Maharashtra HSC Mechanical Maintenance (Bifocal) study plan
Maharashtra HSC Mechanical Maintenance (Bifocal) · Give each week a clear focus.
8 weeks · About 6 hours per week
Machining Processes and Machine Tools & Hand Tools, Bench Work and Fitting
Sketch and label the principal parts and motions of a lathe, drilling machine, and milling machine, then state one maintenance-relevant wear point on each.
Produce orthographic views (front, top, side) of a simple stepped shaft and a V-block to IS drawing conventions, including dimensioning and section hatching.
Identify and demonstrate the correct use of at least eight fitting-shop hand tools, explaining the safety rule for each.
Calculate cutting speed, feed, and machining time for a turning and a drilling operation from given data.
Your checkpoint
A single worked sheet containing three orthographic drawings (dimensioned) plus a table of eight hand tools with their use, care, and safety rule, and four solved machining calculations with units shown.
Machining Processes and Machine Tools & Mechanical Maintenance Practices and Troubleshooting
Classify the main machine tools by operation and list the specific maintenance checks performed on each before and after a shift.
Explain the procedure for aligning a workpiece and a machine vice on a milling table, and describe the symptoms of a misaligned setup.
Diagnose five common machining faults (chatter, poor surface finish, taper turning error, drill breakage, tool overheating) by listing cause, check, and corrective action for each.
Describe the procedure for mounting and removing a drill chuck and for replacing a lathe chuck safely.
Your checkpoint
A troubleshooting matrix of five machining faults with columns for symptom, likely causes, inspection step, and corrective action, plus a one-page pre-shift machine check list for any two machine tools.
Mechanical Maintenance Practices and Troubleshooting & Measuring Instruments and Metrology
Select and use the correct measuring instrument for a given tolerance band, justifying the choice by least count and range.
Read and record measurements from a vernier caliper, micrometer, and dial indicator, and calculate the least count of each from its scale divisions.
Carry out a preventive maintenance routine on a bearing housing: check clearance, runout, and fastener torque, and record readings.
Explain the difference between preventive, predictive, and breakdown maintenance and give one plant example of each.
Your checkpoint
A measurement record sheet of at least ten readings taken on real or simulated parts, each with instrument used, least count, reading, and whether it passes a stated tolerance, plus a written preventive maintenance procedure for one assembly.
Lubrication, Bearings and Power Transmission & Engineering Materials and Heat Treatment
Match lubricant type (mineral, synthetic, grease, solid) to at least five service conditions and justify each choice.
Describe the construction, fitting, and removal of ball, roller, and taper roller bearings, and state the failure signs of each.
Identify the properties that govern material selection for a shaft, a gear, and a machine bed, and name a suitable material for each.
Explain the purpose and typical temperature range of annealing, normalizing, hardening, and tempering, and describe one defect from each process.
Your checkpoint
A two-part reference chart: a lubrication and bearing selection chart covering five service conditions, and a heat-treatment table listing process, purpose, temperature range, cooling medium, and one resulting defect.
Engineering Materials and Heat Treatment & Engineering Drawing and Workshop Calculation
Perform workshop calculations for a belt drive: velocity ratio, belt length, and power transmitted, with units carried through.
Calculate the blank size and bend allowance for a simple sheet-metal component and the mass of a machined part from its volume and density.
Interpret a given surface roughness symbol and a geometric tolerance frame, and explain what each requires of the manufacturing process.
Describe the hardness testing methods (Brinell, Rockwell, Vickers) and state which is appropriate for a hardened gear tooth and why.
Your checkpoint
A calculation workbook of at least eight solved problems (belt drives, blank size, mass, tolerance interpretation) with formulae, substitution, and final answers in correct units.
Industrial Safety, Housekeeping and Environmental Practices & Basic Electrical and Instrumentation Knowledge for Maintenance
Carry out a workplace hazard identification for a fitting or machine shop and rank five hazards by severity and likelihood.
State the correct response and the correct extinguisher class for electrical, oil, and wood fires, and describe lockout/tagout for a machine under repair.
Explain the earthing requirement for a machine tool and describe how to test earth continuity with a multimeter.
Use a multimeter to measure voltage, current, and resistance, and interpret a reading that indicates a fault in a motor circuit.
Describe the segregation and disposal route for metal swarf, used oil, and coolant in a workshop.
Your checkpoint
A hazard register of five shop hazards with severity, likelihood, control measure, and responsible person, plus a one-page electrical safety checklist covering earthing, insulation, and lockout/tagout.
Mechanical Maintenance Practices and Troubleshooting & Industrial Visit, Project Work and Entrepreneurship
Write a structured troubleshooting report for a simulated breakdown, following the sequence: observe, isolate, test, correct, verify.
Plan an industrial visit with a defined observation checklist covering layout, maintenance records, and safety practices.
Draft a project outline for a small maintenance-related improvement, stating objective, method, resources, and expected outcome.
Prepare a cost estimate for a small workshop or repair service, separating fixed and variable costs and stating a break-even quantity.
Your checkpoint
A complete breakdown report (one simulated fault, full sequence documented) plus a one-page industrial visit plan with observation checklist and a project outline of not more than one page.
Measuring Instruments and Metrology & Hand Tools, Bench Work and Fitting & Machining Processes and Machine Tools & Mechanical Maintenance Practices and Troubleshooting & Lubrication, Bearings and Power Transmission & Industrial Safety, Housekeeping and Environmental Practices & Basic Electrical and Instrumentation Knowledge for Maintenance & Industrial Visit, Project Work and Entrepreneurship & Engineering Drawing and Workshop Calculation & Engineering Materials and Heat Treatment
Complete two full-length timed mock papers under exam conditions and record the score for each domain.
Re-study only the two weakest domains identified from the mock results, using the earlier deliverables as revision notes.
Recite from memory the least count, safety rule, or key formula for each domain in a rapid self-test.
Finalize the project outline and visit report into a submission-ready format.
Your checkpoint
Two scored mock papers with a domain-wise score table, a one-page list of weak areas with the corrective action taken, and the finalized project and visit documents.
Milestones
Week 2: Can draw and dimension a simple component and solve cutting-speed and machining-time problems without referring to notes.
Week 4: Can read a vernier and micrometer correctly and justify a lubricant and bearing choice for five given service conditions.
Week 6: Can complete a hazard register and demonstrate safe multimeter use and earth continuity testing.
Week 8: Both mock papers completed within time, with domain-wise scores recorded and the two weakest domains revised.