quality assurance
requirements and statistical
process control (IE3) (Maths)
Investigating processes and quality
A group discussion on ‘What is quality?”
including suggestions on how quality can be
managed.
The learners are introduced to a range of
approaches to quality management and
produce a league table of techniques,
justifying the position of each approach in
the league table.
Learners research the assembly systems
employed by a range of employers, detailing
the way quality is managed. Learners
critically compare the approach identified
Points to note

Link to Unit 557 Application of computers,
possibility of co-teaching this unit with 557.

CNC processes include:
milling

profile cutting

3 Axis machines

4 Axis machines, Turning

(vi) is a commercial company specialising in
assembly systems.

Quality Control,

(vii) is the Chartered Quality Institute with a
range of quality linked resources.

Quality Assurance

(viii) is the Lloyds Register Quality
Assurance site, containing factsheets and
podcasts relating to quality assurance.

Total Quality Management

Statistical Process Control

Opportunities for employer visits and
employer master classes to explore the
techniques used in action.

(ix) is a site selling production planning



Quality approaches include:
To maximise employer engagement the
learning objectives of units 557, 560, and
561 should be compared for opportunities of
synergy with the possibility of material for all
three units being covered in a combined
approach.
= ICT opportunity
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Sample Diploma Scheme of Work
OCR Level 3 Principal Learning in Engineering H811 Unit F561:
Production and manufacturing
Suggested
teaching time
20 hours
Topic outline
Topic
Suggested teaching and homework
activities
= Innovative teaching idea
6 of 9
Suggested resources
with the approaches in the league table.
considerations (EP3)
Use appropriate software to
produce a coherent project
plan and schedule for the
production of a specified
engineered product (EP3)
(ICT)
Investigating processes and quality
resources, containing descriptions of the
processes and further online resources.


Learners practice using a range of
production planning techniques.

Learners are given or select a product and
using the research undertaken, individually
produce a production plan for that product
using one of the planning techniques they
have practiced. The plan should detail and
justify the choices for: Manufacturing
Systems, Manufacturing Processes,
Assembly System, Computer integration,
Quality management.
Points to note
(x) is a site with a useful You Tube video
demonstrating how to use Excel to create a
Gantt Chart.
= ICT opportunity
Engineering Diploma
Sample Diploma Scheme of Work
REFERENCES
(i)
http://guidebook.dcma.mil/226/instructions_files/Important%20Manufacturing%20Process%20List.doc this is a document from a USA
procurement site, with a comprehensive list of manufacturing processes. There are no details of the processes but a very comprehensive list.
(ii)
http://www.mas.berr.gov.uk/ Manufacturing Advisory Service Site
(iii)
http://openlearn.open.ac.uk/course/view.php?id=3317 OpenLearn resource from the Open University
(iv)
http://www.cadtutor.net/ Online CAD tutorials
(v)
http://www.cadinschools.org/ Schools specific CAD resources, included in the Shape the Future Networks catalogue.
(vi)
http://www.assemblysystem.co.uk/ a commercial supplier of assembly systems
(vii)
http://www.thecqi.org/ The Chartered Quality Institute
(viii)
http://www.lrqa.co.uk/default.aspx Lloyds Quality Register Assurance
(ix)
http://www.productionplanning.com/index.asp Commercial Production Planning site
(x)
http://www.projectsmart.co.uk/creating-a-gantt-chart-using-excel.html You tube video
= Innovative teaching idea
Engineering Diploma
= ICT opportunity
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Sample Diploma Lesson Plan
OCR Level 3 Principal Learning in
Engineering H811 Unit F561: Production and
manufacturing
Quality
OCR recognises that the teaching of this qualification 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
Understand the concept of Quality in terms of fitness for purpose
Objective 2
Understand the relative merits and limitations of different approaches to quality
management
Objective 3
Be able to justify the choice of quality management
Recap of previous experience and prior knowledge

Learners have been introduced to the concepts of different manufacturing systems and
processes including the use of computers. These concepts are now developed to explore
how the quality of the finished product can be managed.
Content
Time
Content
5 minutes
Group activity - What do you understand by the term “Quality”?
20 minutes
Slide-show presentation: Quality Control, Quality Assurance, Total Quality
Management, Statistical Process Control. Presentation introduces the 4
approaches and presenter leads group through discussion on what each
approach means and the benefits and limitations.
10 minutes
Pod cast – using the resources from the Lloyds Quality Register Assurance,
group is introduced to pod casts and factsheets on Quality Assurance.
15 minutes
Group Activity – Asking the question, “Which approach to quality management
would you want to be used on the manufacture of the brakes of your car?” as a
prompt the group creates a hierarchy of approaches, including the requirements,
benefits and limitations of each approach.
Considerations include cost, complexity, waste, reliability and flexibility.
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Engineering Diploma
Sample Diploma Lesson Plan
Consolidation
Time
Content
10 minutes
Class discussion followed by Learning Log entry - what should a business
consider when choosing how to manage quality?
Homework
Using a manufacturing business that has been researched or visited as part of
the course, write a report with a section for each of the approaches to managing
quality suggesting what the approach would look like.
The report should conclude with a comparison with the actual system used by
the business.
Engineering Diploma
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