Career Blade Industrial-Maintenance-Keeping-Machinery-Running
INDUSTRIAL MAINTENANCE: KEEPING MACHINERY RUNNING
LESSON PLAN OVERVIEW
Career: Industrial machinery mechanics and machinery maintenance workers maintain and repair factory equipment and other industrial machinery, such as conveying systems, production machinery, and packaging equipment. Millwrights install, dismantle, repair, reassemble, and move machinery in factories, power plants, and construction sites.
Lesson: This lesson plan introduces students to the role of an Industrial Machinery Mechanic, and to demonstrate the skills a Machinery Mechanic uses to keep industrial equipment working properly to avoid shutdowns and meet production goals.
Grade Level: Middle Grades
Learning Objectives:
〉 Students will explore the role of an Industrial Machinery Mechanic and how they schedule and carryout routine equipment maintenance in a manufacturing plant.
〉 Students will learn why it is important to routinely maintain equipment and machinery in a manufacturing plant and practice reading a maintenance manual.
〉 Students will research car maintenance and create a checklist for routine car maintenance to understand the importance of performing ongoing maintenance on machinery.
〉 Students will also gain an insight into the Industrial Machinery Mechanic profession, including common job tasks, salary, career pathway, and credentials required to perform the job.
Materials Needed:
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TEACHER GUIDE
Lesson Instructions: The following lesson plans will help you demonstrate to students common skills and procedures used in the unit about an Industrial Machinery Mechanic. Begin each lesson by reading the Class Message below to your students, then have them watch the recommended Video Introduction. Afterwards, facilitate discussion with the Class Questions listed.
After the discussion, students will work on the included activities. Each activity has a printable worksheet with student instructions and areas to record their work. Have students read their worksheets before beginning each activity.
You should also familiarize yourself with the student worksheets to help demonstrate any procedures and help facilitate the ending activity discussion .
Class Message: Today we are going to explore some of the responsibilities and duties of an Industrial Machinery Mechanic, which is a career within the Manufacturing industry. An Industrial Machinery Mechanic’s job is to ensure that all equipment, tools, and machinery are properly calibrated and maintained to prevent shutdowns and meet production goals.
Industrial Machinery Mechanics maintain and repair factory equipment and other industrial machinery, such as conveying systems, production machinery, and packaging equipment.
In this lesson, we will discuss some common Industrial Machinery Mechanic tasks, like reading technical manuals to understand equipment and controls and creating a maintenance schedule to keep machinery operating properly.
Let’s watch this brief video to better understand the role of an Industrial Machinery Mechanic and how they affect our everyday lives.
Class Discussion Questions:
〉 Think about a car manufacturing plant and all of the parts it takes to assemble the final product, what do you think would happen if a piece of machinery stopped working or malfunctioned during a shift?
〉 What types of duties do you think an Industrial Machinery Mechanic would handle on a daily basis?
〉 Have any of you had the opportunity to visit or tour an industrial plant? If so, share your experience.
〉 What are some of the problems an Industrial Machinery Mechanic may encounter on a daily basis that could affect production?
Activities Overview: This lesson plan includes two student activities. Activity #1 demonstrates an understanding of the daily duties of an Industrial Machinery Mechanic such as monitoring and maintaining tools, equipment, and machinery. Students will read technical manuals and maintenance schedules to understand why maintaining industrial machinery is important to operate productively. Activity #2 requires students to research and prepare a checklist for routine car maintenance to better understand the importance of ongoing maintenance to increase longevity of machinery.
Read and familiarize yourself with the student worksheet for each activity.
Activity #1: Why Machines Need Maintenance
Activity Instructions:
〉 Hand out the student worksheet.
〉 Facilitate introduction of activity.
〉 After completion, facilitate discussion questions for this activity.
Activity Questions:
〉 Before performing any maintenance on the Air Compressor, what do you need to do FIRST? Disconnect Electrical Power, Lockout and Tag Switch at MCC
〉 How often do you need to check the Thermometers? Once a Year
〉 Which processes have to be performed weekly? Check Oil Level: 1 hp and Air Dryers
〉 What is the first process you need to perform when maintaining the Pressure gauges? Isolate pressure gauge by closing the proper valves
〉 How would you know how to calibrate the Transmitters and Controllers? Locate Calibrate Transmitters and Controllers information in the Manufacturer’s Manual
〉 How often should you change the oil in the Air Compressor? Once a Year or every 2,000 hours
〉 Which process should you do every day? Check the Air Compressor oil pressure
Activity #2: Create a Car Maintenance Checklist
Strategic Planning is a way of solving complex problems through a creative process that integrates brainstorming, collaboration, and the possibilities of new technologies and processes. In this exercise, students will use Strategic Planning to explore ways to better maintain a mechanical piece of machinery –an automobile.
Instructions are shown below, along with handouts that students can use to document their progress in the project. You may decide to extend this project over several class periods in order to let students work in depth to develop their own solutions to problems. This design challenge should take anywhere from 1 to 2 hours or more, depending on the age level and how detailed you expect the results to be. Students may select from the suggested scenarios in the activity, or come up with their own ideas to properly maintain a mechanical system.
Activity Instructions:
〉 Hand out the student worksheet.
〉 Students will need access to a computer.
〉 Assign students into groups.
〉 Facilitate introduction of activity.
〉 After completion, facilitate discussion question for this activity
Activity Results:
〉 In teams, research preventive maintenance procedures to perform on an automobile for peak performance and to extend the life of the vehicle and create a Maintenance Checklist.
〉 Next, create a presentation for your Car Maintenance Checklist to present to the class to include either a demonstration of a procedure, create a poster display, a PowerPoint presentation, or other form of presentation.
CAREER INSIGHT
Career Highlight: This lesson plan highlights some of the skills an Industrial Machinery Mechanic uses on a daily basis to maintain industrial equipment, tools, and machinery. See Employers in My Area section to contact businesses and organizations in your area about classroom demonstrations, on-site visits, or other additional career exposure opportunities.
Featured Career:
Industrial Machinery Mechanic
Career Descriptions: Industrial machinery mechanics and machinery maintenance workers maintain and repair factory equipment and other industrial machinery, such as conveying systems, production machinery, and packaging equipment.
Industrial machinery mechanics, machinery maintenance workers, and millwrights typically do the following:
〉 Read technical manuals to understand equipment and controls
〉 Disassemble machinery and equipment when there is a problem
〉 Repair or replace broken or malfunctioning components
〉 Perform tests and run initial batches to make sure that the machine is running smoothly
〉 Detect minor problems by performing basic diagnostic tests
〉 Test malfunctioning machinery to determine whether major repairs are needed
〉 Adjust and calibrate equipment and machinery to optimal specifications
〉 Clean and lubricate equipment or machinery
〉 Move machinery and equipment
Industrial machinery mechanics, also called maintenance machinists, keep machines in working order by detecting and correcting errors before the machine or the products it produces are damaged. Many of these machines are increasingly run by computers.
Other Names for this Career: Industrial Machinery Mechanic, Industrial Mechanic, Mechanic, Master Mechanic, Maintenance Technician, Maintenance Mechanic, Machine Adjuster, Fixer, Loom Fixer, Overhauler
STANDARDS ALIGNMENT
Activity #1: Why Machines Need Maintenance
Reading Standards: Range of Reading and Level of Text Complexity – Standard 10 R.RRTC.10
Make inferences in increasingly complex text and logically explain their thinking;
〉 Read and comprehend a variety of literary nonfiction at the high end of the grades 68 text complexity band independently and proficiently.
〉 Read and comprehend a variety of literary nonfiction throughout the grades 6-8 text complexity band proficiently, with a gradual release of scaffolding at the high end as needed.
〉 Read and comprehend a variety of literary nonfiction throughout the grades 6-8 text complexity band proficiently, with a gradual release of scaffolding at the high end as needed.
Reading Standards: Craft and Structure
〉 Determine the meaning of words and phrases as they are used in a text, including figurative, connotative, and technical meanings; analyze the impact of a specific word choice on meaning and tone, including analogies and allusions to other texts.
〉 Determine the meaning of words and phrases as they are used in a text, including figurative, connotative, and technical meanings; analyze the impact of specific word choices on meaning and tone, including allusions to other texts and repetition of words and phrases.
〉 Determine the meaning of words and phrases as they are used in a text, including figurative, connotative, and technical meanings.
Activity #2: Create a Car Maintenance Checklist
Writing Standards: Research to Build and Present Knowledge
〉 Conduct research to answer a question (including a self-generated question), drawing on multiple sources and generating additional related, focused questions that allow for multiple avenues of exploration.
〉 Conduct research to answer a question, drawing on multiple sources and generating additional related, focused questions for further research and investigation
〉 Conduct research to answer a question, drawing on multiple sources and refocusing the inquiry when appropriate.
〉 Support interpretations, analyses, reflections, or research with evidence found in literature or informational texts, applying grade 8 standards for reading; assess whether the reasoning is sound and the evidence is relevant and sufficient to support the claims and recognize when irrelevant evidence is introduce
〉 Support interpretations, analyses, reflections, or research with evidence found in literature or informational texts, applying grade 7 standards for reading; assess whether the evidence is relevant and sufficient to support the claims.
〉 Support interpretations, analyses, reflections, or research with evidence found in literature or informational texts, applying grade 6 standards for reading.
School Counseling Model and Standards
〉 Develop and practice effective technology skills
〉 Demonstrate critical thinking and decision-making skills to make informed decisions
〉 Communicate effectively using oral, written, and listening communications skills.
EDUCATOR RUBRIC
ITEM
Research /Identify the Problem
Does Not Meet Expectations
Meets Expectations Exceeds Expectations
The group’s research was limited to fewer than 3 sources and lacked detail to support their checklist decision. The group had 3 resources documented and had adequate support for their check list decision
The group had more than 3 resources documented and were able to locate specific details and areas of congruence and incongruence between different resources highlighting why their checklist decisions were made.
Maintenance Check List
Presentation
The group’s plan lacked detail and was not comprehensive. The checklist lacked supporting information.
The presentation indicated a lack of understanding of the task through their lack of detailed explanation.
The groups checklist was comprehensives and contained facts and details supporting their choices
The presentation was clear and concise and demonstrated a complete and thorough understanding of the task through the addition of supporting details and explanation.
Team Work Student did not work well in their team. Student worked will in their team and contributed equally.
The groups checklist was both comprehensive and included numerous and abundant additional facts and details supporting their choices.
The presentation was clear and concise and demonstrated a complete and thorough understanding of the task through the addition of supporting details and explanation and included nuances not captured easily by other groups.
Student worked well in their team, contributed equally and exhibited leadership.
ACTIVITY #1: WHY MACHINES NEED MAINTENANCE
Introduction: In manufacturing, most systems, equipment, and machinery are operating 24 hours a day, 7 days a week. When you have a production schedule to meet, it is important that equipment function properly and does not break down causing a shutdown of the operation.
The main purpose for routine maintenance is to ensure that all systems, equipment, and machinery is operating at 100% efficiency at all times. By performing daily inspections, problems can be detected and corrected before they become a major problem and possibly shutdown the production line.
Activity Description: In this activity, you will practice reading information from a technical manual and maintenance schedule to understand why maintaining industrial machinery is so important to operate productively.
Activity Procedure: Read the following information on maintaining Pneumatic Controls and Maintenance Schedule, then answer the questions that follow. A Pneumatic Control system utilizes compressed air to communicate commands from controllers to the equipment instead of an electric or electronic control signal.
Before performing any maintenance on the Air Compressor, what do you need to do FIRST?
How often do you need to check the Thermometers?
Which processes have to be performed weekly?
What is the first process you need to perform when maintaining the Pressure gauges?
How would you know how to calibrate the Transmitters and Controllers?
How often should you change the oil in the Air Compressor?
Which process should you do every day?
Activity Discussion:
〉 How easily were you able to easily follow and understand the excerpt from the Pneumatic Controls manual and maintenance checklist?
〉 This activity was just one process from a Maintenance Manual. Do you think it would be difficult to remember all of the things you need to do as an Industrial Machinery Mechanic? How could you remember everything you need to do?
〉 What are some things you could do to help you remember what maintenance procedures need to be on a daily basis?
*Table 17-1. Air compressor and piping
Air Compressor and Piping
Action Frequency
WARNING!
BEFORE BEGINNING ANY MAINTENANCE ON THE AIR COMPRESSOR, DISCONNECT ELECTRICAL POWER, LOCKOUT AND TAG SWITCH AT MCC.
Air Compressor and Lines
Check oil pressure. day
Check oil level:
1 hp
¼ through ¾ ph week mo
Check percent on-time. mo
Check air distribution system for leaks. mo
Operate safety valves. mo
Check and replace intake filter (more often if necessary). mo
Check belt tension. mo
Inspect valve assemblies 6 mos
Check P/E switch setting. yr
Inspect all electrical contacts. yr
Check amp draw on motors. yr
Check pump-up times. Yr
Change oil. Yr/2K hrs
Air Dryers
Check air dryers for proper air drying. Change filter media if required. Repair or replace dryer if necessary. week
Filters
If filters are supplied on regulators, drain out condensation. If filters are not operating properly, repair or replace as needed. mo
Pressure Regulator
Check air pressure regulators for proper operation. Adjust, repair, or replace if necessary. mo
*Table 17-2. Pneumatic control system instrumentation and electrical
Pneumatic Control System Instrumentation & Electrical Action Frequency
Transmitters and Controllers
Calibrate and adjust in accordance with the manufacturer’s recommendations. mo
Thermometers
Check for accuracy. Remove thermometers from their wells and check against calibrated thermometer in controlled temperature bath. yr
Pressure Gauges
Isolate pressure gauge by closing the proper valves. Remove and check in a fixture against a calibrated gauge. Adjust as required following equipment manufacturer’s instructions yr
Motors
Check and clean cooling airflow passages on electric motors as necessary so that nothing obstructs airflow.
All Electrical Devices
Check, clean, and tighten terminals at motors, starters, disconnect switches, etc.
Wiring
Check insulation on conductors in starters, switches, and junction boxes at motors for cracks, cuts, or abrasions. Replace wiring as required and correct cause of damage.
6 mos
6 mos
6 mos
*Taken from - Department of the Army TM 5-692-1, Maintenance of Mechanical and Electrical Equipment at Command, Control, Communications, Computer, Intelligence, Surveillance, and Reconnaissance (C4ISR) Facilities - Recommended Maintenance Practices, 22 July 2005.
ACTIVITY #2: CREATE A CAR MAINTENANCE CHECKLIST
Introduction: Today, we are going to research and prepare a checklist for routine car maintenance to better understand the importance of ongoing maintenance to increase longevity of machinery.
Activity Description: This activity challenges students to create a maintenance checklist to extend the life of an automobile through preventive maintenance.
Activity Procedure: In teams, research preventive maintenance procedures to perform on an automobile for peak performance and to extend the life of the vehicle
DISCUSSING IDEAS FOR ROUTINE CAR MAINTENANCE
Separate into groups and discuss the following:
〉 Does anyone on the team have experience with automobile maintenance? If so, share experience.
〉 List some of the items that need to be regularly checked on an automobile. Discuss these questions in your group and assign a team member to take notes below:
RESEARCH TO LEARN MORE ABOUT ROUTINE CAR MAINTENANCE
Next, using the internet, search for information on routine car maintenance. Here are some links to get you started:
〉 Carcare.org: A Little Auto Care Goes a Long Way (http://tn-caps.com/r/68LM1)
〉 EPA: Car Maintenance is a Must! (http://tn-caps.com/r/68LM3)
Consider these questions:
〉 What maintenance processes can you perform on your own?
〉 What maintenance processes do you need to have a professional perform?
Discuss research in your group and assign a team member to take notes below:
CREATE A CAR MAINTENANCE CHECKLIST
Using your group discussion and internet search, create a Car Maintenance Checklist. Use the Maintenance Checklist from Activity #1 as a guide.
Create a presentation of your Car Maintenance Checklist to present to the class to include either a demonstration of a procedure, create a poster display, a PowerPoint presentation, or other form of presentation.
Assign a team member to document your Car Maintenance Checklist below:
Assign a team member to present your Car Maintenance Checklist to the class
Activity Results: In this activity, students created a solution to a problem using Strategic Planning.
In this process, they:
〉 Identified the problem
〉 Explored the problem
〉 Created ideas to solve the problem
〉 Tested the solution by presenting the solution to others
In teams, students researched preventive maintenance procedures to perform on an automobile for peak performance and to extend the life of the vehicle.
Students then used the research to create a Car Maintenance Checklist and then presented the Checklist to the class.
Activity Discussion:
〉 How did this activity help you understand the importance of having documented maintenance procedures?
〉 How does having information documented in procedures to follow help an Industrial Machinery Mechanic in their job? What are some other resources an Industrial Machinery Mechanic can use to help them on the job?
