T-Levels Engineering, Manufacturing, Processing and Control Syllabus

Engineering, Manufacturing, Processing and Control syllabus — full chapter and topic list

Expand any chapter to see its topics and sub-topics. This is the whole examinable outline for Engineering, Manufacturing, Processing and Control in T-Levels, not a summary of it.

1. 1

   Core: Engineering and Manufacturing Foundations

   4 topics

   • Working within the engineering sector
     • Sectors, roles and career pathways
     • Professional behaviours and ethics
   • Health, safety and regulation
     • HASAWA, PUWER and COSHH
     • Risk assessment and safe working
   • Engineering and manufacturing principles
     • Mechanical and electrical principles
     • Materials, properties and selection
   • Sustainability and the circular economy
2. 2

   Core: Design, Mathematics and Science

   4 topics

   • Engineering mathematics
     • Algebra, trigonometry and graphs
     • Units, measurement and tolerances
   • Engineering science
     • Forces, motion and energy
     • Electrical and thermal principles
   • Engineering design process
     • Specification and concept generation
     • CAD and technical drawing standards
   • Quality management and continuous improvement
3. 3

   Core: Manufacturing and Process Control

   4 topics

   • Manufacturing processes and methods
     • Machining, forming and joining
     • Additive and subtractive manufacturing
   • Automation and control systems
     • PLCs, sensors and actuators
     • Industry 4.0 and smart manufacturing
   • Production planning and lean principles
   • Inspection, metrology and testing
4. 4

   Occupational Specialism: Mechanical/Manufacturing Engineering

   4 topics

   • Interpreting engineering drawings and data
   • Manufacturing and machining operations
     • Setting up and operating machinery
     • CNC programming and operation
   • Assembly and fitting techniques
   • Inspection and quality assurance
5. 5

   Occupational Specialism: Maintenance Engineering and Control

   4 topics

   • Planned and reactive maintenance
     • Preventive maintenance schedules
     • Condition monitoring
   • Fault diagnosis and rectification
   • Mechanical and electrical maintenance
   • Control and instrumentation systems

Engineering, Manufacturing, Processing and Control flashcards for T-Levels

21 of 51 cards from the Engineering, Manufacturing, Processing and Control deck — real questions with worked answers.

1. What is meant by the term 'engineering sector' in the context of T-Level study?

   The broad field of industries that design, manufacture, maintain and control physical products and systems — including mechanical, electrical, electronic, manufacturing, processing and control engineering — supported by standards, regulation and a skilled, multi-disciplinary workforce.

2. Name the four main classifications of engineering disciplines a T-Level student should know.

   Mechanical engineering, electrical/electronic engineering, manufacturing (production) engineering, and control/instrumentation engineering. (Civil and chemical/process are also often included.)

3. What is the difference between a technician, an engineer and a craftsperson in an engineering organisation?

   A craftsperson performs skilled manual/practical tasks; a technician applies practical and theoretical knowledge to support design, testing and maintenance; an engineer applies advanced theory and mathematics to design, analyse and manage projects and solutions.

4. Under UK law, what is the principal piece of legislation governing workplace health and safety?

   The Health and Safety at Work etc. Act 1974 (HASAWA), which places general duties on employers, employees and the self-employed to ensure health, safety and welfare so far as is reasonably practicable.

5. What do the regulations 'PUWER' and 'LOLER' cover in an engineering workplace?

   PUWER (Provision and Use of Work Equipment Regulations 1998) covers the safe provision, use and maintenance of work equipment; LOLER (Lifting Operations and Lifting Equipment Regulations 1998) covers the safe use, inspection and certification of lifting equipment.

6. In risk assessment, how is risk defined in relation to hazard?

   A hazard is anything with the potential to cause harm; risk is the likelihood that the hazard will cause harm combined with the severity of that harm. Conceptually $\text{Risk} = \text{Likelihood} \times \text{Severity}$.

7. List the hierarchy of control measures for reducing risk, from most to least effective.

   1. Elimination, 2. Substitution, 3. Engineering controls (e.g. guarding), 4. Administrative controls (e.g. safe systems of work, training), 5. Personal Protective Equipment (PPE) as a last resort.

8. What is the purpose of COSHH regulations?

   The Control of Substances Hazardous to Health Regulations require employers to assess, prevent or control exposure to hazardous substances (chemicals, fumes, dusts, biological agents) to protect workers' health.

9. State Newton's three laws of motion as used in engineering principles.

   1st: a body remains at rest or in uniform motion unless acted on by a resultant force. 2nd: $F = ma$ (force = mass × acceleration). 3rd: every action has an equal and opposite reaction.

10. What is the equation relating stress, force and cross-sectional area, and its SI unit?

    $$\sigma = \frac{F}{A}$$ where $\sigma$ is stress, $F$ is force (N) and $A$ is area (m²). The SI unit is the pascal ($\text{Pa} = \text{N/m}^2$).

11. Define strain and state how Young's modulus relates stress and strain.

    Strain is the fractional change in length, $\varepsilon = \frac{\Delta L}{L}$ (dimensionless). Young's modulus is the ratio of stress to strain within the elastic limit: $E = \frac{\sigma}{\varepsilon}$.

12. What is the 'circular economy' and how does it differ from a linear economy?

    A circular economy keeps materials and products in use for as long as possible through reuse, repair, remanufacture and recycling, designing out waste. A linear economy follows a 'take–make–dispose' model.

13. State the waste hierarchy used to support sustainable engineering, from most to least preferred.

    Prevention (reduce), Reuse, Recycle, Recovery (e.g. energy from waste), Disposal (landfill) as the least preferred option.

14. What do the '6 Rs' of sustainable design stand for?

    Rethink, Refuse, Reduce, Reuse, Repair, Recycle — a framework for reducing the environmental impact of products and processes.

15. Rearrange Ohm's law to express current, and give its three forms.

    Ohm's law: $V = IR$. Therefore $I = \frac{V}{R}$ and $R = \frac{V}{I}$, where $V$ is voltage (V), $I$ is current (A) and $R$ is resistance ($\Omega$).

16. What is the formula for electrical power in terms of voltage, current and resistance?

    $P = VI = I^{2}R = \frac{V^{2}}{R}$, where power $P$ is measured in watts (W).

17. How do you find the total resistance of resistors connected in series and in parallel?

    Series: $R_{T} = R_{1} + R_{2} + \dots + R_{n}$. Parallel: $\frac{1}{R_{T}} = \frac{1}{R_{1}} + \frac{1}{R_{2}} + \dots + \frac{1}{R_{n}}$.

18. State the trigonometric ratios SOH-CAH-TOA for a right-angled triangle.

    $\sin\theta = \frac{\text{opposite}}{\text{hypotenuse}}$, $\cos\theta = \frac{\text{adjacent}}{\text{hypotenuse}}$, $\tan\theta = \frac{\text{opposite}}{\text{adjacent}}$.

19. State Pythagoras' theorem for a right-angled triangle.

    $$c^{2} = a^{2} + b^{2}$$ where $c$ is the hypotenuse and $a$, $b$ are the two shorter sides.

20. What is the equation of a straight line and what do its terms represent?

    $y = mx + c$, where $m$ is the gradient (slope) and $c$ is the $y$-intercept (the value of $y$ when $x = 0$).

21. Give the SUVAT equations of motion for constant acceleration.

    $v = u + at$; $s = ut + \frac{1}{2}at^{2}$; $v^{2} = u^{2} + 2as$; $s = \frac{(u+v)}{2}\,t$, where $u$/$v$ are initial/final velocity, $a$ acceleration, $s$ displacement, $t$ time.

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