competency in skills and knowledge through assessment tests,
but are not required to complete a specific number of hours.
Electrical and Electronic Equipment Assembler
USDOL
Work Process Content
On the Job Training
Follows safety practices
11
- Develops and practices safe working habits to ensure the safety Of fellow workers and self
- Observes all company policies regarding safety equipment and procedures
- Locates Materials Safety Data Sheets (MSDS)
- Locates first-aid materials and implements employer's first-aid procedures, when necessary
- Inspects equipment and tools for defects, checks whether equipment is energized or not, and ensures proper working order (e.g., electrostatic discharge safety)
- Uses personal protective equipment while completing assigned tasks
- Maintains a clean, orderly, foreign object damage (FOD) free work area
- Provides safety instructions for electronic systems users
- Completes necessary safety training as directed by supervisors (e.g., OSHAIO, CPR, NFPA, lock out/tag out, etc.)
- Safely and appropriately operates lifting equipment
- Optional: Adheres to FDA standards when applicable
Interprets and communicates plans to prepare for assembly of systems
5
- Reads and interprets schematic drawings, diagrams, blueprints, specifications, work orders, or reports to determine material requirements or assembly instructions.
- Reviews blueprints or other instructions to determine operational methods or sequences.
- Explains assembly procedures or techniques to other workers and supervisors.
- Marks or tags identifications on parts for assembly.
- Follows instructions and standard operating procedures to complete the installation, repair, or maintenance of products
Assembles electrical or electronic systems
6
- Assembles support structures and installs components, units, subassemblies, wiring, motor controls, or assembly casings, using appropriate tools
- Fabricates or forms parts, components, or structures according to specifications, using appropriate tools
- Coats structure as specified using appropriate surface finish
- Positions, aligns, or adjusts workpieces or electrical parts to facilitate wiring or assembly to meet product specifications
- Inspects assemblies to ensure product specifications have been met
- Optional: Drills or taps holes in specified equipment locations to mount control units or to provide openings for elements, wiring, or instruments
Provides maintenance and repairs on equipment and systems
9
- Adjusts, repairs, or replaces electrical or electronic components to correct defects and to ensure conformance to specifications
- Conducts preventive maintenance outlined by manufacturers’ service manuals
- Cleans parts, using specified cleaning techniques
- Advises clients and internal team members on issues related to repairs, installations, or equipment designs
- Inspects wiring installations, assemblies, or circuits to ensure they meet specified requirements
- Optional: Tests wiring installations, assemblies, or circuits to ensure they meet specified requirements
- Optional: Verifies instruments meet calibration requirements.
- Optional: Identifies and follows the steps needed for a preventative maintenance plan
- Optional: Performs repairs using appropriate hand tools following safety guidelines
Effectively plans and communicates production process with internal teams
9
- Communicates with supervisors or engineers to discuss work activities, recommend preventive maintenance or to resolve production problems
- Records, reviews or maintains operational or production data
- Follows company protocols for communication with colleagues
- Ensures the accurate transfer of information across internal teams
- Abides by principles of inclusion and equity in communication with team members and superiors
- Fosters open communication through active listening and facilitates shared understanding across teams
- Accepts constructive feedback to initiate communication improvements
- Abides by management principles, following company protocols (e.g., ISO certification, lean management)
- Optional: Provides suggestions to management on areas for improvement
Ensures proper functioning of electronic system
9
- Checks function and quality of individual components during the system installation process
- Uses flow meter to ensure proper power flow to and output from electronic system
- Tests electrical components or systems to verify proper function at the completion of assembly
- Uses programmable logic controllers (PLCs) to configurate input and output
- Conducts proper function test in accordance with test specifications
- Ensures all equipment is calibrated in accordance with calibration schedule
- Identifies and reports malfunctioning components of installations during assembly
- Records discrepancies or issues with electronic equipment
- Optional: Conducts quality inspection for compliance, as appropriate
Uses technology to assist in the assembly of electronic systems
5
- Uses resource planning software for production planning (e.g., Sage 100 ERP, MRP, SAP software)
- Uses spreadsheet software (e.g., Microsoft Excel) for documentation and tracking
- Remains up to date and proficient in emerging industry and internal company software (CAD, Solid Works, etc.)
- As appropriate, shows ability to use additive manufacturing techniques (e.g., 3D printing or other techniques)
- Optional: Programs automative machinery to complete designated tasks
Catalogs and distributes materials to appropriate stakeholders
6
- Optional: Reviews, marks, and tags components so that stock inventory can be tracked and identified
- Optional: Distributes materials, supplies, or subassemblies to work areas
- Optional: Completes checklist or creates a record of the distribution of materials
- Optional: Packs finished assemblies for shipment, and transports them to storage areas, using appropriate equipment
- Optional: Follows a process of database management for record keeping
- Optional: Oversees logistics of finished products; ensures that the processes of packing, storing, and shipping of finished product meets specified requirements
Related Instruction Content
Training Provider(s):
Employer Onboarding
3
Sample learning objectives Explain the mission of the employer’s organization. Explain the organizational structure of the employer’s organization. Explain the chain-of-command in the employer’s organization, as well as the steps an employee should take to report concerns about practices or behaviors in the workplace or to share ideas about how to improve processes or efficiencies. Explain the employer’s policies for workplace conduct and ethics. Explain the employer’s policies regarding medical leave and vacation. Explain the requirements of the apprenticeship program and the role of the apprentice in the organization’s business activities.
Technical Mathematics
45
Sample learning objectives Perform calculations involving addition, subtraction, multiplication, and division. Convert fractions to decimals and decimals to fractions; add, subtract, multiply and divide fractions and decimals and calculate proportions and ratios. Calculate rates of change. Calculate percentages and use percentages to determine the amount of materials to be used. Measure properly using a tape measure, convert between measurement systems (such as English to metric), and determine unknown measurements using algebra, geometry, or trigonometry. Use scientific notation and manipulate numbers expressed with exponents. Use algebraic techniques to solve for unknown variables, solve linear equations, follow correct order of operations, use the distributive law, and solve systems of equations. Define the various types and components of triangles, determine interior and exterior triangle angles, use the Pythagorean Theorem to solve problems for right triangles, and determine perimeter and area of triangles. Identify squares, rectangles, parallelograms, trapezoids, hexagons, octagons, pentagons, and quadrilaterals and calculate their perimeter and area. Calculate the diameter, radius, circumference, and arc of a circle. Use the Laws of Sines and Cosines to determine angles. Define and use mean, median, mode, and standard deviation. Create and interpret graphs.
Occupational Safety in the Manufacturing Environment
5
Sample learning objectives Explain and demonstrate compliance with best practices for ensuring a safe work environment. Explain OSHA regulations regarding hazardous materials. Demonstrate proper and consistent use of appropriate Personal Protective Equipment. Explain the importance of and demonstrate consistent application of Lockout/Tagout procedures. Describe OSHA regulations regarding energy isolation and demonstrate consistent compliance with those regulations. Describe OHSA regulations for storage, handling, and use of hazardous materials. Demonstrate the ability to locate and use Material Safety Data Sheets to determine how hazardous materials should be stored, transported, and used and to explain steps one should take should there be accidental exposure to the material. Demonstrate the ability to use appropriate equipment to extinguish fires. Explain the steps one should take in the event of broken bones, burns or lacerations, and describe how one should protect themselves and others from exposure to bloodborne pathogens. Identify safety equipment used in mechanical engineering, such as machine guarding. Describe and follow appropriate safety protocols when working around forklifts, trucks, and other vehicles.
Fundamentals of Electronics
45
Sample learning objectives Explain the principles of voltage and current and how they apply to electrical transmission. Differentiate between cathodes and diodes. Describe atomic structure, the role of electrons, and the process of energy release. Describe electron current flow and differentiate between AC and DC circuits. Differentiate between direct and alternating voltage and current sources. Discuss the process by which voltage is converted to current. Explain the importance of grounding. Explain the different types of electron emissions. Define and explain the purpose of semiconductors, amplifiers, and digital circuits. Explain the principles of rectification, amplification, control, and generation. Discuss the conversion of light into electricity and electricity into lights. Explain and properly use fundamental laws of physics/electricity including Ohm’s Law, Kirchoff’s laws, Thevenin’s theorem, Norton’s theorem. Identify and explain the function of diodes, transistors, integrated circuits (active components) as well as resistors, capacitors, and inductors (passive components). Differentiate between discrete and integrated components and explain how each is used in electronics and electronics assemblies. Explain the function and structure of semiconductors and differentiate between the different types of commonly used semiconductors. Discuss the function and structure of semiconductor diodes. Describe the purpose and give examples of special purpose diodes. Discuss the structure, function, and purpose of transistors. Explain the key safety protocols used by individuals who work with electricity to safeguard themselves, other workers, and property. Explain the purpose of lock out/tag out procedures and demonstrate the ability to properly perform a lock out/tag out operation.
PLCs and Robotic Assemblers
20
Sample learning objectives Explain the basic theory of PLC function and the elements of PLC programming, including inputs, outputs and conversions. Explain and use PLC programming instructions, comparators, and operators. Explain the purpose of proportional integral derivative control loops. Set up programs to configure modules, modify scale and resolution and develop function and program files. Demonstrate the ability to apply digital control logic. Explain the importance of alarms and notifications and build them into PLC programs. Design human–machine interfaces. Explain the benefits and limitations of robotic assemblers. Program and troubleshoot robotic assemblers. Demonstrate the ability to clean, maintain and operate PLCs and robotic arms.
Electronics Assembly (based on the IPC syllabus for Electronics Assembly for Operators)
50
Sample learning objectives Define key terms used in the electronics assembly industry, such as components, electronic assemblies, active versus passive, discrete versus integrated, through-hole mount, surface mount, 3D printing, programmable logic controller, robotics, and tolerance. Identify abbreviations and symbols commonly used in the electronics industry. Explain the role of IPC standards in the electronics industry and explain the purpose and requirements of key IPC standards. Explain the purpose, structure, attachment methods and uses of Printed Circuit Boards (PCBs). Differentiate between and describe the assembly and soldering process for surface-mount technology (SMT) and through-hole (TH) technology. Identify the source and risks of electrostatic discharge in electronics assembly, the function of grounding and static control devices, and proper handling of PCBs, PCAs, and foreign objects debris (FOD). Identify electronics components, differentiating between component polarity and orientation, between wires, cables, and harnesses. Identify types of terminals and hardware used in electronic assemblies. Identify the common components and features of a Printed Circuit Board (PCB) and Printed Circuit Assembly (PCA). List and define component types and characteristics and explain how these characteristics affect placement. Demonstrate the ability to use and interpret assembly drawings, specifications, and measurements to perform high quality assemblies and explain how the Bill of Materials is used in the assembly process. Demonstrate the ability to set up machines for assembly. Identify and troubleshoot process defects. Demonstrate use of standard safety practices used to mitigate risks to assemblers, their equipment, and their products.
Introduction to Soldering (based on the IPC Soldering Fundamental I Syllabus https://img.ipcedge.org/Training_Courses_Syllabus/Soldering_Fundamentals_I_Course_Sy llabus_5-20.pdf )
20
Sample learning objectives Describe the differences between welding, brazing, and soldering, and discuss the different types of soldering processes used in the electronics industry. Differentiate between through-hole and surface-mount components. Explain the characteristics and function of solder and flux. Identify and safely usEe hand soldering tools. Select the correct solder wire, solder tip, and solder temperature to perform assembly. Explain the role of wetting and oxides in the soldering process. Demonstrate proper use of Material Safety Data Sheets (MSDS) and Personal Protection Equipment (PPE) to engage in safe soldering. Discuss the health and environmental hazards of lead products and compare the characteristics and hazards of tin-fee and lead-free solder. Demonstrate the ability to handle and dispose of leaded solder and cleaning products properly. Identify materials used in the soldering process. Explain the causes and consequences of oxides. Explain why and how flux, tip tinner, solder wick, and post-soldering cleaners are used in the hand soldering process. Demonstrate safe and proper use of hand soldering tools and equipment, including a soldering station, soldering iron, hot air gun, and microscope. Demonstrate the ability to select the correct solder wire, solder tip, and solder temperature setting based on the type of components and joints involved in assembly. Form and bend plated through-hole (PTH) components for insertion and soldering. Explain the importance of cleaning and demonstrate the ability to clean a board after hand soldering. Demonstrate the ability to perform proper cleaning processes for no-clean and water-soluble flux residues.
Surface Mount Components
10
Sample learning objectives Explain the process of surface mount technologies. Explain the principles of reflow soldering. Explain the process of reflow soldering, the reflow process setup, requirements for fixturing and tooling, baseline process parameters, and their influence on solder joint quality. Demonstrate the ability to troubleshoot common process defects. Explain the process of wave soldering and its purpose and function in the electronics industry. Explain the purpose of and demonstrate the ability to use proper wave soldering materials, such as solders, fluxes, substrates, surface finishes, fixturing and support, and components. Demonstrate the ability to use wave soldering equipment, including fluxers, preheaters, solder pots, conveyors, and controls. Explain the process, function, and best uses of selective soldering. Demonstrate the ability to perform the selective soldering process, inspect products, identify defects, and develop process improvements or cures. Explain the purpose and processes for cleaning as well as the importance of evaluating material compatibility prior to initiating cleaning. Demonstrate the ability to properly clean components and assemblies.
Troubleshooting and Inspecting Electronic Assemblies
20
Sample learning objectives Explain the significance of IPC-A-610 in ensuring the quality of electronic assemblies. Define the acceptance criteria for through-hole components including component orientation, spacing and alignment; secure component mounting; sufficient lead length; intact component leads of PCB lands; solder quality, and solder joints. Inspect assemblies using these criteria. Define the acceptance criteria for surface-mount components including proper component orientation, spacing and alignment; component integrity; proper solder joint formation including wetting and fillet formation; lack of visible voices, excessive solder or solder bridging; and lack of misaligned components. Inspect assemblies using these criteria. Define the acceptance criteria for mixed-technology assemblies and properly inspect such assemblies. Inspect solder joints, joint fillets, joint shape, solder cleanliness, and joint strength. Inspect assemblies for cleaning and coating quality, coating thickness and coating material. Inspect assemblies for proper marking and labeling. Properly record/report defects and recommend corrective measures to eliminate future defects.