QUALIFICATIONS PACK - OCCUPATIONAL STANDARDS FOR ELECTRONICS INDUSTRY

Contents 1. Introduction and Contacts..……P1 2. Qualifications Pack…………........P2 3. OS Units………………………….….....P3

What are Occupational Standards(OS)?  OS describe what individuals need to do, know and understand in order to carry out a particular job role or function  OS are performance standards that individuals must achieve when carrying out functions in the workplace, together with specifications of the underpinning knowledge and understanding Contact Us: ESSCI, New Delhi Electronics Sector Skills Council of India 422, Okhla Industrial Estate, Phase-III, New Delhi-110020 E-mail: [email protected]

4. Glossary of Key Terms………....P16

5. Nomenclature for QP & OS…..P18

Introduction Qualifications Pack- Pick and Place Assembly Operator SECTOR: ELECTRONICS SUB-SECTOR: PCB Assembly OCCUPATION: Assembly and Soldering REFERENCE ID: ELE/Q5102 ALIGNED TO: NCO-2004/ NIL Pick and Place Assembly Operator: Pick and Place Operator operates the automated pick-and-place machine for assembling components on the printed circuit board (PCB). Brief Job Description: The individual on the job, programs, operates and mantains the automated pick-and-place machine for placing different types of components on the surface of PCBs for soldering. Personal Attributes: The job requires the individual to have: attention to details, good eyesight and visual accuracy and to work for long hours generally in a standing position. 1

Qualifications Pack For Pick and Place Assembly Operator

ELE/Q5102

Job Details

Qualifications Pack Code Job Role

Pick and Place Assembly Operator

Credits(NVEQF/NVQF/NSQF) TBD [OPTIONAL] Sector Electronics Sub-sector PCB Assembly Occupation

Assembly & Soldering

Job Role Role Description NVEQF/NVQF level Minimum Educational Qualifications Maximum Educational Qualifications Training Experience

Applicable National Occupational Standards (NOS)

Version number

1.0

Drafted on Last reviewed on

06/02/14 24/03/14

Next review date

24/03/15

Pick and Place Assembly Operator Operating the automated pck-and-place machine for assembling components on PCB surface; loading and maintaining the machine 4 10th/12th standard passed ITI/Diploma Not Applicable Not Applicable Compulsory:

1. ELE/N5102 Operate pick-and-place machine 2. ELE/N9919 Work with superiors and colleagues 3. ELE/N9920 Follow safety procedures Optional: Not applicable

Performance Criteria

As described in the relevant OS units

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ELE/N5102 Operate pick-and-place machine --------------------------------------------------------------------------------------------------------------------

Overview This unit is about mounting and assembling the components in the printed circuit boards for soldering using the pick-and-place machine.

3

ELE/N5102

National Occupational Standard

Unit Code Unit Title (Task) Description

Scope

Operate pick-and-place machine ELE/N5102 Operate pick-and-place machine for PCB assembly This OS unit is about assembling surface-mount components on the printed circuit boards (PCB) by operating the automated pick-and-place machine after loading with reels of components and program as well as maintaining the machine This unit/task covers the following:     

Program and load the pick and place machine Load components and operate the machine for assembling on PCBs Check visually and ensure after aseembly cycle is complete Undertake preventive maintenance on the machine Achieve productivity and quality standards

Performance Criteria(PC) w.r.t. the Scope

Element

Performance Criteria

Programming pickand-place machine

To be competent, the user/individual on the job must be able to: PC1. inspect printed solder paste for accuracy PC2. load specified programs on machine’s computer according to PCB assembly plan PC3. program the coordinates as per customer specified design chart or as per the design of the board PC4. identify components accurately and where how to place them on the reel PC5. troubleshoot and optimize program To be competent, the user/individual on the job must be able to: PC6. set up tools and parts to operate the machine PC7. warm up machine for prescribed time period PC8. load and check all components to the feeders according to program PC9. load feeders according to chosen program PC10. adjust PCB transport rails for all machines PC11. re-check value loaded on particular wheel and program PC12. ensure specified gap between two boards for secure placing of components on each PCB PC13. ensure the boards and components are not disturbed PC14. check the daily PCB-loading list PC15. recognize width of component reels PC16. observe proper ESD and contamination prevention handling practices PC17. keep records of assembly PC18. monitor the operation of equipment to ensure that assemblies are in compliance with standards. PC19. hand over the finished boards to reflow machine operator PC20. reload the components as and when the reel or tray becomes empty PC21. monitor the pick-and-place assembling and soldering process PC22. clearance the reel path if it gets stuck due to improper flow of components

Operating pick-andplace machine

4

ELE/N5102 Visual checking

Undertaking preventive maintenance Achieving productivity and quality standards

Operate pick-and-place machine To be competent, the user/individual on the job must be able to: PC23. cross check the PCB and components received from screen printing section prior to assembly PC24. visually check to ensure that solder paste is as per specifications before starting pick-and-place operation PC25. visually check on the assembled board for components missed out against design chart To be competent, the user/individual on the job must be able to: PC26. maintain machine to avoid downtime PC27. perform regular cleaning as prescribed by machine manufacturer PC28. perform weakly greasing and cleaning of nozzles To be competent, the user/individual on the job must be able to: PC29. ensure correct components are placed on PCBs PC30. ensure the components are damage free PC31. maintain component reels in stocking locations and return after use PC32. achieve 100% target number of boards to be assembled PC33. deliver board in time to the next process PC34. ensure zero defects in mounting

Knowledge and Understanding (K) A. Organizational Context (Knowledge of the company / organization and its processes)

B. Technical Knowledge

The individual on the job needs to know and understand: KA1. company’s policies on: incentives, delivery standards and personnel management and Intellectual Property Rights (IPR) KA2. work flow involved in assembly process of the company KA3. importance of the individual’s role in the workflow KA4. reporting structure KA5. profile of clients KA6. component stocking policy KA7. safety and quality standards followed in the organization The user/individual on the job needs to know and understand: KB1. basic electronics and component identification KB2. pick-and-place machine functioning and controls KB3. basic programming and loading KB4. setting up, loading pick-and-place machine KB5. techniques of cleaning stencil KB6. colour codes and polarity of components KB7. regulation of operating speed and temperature KB8. LEDs and special mounting tecnique, junction temperature, types of assembly, metal core PCB, spike correction KB9. operation of LED mounting machine KB10. Electro-static discharge (ESD) precautions KB11. manual soldering and rework of SMT components KB12. PCB design basics KB13. commonly ocuring machine defects

5

ELE/N5102

Operate pick-and-place machine

Skills (S) [Optional] A. Core Skills/ Generic Skills

Reading and Writing Skills The user/individual on the job needs to know and understand how: SA1. to maintain necessary logs and records SA2. to read job sheet, load plans, production drawings and interpret assembly drawings SA3. to operate computer SA4. to read production schedules and operations manuals on the sequential start up and operation of pick and place machine SA5. to document the number of PCB processed Communication Skills The user/individual on the job needs to know and understand how: SA6. to effectively communicate with the supervisor on the process issues SA7. to effectively communicate maintenance issues to the maintenance personnel Team work and Multitasking

B. Professional Skills

The user/individual on the job needs to know and understand how: SA8. to be able to work on multiple machines at a time, as instructed SA9. to work as a team and deliver assembled PCBs to next work process on time Reflective Thinking The user/individual on the job needs to know and understand how: SB1. to reduce repetitive errors SB2. to improve work process Analytical Thinking The user/individual on the job needs to know and understand how: SB3. to promptly to resolve problems SB4. to enhance machine performance Using Tools and Machines The user/individual on the job needs to know and understand how: SB5. to operate the pick and place machine SB6. to use hand tools, calipers, microscope, screwdrivers, pliers, cutters, stencils, feeders, supporting pins, and other SMT tools Critical Thinking The user/individual on the job needs to know and understand how: SB7. to spot process disruptions and delays SB8. to interpret instructions furnished in written, oral or schedule form Problem solving and Troubleshooting The user/individual on the job needs to know and understand how: SB9. to reseolve problem during the soldering process SB10. to troubleshoot and correct mechanical problems Arithmetic and Geometry Skills The user/individual on the job needs to know and understand how: 6

ELE/N5102

Operate pick-and-place machine SB11. to use basic math skills and standard and metric measurement SB12. to map x-y coordinates on PCB

NOS Code

ELE/N5102

Credits(NVEQF/NVQF/NSQF) TBD [OPTIONAL] Industry Electronics Industry Sub-sector

PCB Assembly

Version number

1.0

Drafted on

06/02/14

Last reviewed on

24/03/14

Next review date

24/03/15

NOS Version Control

7

ELE/N9919 Work with superiors and colleagues --------------------------------------------------------------------------------------------------------------------

Overview This unit is about the individual’s level of communication with colleagues and other departments within the organisation. It determines the ability to work as a team member to achieve the required deliverables on schedule.

8

ELE/N9919

National Occupational Standard

Unit Code Unit Title (Task) Description Scope

Work with superiors and colleagues ELE/N9919 Work with superiors and colleagues This OS unit is about communicating, coordinating and maintaining proper relationship with colleagues and seniors in order to achieve smooth work flow This unit/ task covers the following:  

Interact with supervisor or superior Coordinate with colleagues

Performance Criteria(PC) w.r.t. the Scope

Element

Performance Criteria

Interacting with supervisor

To be competent, the user/ individual must be able to: PC1. understand work requirements by receiving instructions from reporting supervisor PC2. understand standard operating procedure of the company PC3. escalate problems that cannot be handled including repetitive PCB defects, machine failures, potential hazards, process disruptions, repairs and maintenance of machine PC4. report work completed and receive feedback on work done PC5. resolve personnel issues PC6. rectify errors as per feedback and minimize mistakes to zero in future PC7. communicate about process flow improvements, quality of output, product defects received from previous process, repairs and maintenance of tools and machinery as required and find technical solutions on specific issues PC8. handover completed work and deliver the work of expected quality despite constraints To be competent, the user/ individual must be able to: PC9. collect required spares and raw materials from tool room or stores PC10. deposit unused or faulty materials, parts and tools to stores PC11. assist colleagues where necessary and as per capability PC12. resolve conflicts with colleagues at work to achieve smooth workflow PC13. complete rework in time based on feedback from quality or process departments PC14. put team over individual goals

Interacting with colleagues

Knowledge and Understanding (K) A. Organizational Context (Knowledge of the company / organization and its processes)

The individual on the job needs to know and understand: KA1. company’s policies on: incentives, delivery standards, and personnel management KA2. work flow involved in company’s process KA3. importance of the individual’s role in the workflow KA4. reporting structure

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ELE/N9919 B. Technical Knowledge

Work with superiors and colleagues The individual on the job needs to know and understand: KB1. how to communicate effectively KB2. how to build team coordination

Skills (S) [Optional] A. Core Skills/ Generic Skills

B. Professional Skills

Teamwork and Multitasking The individual on the job needs to know and understand how: SA1. to deliver product to next work process on time SA2. to share work load as required Decision Making The individual on the job needs to know and understand: SB1. how to report potential areas of disruptions to work process SB2. when to report to supervisor and when to deal with a colleague depending on the type of concern Reflective Thinking The individual on the job needs to know and understand: SB3. To reduce repetitive errors and improve work process Critical Thinking The individual on the job needs to know and understand: SB4. how to spot process disruptions and delays

10

ELE/N9919

Work with superiors and colleagues

NOS Version Control

NOS Code

ELE/N9919

Credits(NVEQF/NVQF/NSQF) TBD [OPTIONAL] Industry Electronics Industry Sub-sector

PCB Assembly

Version number

1.0

Drafted on

06/02/14

Last reviewed on

24/03/14

Next review date

24/03/15

11

ELE/N9920 Follow safety procedures --------------------------------------------------------------------------------------------------------------------

Overview This unit is about the worker’s commitment towards reporting potential hazards and containing accidents in order to make the work environment safe, healthy and secure, for self and colleagues

12

ELE/N9920

National Occupational Standard

Unit Code Unit Title (Task) Description Scope

Follow safety procedures ELE/N9920 Follow safety standards This OS unit is about following safety procedures, communicating potential hazards and dangers of accidents on the job This unit/ task covers the following:  Understand potential sources of accidents  Use safety gear to avoid accidents  Understand the safety procedures followed by the company

Performance Criteria(PC) w.r.t. the Scope

Element

Performance Criteria

Understanding potential sources of accidents

To be competent, the user/individual on the job must be able to: PC1. spot and report potential hazards on time PC2. follow company policy and rules regarding hazardous materials PC3. avoid accidents related to use of potentially dangerous chemicals, gases, sharp tools and hazards from machines which involves exposure to possible injuries such as cuts, bites, stings, minor burns, etc. PC4. Handle with care when using an electrical drill and sharp cutting objects To be competent, the user/individual on the job must be able to: PC5. understand which safety gear must be used for a particular task PC6. eye, respiratory and hearing protection as per company policy PC7. use safety gear such as respirator, mask, skull caps, gloves, googles, jacket , etc., as prescribed for the job To be competent, the user/individual on the job must be able to: PC8. comply with standard health and safety procedure followed in the company while handling an equipment and hazardous materials and tools or situations PC9. understand and follow the evacuation procedure properly such as fire drills, emergency evacuation procedures, first aid to self and others, etc., which help in case of an emergency To be competent, the user/ individual must be able to: PC10. take adequate safety measures while on work to prevent accidents PC11. ensure zero accidents in work PC12. avoid damage of components due to negligence in ESD procedures PC13. ensure no loss for company due to safety negligence PC14. ensure proper machine maintenance, work process achieving quality outputs as per the company standard To be competent, the user/ individual must be able to: PC15. improve process flow to reduce anticipated or repetitive hazards PC16. report on mishandling of tools, machines or hazardous materials and on electrical problems that could result in accident PC17. escalate about any hazardous materials or things found in the premises PC18. report about any breach of safety procedure in the company PC19. follow electrostatic discharge (ESD) measures for electronic component safety

Using safety gear

Understanding of safety procedures

Following daily safety measure

Communicating to supervisor

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ELE/N9920

Follow safety procedures

Knowledge and Understanding (K) A. Organizational Context (Knowledge of the company / organization and its processes)

The individual on the job needs to know and understand: KA1. company’s policies on handling: harmful chemicals and sharp tools, safety and hazards of machines, fire safety/drill, first aid and, disposal of harmful chemicals and materials, quality standards KA2. company occupational safety and health policy followed KA3. company emergency evacuation procedure KA4. company’s medical policy

B. Technical

The individual on the job needs to know and understand: KB1. how to maintain the work area safe and secure KB2. how to handle hazardous material KB3. how to follow safety procedures while operating hazardous tools and equipment KB4. emergency procedures to be followed such as fire accidents and fire safety education KB5. how to use machines and tools without causing bodily harm KB6. first aid execution KB7. disposal of hazardous chemicals, tools and materials by following prescribed environmental norms or as per company policy

Knowledge

Skills (S) [Optional] A. Core Skills/ Generic Skills

B. Professional Skills

Communication Skills The individual on the job needs to know and understand how: SA1. to effectively communicate the danger SA2. to understand the quality standard of the company Reflective Thinking The individual on the job needs to know and understand how: SA3. to learn from past mistakes regarding use of hazardous machines, tools or chemicals Critical Thinking The individual on the job needs to know and understand: SA4. how to spot danger SA5. procedure to follow in the event of a fire or other hazard Handling Safety Equipment The individual on the job needs to know and understand: SA6. how to use safety materials such as gloves, etc. SA7. how to use safety equipments such as fire extinguisher during fire accidents Decision Making The individual on the job needs to know and understand: SA8. importance of reporting potential sources of danger SA9. appropriate actions to be taken in the event of an accident SA10. procedure for disposing of hazardous materials, safely and following environmental guidelines

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ELE/N9920

Follow safety procedures

NOS Version Control

NOS Code

ELE/N9920

Credits(NVEQF/NVQF/NSQF) TBD [OPTIONAL] Industry Electronics Industry Sub-sector

PCB Assembly

Version number

1.0

Drafted on

06/02/14

Last reviewed on

24/03/14

Next review date

24/03/15

15

Qualifications Pack For Pick and Place Assembly Operator

Keywords /Terms

Definitions

Sector

Sub-sector Occupation Function

Sub-function Job role Occupational Standards (OS)

Performance Criteria National Occupational Standards (OS) Qualifications Pack (QP)

Unit Code Unit Title Description

Scope

Knowledge and Understanding Organisational Context

Description Sector is a conglomeration of different business operations having similar business and interests. It may also be defined as a distinct subset of the economy whose components share similar characteristics and interests. Sub-sector is derived from a further breakdown based on the characteristics and interests of its components. Occupation is a set of job roles, which perform similar/ related set of functions in an industry. Function is an activity necessary for achieving the key purpose of the sector, occupation, or an area of work, which can be carried out by a person or a group of persons. Functions are identified through functional analysis and form the basis of OS. Sub-functions are sub-activities essential to fulfil the achieving the objectives of the function. Job role defines a unique set of functions that together form a unique employment opportunity in an organisation. OS specify the standards of performance an individual must achieve when carrying out a function in the workplace, together with the knowledge and understanding they need to meet that standard consistently. Occupational Standards are applicable both in the Indian and global contexts. Performance criteria are statements that together specify the standard of performance required when carrying out a task. NOS are occupational standards which apply uniquely in the Indian context. QP comprises the set of OS, together with the educational, training and other criteria required to perform a job role. A QP is assigned a unique qualifications pack code. Unit code is a unique identifier for an Occupational Standard, which is denoted by an ‘N’ Unit title gives a clear overall statement about what the incumbent should be able to do. Description gives a short summary of the unit content. This would be helpful to anyone searching on a database to verify that this is the appropriate OS they are looking for. Scope is a set of statements specifying the range of variables that an individual may have to deal with in carrying out the function which have a critical impact on quality of performance required. Knowledge and understanding are statements which together specify the technical, generic, professional and organisational specific knowledge that an individual needs in order to perform to the required standard. Organisational context includes the way the organisation is structured and how it operates, including the extent of operative knowledge managers have of their relevant areas of responsibility. 16

Technical Knowledge

Acronyms

Core Skills/ Generic Skills

Keywords /Terms

Qualifications Pack For Pick and Place Assembly Operator Technical knowledge is the specific knowledge needed to accomplish specific designated responsibilities. Core skills or generic skills are a group of skills that are the key to learning and working in today’s world. These skills are typically needed in any work environment in today’s world. These skills are typically needed in any work environment. In the context of the OS, these include communication related skills that are applicable to most job roles. Description

IPR

Intellectual Property Rights

NOS

National Occupational Standard(s)

NVQF

National Vocational Qualifications Framework

NSQF

National Qualifications Framework

NVEQF

National Vocational Education Qualifications Framework

PCB

Printed Circuit Board

QP

Qualifications Pack

17

Qualifications Pack For Pick and Place Assembly Operator

Annexure Nomenclature for QP and NOS Qualifications Pack 9 characters

[ABC]/ Q 0101

[Insert 3 letter codes for SSC]

QP number (2 numbers)

Q denoting Qualifications Pack

Occupation (2 numbers)

Occupational Standard

An example of NOS with ‘N’

9 characters

[ABC] /N0101

[Insert 3 letter code for SSC]

OS number (2 numbers)

N denoting National Occupational Standard

Occupation (2 numbers)

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Qualifications Pack For Pick and Place Assembly Operator

The following acronyms/codes have been used in the nomenclature above: Range of Occupation numbers

Sub-sector Passive Components

01 - 10

Semiconductors

11 - 20

PCB Manufacturing

21 - 30

Consumer Electronics

31 - 40

IT Hardware

41 - 50

PCB Assembly

51 - 55

Solar Electronics

56 - 60

Strategic Electronics

61 - 65

Automotive Electronics

66 - 70

Industrial Electronics

71 - 75

Medical Electronics

76 - 80

Communication Electronics

81 - 85

PCB Design

86 - 90

LED

91 - 95

Sequence

Description

Example

Three letters Slash

Industry name /

ELE /

Next letter

Whether QP or NOS

Q

Next two numbers

Occupation code

01

Next two numbers

OS number

01

19