A PROJECT APPROACH TO DELIVERY – JAGUAR LAND ROVER – HIGH PERFORMANCE FUEL FILTERVersion 1

Cambridge TECHNICALS LEVEL 3

ENGINEERING

ocr.org.uk/engineering

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

2

CONTENTS

Introduction 3

Jaguar Land Rover and OCR 5

About the modules and activities 6

Assessment of units 7

Delivering the project holistically 9

The Project Brief 0

MODULE 1 – Computers in manufacturing and producing prototypes 11

MODULE 2 – Making a pre-production fuel pump using computer numerical 13 control (CNC)

MODULE 3 – Planning for manufacture using lean and quality techniques 15

MODULE 4 – Inspection and testing 17

Other resources 19

Opportunities for holistic delivery of other units 20

Opportunities for meaningful employer engagement 21

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

33

INTRODUCTIONThe purpose of this guide is to give you an overview of how you could holistically deliver a range of units from Cambridge Technicals in Engineering Level 3 (Manufacturing pathway) though the delivery of a project.

When delivering any qualification it is always useful to be able to look at the full range of units selected and consider how they are or could be linked together – a holistic approach.

A holistic approach will provide you with a structured plan to teach the learners how a range of topics work together across a number of units, providing them with some understanding of how skills and knowledge link together in a working environment.

This project enables the delivery and facilitation of learning of the following units:

Unit 17 – Computer Aided Manufacturing (CAM)

Unit 18 – Lean and quality

Unit 19 – Inspection and testing

The intention is that the learners will be taught a range of knowledge and skills within each of the units and then carry out relevant review activities at various stages. Each of the review activities (once successfully completed by the learner) will provide all the required underpinning knowledge for their final assessment.

The practice review activities within the modules must not be used for Cambridge Technicals Engineering Level 3 final assessment purposes.

Model assignments for each of the Cambridge Technicals Engineering Level 3 units can be found at www.ocr.org.uk

It is assumed that the learners will be given the opportunity to carry out activities that will enable them to practice the skills they have learned within each module prior to being given final assessment activities.

When considering a holistic approach to delivery and learning it is important to consider the overall objectives. In this guide the objectives are to:

• Deliver all three units to achieve the Cambridge Technicals Engineering Level 3

• Structure a programme of learning and reviews which is exciting and engaging for learners

• Provide learners with an overview of how the knowledge and skills gained in one unit, support the knowledge and skills used within other units

• Provides the learners with an opportunity to consider how they would use their social and communication skills holistically within the working environment.

Please note that this Project Approach should not be used directly for assessment purposes. It is intended to support the teaching and learning of the units specified.

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

4

Unit LO

Unit 17 Computer Aided Manufacturing (CAM)

LO1 Understand how computers are used in manufacturing systems

LO2 Be able to produce CNC programs for the manufacture of components

LO3 Be able to set-up and operate a CNC machine to produce components

LO4 Be able to produce components using additive manufacturing techniques

Unit 18 Lean and quality

LO1 Understand lean manufacturing

LO2 Understand approaches used to ensure quality in manufacturing

LO3 Be able to apply lean manufacturing and approaches used to ensure quality

LO4 Be able to plan manufacturing production using lean and quality principles and approaches

Unit 19 Inspection and testing

LO1 Understand how inspection and testing methods and processes improve quality control

LO2 Understand how defects can occur in manufacturing materials, processes and components

LO3 Understand how destructive testing methods are used for quality assurance in manufacturing

LO4 Understand how non-destructive testing methods are used for quality assurance in a manufacturing environment

LO5 Understand automatic inspection and testing techniques which are used in manufacturing

THIS PROJECT APPROACH ENABLES THE DELIVERY AND FACILITATION OF LEARNING OF THE FOLLOWING UNITS:

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

5

JAGUAR LAND ROVER AND OCRJaguar Land Rover has ambitious plans for global growth which are supported by innovation in new products, engines and environmental technologies. The company is the UK’s leading investor in automotive research and development and is successfully delivering breakthroughs in engineering, performance and sustainability. However, it’s critical that we encourage more talented young people to become the next generation of engineers and technologists to address the skills shortage and sustain the business over the long term. This is why Jaguar Land Rover is committed to training over 500 apprentice and graduate trainees annually across engineering, manufacturing and business functions across the Company.

Jaguar Land Rover is delighted to partner OCR and support them in addressing the skills gap through this exciting project. The project provides students with an opportunity to engage in a series of learning tasks that facilitate vocational/applied learning and helps them to experience not only academic rigor but the technical ability needed for today’s roles. This Project for Manufacturing, gives students the chance of quality academic study combined with real world activity, a grounding which equips students earlier with skills, experience, and enthusiasm to join a workforce and make a real contribution.

Les RatcliffeHead of Community Relations Jaguar Land Rover

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

6

ABOUT THE MODULES AND ACTIVITIESFor the purpose of this guide the intention is for learners to undertake investigation and production tasks relevant to manufacturing. Learners will be able to develop and demonstrate these in the context of producing prototypes and pre-production versions of a high performance fuel filter including investigating how the fuel filter will be manufactured using lean and quality principles and appropriate inspection and testing techniques. The project approach has been developed in partnership with Jaguar Land Rover, and is supported by Jaguar Land Rover resources.

The guide is divided into four modules which may be sub-divided or combined according to the teaching time available.

The tables below show where each of the modules in this project provides delivery approaches and learning opportunities to ensure a thorough review of skills and understanding, prior to final assessment and evidencing by the learner.

Please note that should assessment be presented in a similar holistic way, learners must be able to present clearly mapped evidence for each of the centre-assessed units Unit 17, Unit 18, and/or Unit 19.

BY UNIT/LEARNING OUTCOME (LO)LO1 LO2 LO3 LO4 LO5

Unit 17 Module 1 Module 2 Module 1 Module 2

Unit 18 Module 2

Module 3

Module 2

Module 3 Module 3

Module 2

Module 3

Unit 19 Module 4 Module 4 Module 4 Module 4 Module 4

BY MODULEUnit LO

Module 1 Unit 17 LO1, LO3

Module 2 Unit 17 LO2, LO4

Unit 18 LO1, LO2, LO4

Module 3 Unit 18 LO1, LO2, LO3, LO4

Module 4 Unit 19 LO1, LO2, LO3, LO4, LO5

Where possible this Project Approach would benefit from practical activities, with the intention that learners produce a prototype and pre-production versions of the fuel filter. Learners could also use inspection and testing techniques to verify the accuracy and quality of their pre-production fuel filter.

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

7

ASSESSMENT OF UNITSThis project provides opportunities to produce additional and separate evidence to meet the assessment requirements of Unit 17, 18, and 19.

Unit no. Unit title How are they assessed?

Unit 17 Computer Aided Manufacturing (CAM) Assessed by you, moderated by OCR

Unit 18 Lean and quality Assessed by you, moderated by OCR

Unit 19 Inspection and testing Assessed by you, moderated by OCR

This project approach should be read in conjunction with the published grading criteria in each unit specification.

7

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

8

DELIVERING THE PROJECT HOLISTICALLYThis Project Approach provides a direct opportunity to deliver the following units in the Manufacturing pathway holistically:

Unit 17 – Computer Aided Manufacturing (CAM)

Unit 18 – Lean and quality

Unit 19 – Inspection and testing

It also provides opportunities to include further units into its synoptic delivery including, but not limited to:

Unit 1 – Mathematics for engineering

Unit 2 – Science for engineering

Unit 3 – Principles of mechanical engineering

Unit 10 – Computer Aided Design

Unit 11 – Materials science

Unit 22 – Engineering and the environment

Examples of how these further units might be related to this Project Approach are included in the Opportunities for holistic delivery of other units section .

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

9

THE PROJECT BRIEF

The learner version of the Project Brief is available from http://www.ocr.org.uk/qualifications/vocational-education-and-skills/cambridge-technicals-engineering-level-3-certificate-extended-certificate-foundation-diploma-diploma-05822-05825/

Jaguar Land Rover (JLR) is a world-leading designer and manufacturer of luxury cars and rugged all-terrain vehicles (see http://www.jaguarlandrover.com)

All JLR vehicles contain precision-made fuel filters to avoid damage to the engine and parts that could be caused by fuel contamination. If abrasive particles of dirt, sand and rust present in contaminated fuel come into contact with fuel injectors and surrounding components they can cause damage leading to a rise in emissions and reduction in power and fuel economy. The problem of contaminated fuel is particularly critical in some overseas countries.

To ensure the robustness of the fuel system in wider markets, and the ability of JLR vehicles to survive and thrive in the harshest environments sometimes requires the inclusion of an additional fuel filer to remove contaminants even at the microscopic level.

JLR is in the process of designing a new fuel filter for their vehicles. The design is shown below. The filter casing is made as a two-part injection moulded PA66 GF35 plastic enclosure which is friction welded together after the filter element has been inserted. It has relatively simple geometry with a central connecting point at one end and an offset connector at the other end. Critical parts of the geometry are the push-fit connectors at either end which are a close tolerance with a fine surface finish.

The design process requires prototypes and pre-production versions of the filter casing to

be manufactured for testing before the final filter design is committed to production. A pre-production version of the filter casing could be made using aluminium or other suitable material.

JLR outsource the final production of many of their components, and this part will be manufactured using injection moulding processes in India to strict quality standards. The filter casing is then friction welded closed once the filter element has been inserted. Filters are inspected and leak tested.

JLR require the production of prototype and pre-production versions of the fuel filter casing. They also require an investigation of how lean and quality principles could be used in the production of the fuel filter, and how inspection and testing techniques can be used to guarantee the quality of finished parts.

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

10

Your tasks are to:

• produce a prototype using additive manufacturing

• produce a pre-production version of the fuel filter casing using Computer Numerical Control (CNC) machining ready for testing

• investigate how the principles of lean and quality can be applied to production of the fuel filter casing

• investigate how inspection and testing techniques can be used to ensure the accuracy and quality of the fuel filter.

In order to do this, you will need to:

• investigate how computers are used in manufacturing systems

• produce a prototype fuel filter casing using additive manufacturing methods

• produce a prototype fuel filter casing using Computer Numerical Control (CNC) machining

• investigate how lean and quality principles can be applied to manufacture of the fuel filter

• produce a plan for manufacture which incorporates lean and quality principles

• investigate how inspection and testing methods can be used for the pre-production prototypes and production versions of the fuel filter casing

• investigate how defects could impact on the filter during manufacture and once in-service.

This work can be undertaken as an individual or within a team. If working within a team learners are expected to contribute to each of the areas (and be able to evidence this contribution) in order to gain the experience and knowledge required to successfully complete the Cambridge Technicals Engineering Level 3 (Manufacturing pathway).

10

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

11

COMPUTERS IN MANUFACTURING AND PRODUCING PROTOTYPES The delivery begins with Unit 17 (LO1 and LO4).

Before learners begin the manufacture of a pre-production version of the fuel filter casing using CNC machining and planning for manufacture using lean and quality techniques they must first have a good understanding of:

• the application of computers in manufacturing systems

• how to produce a prototype using additive manufacturing (rapid prototyping) techniques.

Contained within the following assessment criteria/LO(s)/units:

Learning Outcome LO number Unit number

Understand how computers are used in manufacturing systems

LO1 Unit 17

Be able to produce components using additive manufacturing techniques

LO4 Unit 17

During the delivery of the units, the learners should carry out a range of activities to demonstrate and check their knowledge and understanding. They should also undertake review activities as they work through the programme of learning.

MODULE 1

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

12

PRACTICE REVIEW ACTIVITIES FOR MODULE 1ACTIVITY 1Learners could begin by investigating the application of computers in manufacturing systems. This could include how they are used in additive and subtractive manufacturing processes and also their application in Computer Numerical Control (CNC) (see http://www.technologystudent.com/cam/cnccut1.html). They could explore the advantages of their use in manufacturing and how they are used in automation of the manufacturing process and in computer aided planning. The following document from the Royal Academy of Engineering explores the opportunities and constraints of additive manufacturing: http://www.raeng.org.uk/publications/reports/additive-manufacturing

Learners could relate their investigation to the production of prototypes, pre-production versions and final production of the fuel filter.

ACTIVITY 2Learners could be introduced to the function, purpose and location of a fuel filter in an engine the set the whole project into context. Service manuals available from the Jaguar Land Rover website could be useful in explaining this (https://topix.jaguar.jlrext.com/topix/vehicle/lookupForm)

Learners could use the models for the fuel filter casing and produce prototypes using appropriate additive manufacturing (rapid prototyping) techniques. The design could be modified, enhanced or broken down to accommodate the availability and capability of additive manufacturing facilities available. Critical elements of the design include the offset of the connector at one end, and also the accuracy with which the connectors are manufactured in order to accommodate push-fit fittings.

Learners could produce or modify the 3D geometry of the fuel filter casing, produce suitable data for production of the prototype and safely produce a physical prototype. The following gives an overview of different types of additive manufacturing techniques: http://3dprintingfromscratch.com/common/types-of-3d-printers-or-3d-printing-technologies-overview/

12

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

13

MODULE 2MAKING A PRE-PRODUCTION FUEL PUMP USING COMPUTER NUMERICAL CONTROL (CNC)The delivery then continues through Unit 17 (LO2, and LO3) supported by elements of Unit 19 (LO1, LO2, LO4).

Learners could apply the following to the manufacturing of a pre-production version of the fuel filter casing:

• producing CNC programs to manufacture components

• setting-up and operation of a CNC machines to produce components

• applying appropriate inspection and testing techniques.

Contained within the following assessment criteria/LO(s)/units:

Learning Outcome LO number Unit number

Be able to produce CNC programs for the manufacture of components

LO2 Unit 17

Be able to set-up and operate a CNC machine to produce components

LO3 Unit 17

Understand how inspection and testing methods and processes improve quality control

LO1 Unit 19

Understand how defects can occur in manufacturing, materials, processes and components

LO2 Unit 19

Understand how non-destructive testing methods are used for quality assurance in a manufacturing environment

LO4 Unit 19

During the delivery of the units, the learners should carry out a range of activities to demonstrate and check their knowledge and understanding. They should also undertake review activities as they work through the programme of learning.

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

14

ACTIVITY 1Learners could produce CNC programs in preparation for creating a physical pre-production version of the fuel filter casing. They could use the geometry supplied, or could modify the design to suit the local availability of CNC machining equipment. Learners could use manual CNC programming techniques, and also CAM software. Simulations could be performed prior to physical manufacture to ensure the correct operation of programs. Learners could also consider tooling, program cycle and how it will be loaded to the CNC machine. The following website includes comprehensive resources relating to CNC machining: http://www.cnccookbook.com/CCCNCGCodeCourse.htm

ACTIVITY 2Learners could take programs already created and use CNC machines to manufacture a pre-production version of the fuel filter casing. This could involve setting up the CNC machine and the correct use of datums, jigs and fixtures and tooling. Learners could then perform machining operations such as rough finishing, tool changes, and machining of irregular geometry. Cycle times, the use of macros and coolant could also be considered. Learners can use aluminium to create pre-production versions of the filter casing, or any other suitable material.

ACTIVITY 3Learners could use inspection and testing techniques to check the accuracy and quality of CNC machined components. This could include taking measurements and comparing against specification and visual inspection. It could also include more detailed inspection and testing procedures if access to suitable equipment is available. Learners could modify CNC programs and machine set-up as a result of performing inspection and testing. The following shows examples of inspection and test plans: http://www.qualitysystems.com/support/pages/inspection-and-test-plans

PRACTICE REVIEW ACTIVITIES FOR MODULE 2

14

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

15

PLANNING FOR MANUFACTURE USING LEAN AND QUALITY TECHNIQUESThe delivery then continues through Unit 18 (LO1, LO2, LO3, and LO4)

Learners could investigate and apply the following in order to plan for final production of the fuel filter:

• lean manufacturing principles

• quality control and quality assurance methods

• application of lean manufacturing principles in the context of ensuing quality

• production planning using lean and quality principles and approaches.

Contained within the following assessment criteria/LO(s)/units:

Learning Outcome LO number Unit number

Understand lean manufacturing LO1 Unit 18

Understand approaches used to ensure quality in manufacturing

LO2 Unit 18

Be able to apply lean manufacturing and approaches used to ensure quality

LO3 Unit 18

Be able to plan manufacturing production using lean and quality principles and approaches

LO4 Unit 18

During the delivery of the units, the learners should carry out a range of activities to demonstrate and check their knowledge and understanding. They should also undertake review activities as they work through the programme of learning.

MODULE 3

15

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

16

ACTIVITY 1It is intended that the fuel filter will be produced in India for JLR to strict quality standards. This will include the manufacture of the casing by injection moulding (see http://www.youtube.com/watch?v=eUthHS3MTdA&list=PLQyl1jXTi5lpHVU6lvX2PA7zZ6Xr8vH2K), and the assembly of the filter element into the casing which is then friction welded closed (see http://www.twi-global.com/technical-knowledge/job-knowledge/friction-welding-of-plastics-059/). The materials for the for the casing will be PA66 GF35 (see http://www.materialdatacenter.com/ms/en/Ultramid+A/BASF+SE/371)

Learners could investigate principles of lean manufacturing including lean wastes and lean tools and techniques and suggest how these can be applied to the manufacture of the fuel filter casing and final fuel filter assembly. The following gives a brief introduction to lean manufacturing including lean manufacturing: http://www.lean.org/WhatsLean/History.cfm

ACTIVITY 2Learners could examine how quality control and quality assurance approaches can be used to ensure that the fuel filter assemblies meet JLR’s exceptionally high standards. They could suggest points in the manufacturing process where quality techniques can be applied, including how Total Quality Management (TQM) could be implemented (see http://asq.org/learn-about-quality/total-quality-management/overview/overview.html). They could evaluate how Statistical Process Control (SPC) could be used to inform quality (which could involve interpreting data which the tutor will need to supply). Suitable data could be generated through taking measurements from a range of pre-production versions of the fuel filter made by learners. The following explains the principle of SPC: http://qualityamerica.com/LSS-Knowledge-Center/statisticalprocesscontrol/individual-x_moving_range_charts.php

ACTIVITY 3Learners could perform detailed production planning for the manufacture of the fuel filter housing and assembly of the complete fuel filter. This could include assessing similar manufacturing processes and layouts, production planning (e.g. operations, processes, time, materials, tools and machinery) and other factors. It could also incorporate lean and quality principles, factory layout, automated processes and inspection and testing. The planning process should include some justification. The following shows manufacturing operations taking place at JLR: http://www.youtube.com/watch?v=y5kLsA5vjqs

PRACTICE REVIEW ACTIVITIES FOR MODULE 3

1616

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

17

INSPECTION AND TESTINGDelivery concludes with Unit 19 (LO1 to LO5)

Learners could conclude by considering how inspection and testing techniques can be applied to the manufacture of the fuel filter by exploring:

• how inspection and testing methods and processes improve quality control

• how defects can occur during manufacturing and when in-service

• how destructive testing methods can be used

• how non-destructive methods can be used

• how automatic inspection and testing could be applied.

MODULE 4Contained within the following assessment criteria/LO(s)/units:

Learning Outcome LO number Unit number

Understand how inspection and testing methods and processes improve quality control

LO1 Unit 19

Understand how defects can occur in manufacturing, materials, processes and components

LO2 Unit 19

Understand how destructive testing methods are used for quality assurance in manufacturing

LO3 Unit 19

Understand how non-destructive testing methods are used for quality assurance in a manufacturing environment

LO4 Unit 19

Understand automatic inspection and testing techniques which are used in manufacturing

LO5 Unit 19

During the delivery of the units, the learners should carry out a range of activities to demonstrate and check their knowledge and understanding. They should also undertake review activities as they work through the programme of learning.

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

18

ACTIVITY 1Learners could suggest how inspection and testing methods and processes could be applied to the manufacturing of the fuel filter casing and final assembly. This could include how methods such as Production Parts Approval Process (PPAP) (see http://en.wikipedia.org/wiki/Production_part_approval_process) and First Off Last Off inspection (FOLO) could be applied (see http://www.unido.org/fileadmin/media/documents/pdf/tcb_product_quality.pdf ). It could also include how Statistical Process Control (SPC) could be used to inform quality (which could involve interpreting data which the tutor will need to supply). Learners have already considered SPC in Module 3.

ACTIVITY 2Learners could examine the types of defect that can occur in materials, as a result of manufacturing and when a product is in-service relating these to the fuel filter assembly. The following shows examples of how plastics can fail: http://plasticfailure.com/portfolio/plastic-parts-occasionally-fail/

They could consider defects both in the manufacture of the pre-production version of the fuel filter, and also as a result of the intended injection moulding and friction welding processes.

ACTIVITY 3Learners could investigate and consider how destructive testing could be applied to the quality assurance of the fuel filter. This could include the testing of materials such as tensile testing and testing of hardness. The following shows the tensile testing of plastics: http://www.youtube.com/watch?v=58hw2QxxDro Learners might be able to perform practical destructive testing with access to suitable resources.

ACTIVITY 4Learners could investigate how non-destructive testing techniques could be applied to both the pre-production and production versions of the fuel filter. The British Institute of Non-Destructive Testing (BINDT) website includes a range of useful resources: http://www.bindt.org/videos/ Learners could perform simple visual inspection of pre-production fuel filters they have manufactured, and could suggest how advanced NDT techniques could be applied to the fuel filter once in production. These could include dye-penetrant, ultrasonic and radiographic detection. Learners could justify which techniques would not be appropriate with reasons.

ACTIVITY 5Learners could conclude by considering how the inspection and testing of the fuel filter casing and final filter assembly could be automated. This could include the use of robotics, computer vision, optical inspection and co-ordinate measurement. See http://www.microscan.com/en-us/Technology/MachineVisionSystems/machine-vision.aspx for examples of machine vision and http://www.nikonmetrology.com/en_EU/Literature-Downloads for case studies of automated co-ordinate measurement. It could include other types of automatic test equipment (e.g. the filters are leak tested).

PRACTICE REVIEW ACTIVITIES FOR MODULE 4

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

19

Below is a list of resources available from the OCR website which can support the delivery of this project.

http://www.ocr.org.uk/qualifications/cambridge-technicals-engineering-level-3-certificate-extended-certificate-foundation-diploma-diploma-05822-05825/

Delivery Guides

Delivery Guides contains suggestions for activities for lessons. There is a Delivery Guide for each unit, structured by learning outcome so that you can see how each activity helps learners cover the unit. We’ve also included links to other resources you might find useful

Lesson Elements

There are three Lesson Elements for each unit. Each one is a fully worked-up lesson activities with teacher instructions and answers along with learner task sheets.

Resources Links

Resources Links provide a range of other resources you might find useful – videos, data sets and other online content. As well as producing a Resources Links for each unit, we’ve also produced a Resources Links specifically for the Project Approach.

Skills Guides

We have produced a range of skills guides covering a variety of topics, including research, communication skills, managing projects, problem solving.

www.ocr.org.uk/i-want-to/skills-guides/

OTHER RESOURCES

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

20

Examples of further units from Cambridge Technicals in Engineering that could be integrated holistically into this Project Approach include those listed below. Examples of how they might be integrated are included.

This Project Approach may also be used to support the delivery of other units in the qualification.

Unit LO How the units/LOs in this table could be integrated into the teaching of this Project Approach (Units 5, 6, 7, 8)

Unit 1 Mathematics for engineering

LO1 Performing production planning calculations

LO4 Calculation of geometry for fuel filter casing

LO6 Performing statistical process control (SPC) calculations

Unit 2 Science for engineering

LO1 Taking measurements for quality control purposes

LO4 Determining material properties for fuel filter casing, interpreting force/extension graphs for plastic materials, introduction to destructive and non-destructive testing

Unit 3 Principles of mechanical engineering

LO1 Understanding forces, stress and strain in materials, understanding materials behaviour

Unit 10 Computer Aided Design (CAD)

LO1-LO4 Application of Computer Aided Design principles to modification of fuel filter casing design, modification of filter casing geometry for additive manufacturing, modification of filter casing geometry for CNC machining

Unit 11 Materials science

LO1 Understanding of the structure of materials e.g. plastic filter casing

LO2 Understanding of materials, failure modes and forms of supply of materials relating to the filter casing

LO3 Understanding of material processing techniques e.g. thermoplastics

LO4 Applications of modern and smart materials e.g. reinforced plastics

LO5 Being able to test material suitability for different applications

Unit 22 Engineering and the environment

LO1 Understanding the sustainable use of materials

LO3 Evaluation of UK environmental targets relating to manufacturing

LO4 Understanding of environmental arguments relating to global manufacturing (e.g. fuel filter is intended to be made in India)

LO5 Innovations relevant to engineering and the environment (e.g. 3D printing)

OPPORTUNITIES FOR HOLISTIC DELIVERY OF OTHER UNITS

CAM

BRIDG

E TECHN

ICALS IN

ENG

INEERIN

GA

PROJEC

T APPRO

ACH TO

DELIVERY

– JAGU

AR LA

ND

ROVER – H

IGH

PERFORM

AN

CE FUEL FILTER

21

This Project Approach provides opportunities for meaningful employer engagement, examples of which are listed below:

Meaningful employer engagement Suggestion/ideas for centres when delivering this Project Approach

1. Learners undertake structured work-experience or work-placements that develop skills and knowledge relevant to the qualification.

Work-placement with engineering employer where the process of design for manufacture, planning for manufacture and manufacture using CNC machining and lean and quality principles can be observed.

2. Learners undertake project(s), exercises(s) and/or assessments/examination(s) set with input from industry practitioner(s).

The project itself has been set with industry input from Jaguar Land Rover.

Tutors could arrange to visit a Jaguar Land Rover manufacturing site (see http://jaguarlandrover.bmetc.ac.uk/)

3. Learners take one or more units delivered or co-delivered by an industry practitioner(s). This could take the form of master classes or guest lectures.

Guest lecture by industry practitioners relating to design for manufacture, additive manufacturing, planning for manufacture, CNC machining, lean and quality principles or inspection and testing.

4. Industry practitioners operating as ‘expert witnesses’ that contribute to the assessment of a learner’s work or practice, operating within a specified assessment framework. This may be a specific project(s), exercise(s) or examination(s), or all assessments for a qualification.

Invited industrial experts acting as witnesses to activities undertaken by learners e.g. the manufacture of a prototype, CNC machining a pre-production fuel filter casing, producing a production plan incorporating lean and quality principles.

OPPORTUNITIES FOR MEANINGFUL EMPLOYER ENGAGEMENT

The

smal

l pri

nt

We’d like to know your view on the resources we produce. By clicking on the ‘Like’ or ‘Dislike’ button you can help us to ensure that our resources work for you. When the email template pops up please add additional comments if you wish and then just click ‘Send’. Thank you.

If you do not currently offer this OCR qualification but would like to do so, please complete the Expression of Interest Form which can be found here: www.ocr.org.uk/expression-of-interest

OCR Resources: the small printOCR’s resources are provided to support the teaching of OCR specifications, but in no way constitute an endorsed teaching method that is required by OCR. Whilst every effort is made to ensure the accuracy of the content, OCR cannot be held responsible for any errors or omissions within these resources. We update our resources on a regular basis, so please check the OCR website to ensure you have the most up to date version.

This resource may be freely copied and distributed, as long as the OCR logo and this small print remain intact and OCR is acknowledged as the originator of this work.

OCR acknowledges the use of the following content:Square down and Square up: alexwhite/Shutterstock.com

Please get in touch if you want to discuss the accessibility of resources we offer to support delivery of our qualifications: resources.feedback@ocr.org.uk

Looking for a resource?There is now a quick and easy search tool to help find free resources for your qualification:

www.ocr.org.uk/i-want-to/find-resources/

OCR is part of Cambridge Assessment, a department of the University of Cambridge. For staff training purposes and as part of our quality assurance programme your call may be recorded or monitored.

© OCR 2016 Oxford Cambridge and RSA Examinations is a Company Limited by Guarantee. Registered in England. Registered office 1 Hills Road, Cambridge CB1 2EU. Registered company number 3484466. OCR is an exempt charity.

General qualificationsTelephone 01223 553998Facsimile 01223 552627Email general.qualifications@ocr.org.uk

www.ocr.org.uk/gcsereform

OCR Customer Contact Centre