Basic Industrial Mechanics Course

Lesson 1 • Role of the Industrial Mechanic

Defines job duties, career pathways, and industry expectations for mechanics. Establishes context for all subsequent technical skills covered in the course.

Lesson 2 • Shop Safety Fundamentals

Covers hazard identification, personal protective equipment, and lockout/tagout procedures. Safety compliance underpins every hands-on task in the course.

Lesson 3 • Overview of Industrial Machine Systems

Introduces mechanical, electrical, pneumatic, and hydraulic subsystems found in factories. Students categorise machine types and understand how subsystems interact.

Lesson 1 • Tool Care and Calibration

Covers cleaning, storage, and periodic calibration of hand tools and measuring instruments. Proper care maintains measurement accuracy and extends tool service life.

Lesson 2 • Common Hand Tools for Mechanics

Identifies wrenches, screwdrivers, hammers, pliers, and cutting tools used in maintenance. Correct tool selection prevents equipment damage and personal injury.

Lesson 3 • Precision Measuring Instruments

Teaches use of calipers, micrometers, dial indicators, and feeler gauges. Accurate measurement is essential for verifying fits, clearances, and alignment.

Lesson 1 • Gaskets, Seals, and O-Rings

Explains static and dynamic sealing methods, material selection, and proper installation to prevent leaks. Seal integrity is critical for hydraulic and pneumatic systems.

Lesson 2 • Reading Mechanical Drawings

Teaches orthographic projection, section views, dimensioning, and assembly drawing interpretation. Drawing literacy enables mechanics to assemble and verify components accurately.

Lesson 3 • Threaded Fastener Identification

Covers bolt grades, thread standards, nut types, and torque specifications for industrial fasteners. Correct fastener selection prevents joint failure under load.

Lesson 1 • Bearing Installation and Removal

Demonstrates press-fit, heat-fit, and puller-based methods for safe bearing installation and removal. Improper technique causes premature bearing failure and shaft damage.

Lesson 2 • Mechanical Couplings and Alignment

Covers rigid, flexible, and fluid coupling types and precision shaft alignment using dial indicators and laser tools. Misalignment is a leading cause of bearing and seal failure.

Lesson 3 • Bearing Lubrication and Failure Analysis

Teaches grease and oil lubrication methods, relubrication intervals, and bearing failure mode identification. Correct lubrication extends bearing life and prevents unplanned downtime.

Lesson 4 • Shaft Design and Keyway Machining

Explains shaft materials, diameter selection, and keyway cutting for torque transmission. Shaft integrity is the foundation for all rotating power transmission components.

Lesson 1 • Roller Chain Drive Systems

Covers chain standards, sprocket alignment, lubrication, and chain elongation measurement. Chain drives transmit high torque and require regular lubrication to prevent wear.

Lesson 2 • Gear Types and Gear Train Analysis

Identifies spur, helical, bevel, and worm gears and calculates gear ratios and output torque. Gear selection determines speed reduction and torque multiplication in a drive.

Lesson 3 • Gearbox Inspection and Maintenance

Teaches oil level checks, seal replacement, gear mesh inspection, and gearbox reassembly. Routine gearbox maintenance prevents catastrophic gear and bearing failures.

Lesson 4 • V-Belt and Flat Belt Drive Systems

Covers belt cross-sections, sheave selection, tension adjustment, and belt replacement procedures. Proper tension prevents slippage and premature belt wear.

Lesson 1 • Hydraulic Pumps and Motors

Covers gear, vane, and piston pump designs, displacement ratings, and motor operation. Pump selection determines system flow capacity and pressure capability.

Lesson 2 • Hydraulic Cylinders and Actuators

Covers single-acting, double-acting, and telescoping cylinder designs, seal replacement, and force calculation. Cylinder condition directly affects machine positioning accuracy.

Lesson 3 • Hydraulic Valves and Control Circuits

Identifies directional, pressure, and flow control valves and traces their function in circuits. Valve configuration determines actuator speed, force, and direction of motion.

Lesson 4 • Hydraulic Fluid Power Principles

Explains Pascal's law, pressure, flow, and power relationships in hydraulic circuits. These principles govern every component selection and system design decision.

Lesson 1 • Air Treatment: FRL Units and Dryers

Covers filter, regulator, and lubricator units and refrigerant and desiccant dryer operation. Clean, dry, regulated air prevents valve and actuator contamination failures.

Lesson 2 • Pneumatic System Troubleshooting

Applies leak detection, pressure testing, and flow measurement to isolate pneumatic faults. Systematic diagnosis minimises compressed air waste and production downtime.

Lesson 3 • Pneumatic Valves and Actuators

Identifies directional control valves, flow controls, and cylinder and rotary actuator types. Correct component selection ensures required force, speed, and cycle rate.

Lesson 4 • Compressed Air System Fundamentals

Explains air compression, pressure drop, flow capacity, and distribution piping design. A well-designed air supply system is the foundation of reliable pneumatic operation.

Lesson 1 • Thermography and Oil Analysis

Explains infrared thermography for electrical and mechanical hot spots and oil analysis for contamination and wear. Both techniques extend equipment life without intrusive inspection.

Lesson 2 • Maintenance Metrics and Continuous Improvement

Defines MTBF, MTTR, OEE, and maintenance cost metrics and uses them to drive improvement. Data-driven decisions transform reactive shops into proactive maintenance organisations.

Lesson 3 • Lubrication Management

Covers lubricant selection, storage, application methods, and contamination control practices. Proper lubrication management accounts for a large share of equipment reliability gains.

Lesson 4 • Preventive Maintenance Programme Design

Covers task identification, frequency setting, and work order generation for PM schedules. A structured PM programme forms the baseline for all reliability improvement efforts.