Model Curriculum · 11/30/2018 · form, package mould, simulation and plating systems Automatic...

EMS Engineer

Model Curriculum

EMS Engineer SECTOR: Electronics

SUB-SECTOR: Electronics Manufacturing System

OCCUPATION: Manufacturing

REF ID: ELE/Q5312, V 1.0

NSQF LEVEL: 6

EMS Engineer

EMS Engineer

1. Curriculum 5

2. Trainer Prerequisites 16

3. Annexure: Assessment Criteria 17

TABLE OF CONTENTS

1. Curriculum 01

2. Trainer Prerequisites 09

3. Annexure: Assessment Criteria 10

EMS Engineer

1

EMS Engineer CURRICULUM / SYLLABUS

This program is aimed at training candidates for the job of a “EMS Engineer”, in the “Electronics

Sector Skills Council of India” Sector/Industry and aims at building the following key competencies

amongst the learner

Program Name EMS Engineer

Qualification Pack Name & Reference ID

ELE/Q5312 VERSION 1.0

Version No. 1.0 Version Update Date 30/11/2018

Prerequisites to Training B. Tech/ Diploma ( Electronics and Communication Engineering / Instrumentation / Electrical and Electronics / Electrical )

Minimum 3 years in relevant industry Training Outcomes

After completing this programme, the participants will be able to:

Identify the role and responsibilities of an EMS engineer

Follow safety rules and procedures

Set up magazine loader to supply PCB and unload the PCB

Set up solder paste stencil printer, mounter and solder paste inspector

Set up reflow oven and EOI

Demonstrate control of SMT material and consumable

Demonstrate control of equipment parts and plan productivity

Apply the control and monitoring of PCB quality

Complete the maintenance of SMT full line process and machines

Conform to the proper documentation process

Demonstrate appropriate interaction with superiors and colleagues

Comply with the organizational structure

EMS Engineer

2

This course encompasses 04 out of 04 National Occupational Standards (NOS) of “EMS Engineer”

Qualification Pack issued by “Electronics Sector Skills Council of India”.

Sr. No.

Module Key Learning Outcomes Equipment Required

1. Introduction

Theory Duration

(hh:mm)

01:00

Practical Duration

(hh:mm)

01:00

Corresponding NOS Code

Bridge module

Identify the topics to be taught in the course

Identify the role and responsibilities of an EMS engineer

Data projector, laptop, computer, speaker, projection screen

2. Follow Safety Rules and Procedures

Theory Duration

(hh:mm)

20:00

Practical Duration

(hh:mm)

30:00


ELE/N5312

Demonstrate work safety as per the company standards at all times

Use suggested Personal Protective Equipment (PPE) such as protective head covers, Electro Static Discharge (ESD) gloves, finger cots, ESD slipper/shoes, ESD wrist bands, aprons and eye protection glasses

Categorize possible risks associated with the work and Apply the necessary safety control measures

Identify electrostatic protected areas with ESD sensitive parts

Apply appropriate ground paths and electrical safety practices while handling power tools and equipment

SMT machines, circuit boards, soldering equipment, feeders,

Soldering unit, stencils, epoxy and soft solder bonders, high precision flip chip bonders, stacked die bonders, trim & form, package mould, simulation and plating systems

Automatic wire bonders, multi axis welding machine, manual wire bonders, table top wire bonders, solder reflow systems and PPEs

3. Set up Magazine Loader to Supply the PCB and Unload the Assembled PCB

Theory Duration

Inspect the critical operating check points and set up the machine for production

Prepare a plan for changeover as per production planning

Inspect the working condition of the machine

SMT machines, circuit boards, soldering equipment, Soldering unit, stencils, epoxy and soft solder bonders, high precision flip chip bonders, stacked die bonders, trim & form, package mould,

EMS Engineer

3

(hh:mm)

20:00

Practical Duration

(hh:mm)

30:00


ELE/N5313

Prepare a preventive maintenance schedule

Create the required documents such as magazine and loading procedure, changeover procedure, production report, work instructions and operating checkpoint and maintenance check sheet as per the company policy

Inspect documents such as production reports, work instructions and operating checkpoint and maintenance check-sheet

simulation and plating systems


4. Set up Solder Paste Stencil printer, Mounter and Solder Paste Inspector

Theory Duration

(hh:mm)

20:00

Practical Duration

(hh:mm)

30:00


ELE/N5313

Prepare the machine and set up it for production

Follow the Standard Changeover Procedure while doing the changeover

Prepare the screen stencil printer parameter set up chart with parameters such as program name, squeegee speed, pressure, snap off, cleaning frequency, board size, print gap and 2D inspection mode

Inspect the critical operating check points as per the standard check sheet

Prepare the specification of stencil mask and order the new stencil

Organize the required documents

Use feeder and nozzle as per the product and prepare part library

Prepare shift data and program as per standard guidelines and run it to check errors

Inspect and control machine drop page (components)

Follow preventive maintenance schedule on a daily, weekly and monthly basis as per the recommendation from the manufacturer

Compute a program and debug it for false call

SMT machines, circuit boards, soldering equipment, feeders, Soldering unit, stencils, epoxy and soft solder bonders, high precision flip chip bonders, stacked die bonders, trim & form, package mould, simulation and plating systems


EMS Engineer

4

Identify defects by checking the feedback and implement the complete corrective action

5. Set up Reflow Oven and AOI

Theory Duration

(hh:mm)

20:00

Practical Duration

(hh:mm)

30:00


ELE/N5313

Set up the soaking temperature profile for glue, Pb and Pb free products

Revise the temperature for air reflow oven and N2 reflow oven

Prepare the model-wise dummy PCB as per the procedure

Revise the temperature of reflow oven as per the output defects

Arrange required documents such as machine operating procedure, changeover procedure, programming and debugging procedure, production reports, work instructions, operating checkpoint and maintenance check sheet as per the company policy

SMT machines, circuit boards, soldering equipment, feeders, carriages and stencil printer



6. Control SMT Material and Consumable

Theory Duration

(hh:mm)

20:00

Practical Duration

(hh:mm)

30:00


ELE/N5313

Prepare a plan for the material supply process such as Inspect the Bill of Material (BOM) , material in/out process , set up to work with the kitting System , material control procedure , in/out process and Inspect storage check point

Arrange consumable control procedure




7. Control Equipment Parts and Plan Productivity

Theory Duration

Set up the line and facilitate installation of equipment

Inspect equipment for proper levelling

Prepare the Incoming Quality Check (IQC) process as per product specifications and application


Soldering unit, stencils, epoxy and soft solder bonders, high precision

EMS Engineer

5

(hh:mm)

20:00

Practical Duration

(hh:mm)

30:00


ELE/N5314

Follow the equipment history card

Identify and arrange the required equipment and spare parts

Inspect the production-line capability including operational loss

Prepare product wise production plan

Demonstrate how to control and estimate processes of machine down time

Demonstrate how to control product efficiency and capacity

flip chip bonders, stacked die bonders, trim & form, package mould, simulation and plating systems


8. Control and Monitor PCB Quality

Theory Duration

(hh:mm)

20:00

Practical Duration

(hh:mm)

30:00


ELE/N5314

Apply corrective actions after analyzing and evaluating quality defects to achieve the highest quality of standards

Take immediate action on any feedback related to quality concerns keeping in mind product specification and applications

Inspect corrective measures undertaken for the defects

Prepare the quality standards to be maintained

Create quality monitoring reports as per the company policies and Apply them

Inspect the corrective action undertaken in case of any quality accidents (defects)




9. Maintain SMT Full Line Process and Machines

Theory Duration

(hh:mm)

20:00

Practical Duration

(hh:mm)

30:00


Operate the maintenance of the SMT full line process and machines

Evaluate the different steps of the production process such as loading bare PCB in loader, screen stencil printer printing, inspecting solder paste, mounting of components, soldering in reflow oven, inspection by AOI and unloading of populated PCB in the magazine rack

Examine defects in the process and take immediate corrective action for any accidents occurring during the process



Automatic wire bonders, multi axis welding

EMS Engineer

6

ELE/N5314 Demonstrate that there is no shut down of machine due to improper maintenance

Complete the regular cleaning and lubrication process as prescribed by the manufacturer of the machine

machine, manual wire bonders, table top wire bonders, solder reflow systems and PPEs

10. Carry out Documentation

Theory Duration

(hh:mm)

20:00

Practical Duration

(hh:mm)

30:00


ELE/N5314

Demonstrate proper maintenance of all reports such as production, part change, stencil cleaning and inspection

Prepare documents such as reports, procedures, work instructions, set up chart and check sheets

Complete correct and accurate entry of production quantity in the report

11. Interact with Colleagues and Superior

Theory Duration

(hh:mm)

12:00

Practical Duration

(hh:mm)

20:00


ELE/N9909

Apply the standard operating procedure and work requirements after receiving instructions from the supervisor

Follow the procedure for reporting completed work and receiving feedback on work done

Identify and repair errors as per the feedback and minimize it

Follow the procedure for handing over completed work and ensuring that the delivered work is of expected quality despite constraints

Arrange for collection of required spares and raw materials from the tool room and deposit of faulty or unused ones

Demonstrate team skills such as supporting colleagues when necessary and resolving conflicts appropriately

12. Organisational Structure

Follow the company policies and procedures

EMS Engineer

7

Theory Duration

(hh:mm)

07:00

Practical Duration

(hh:mm)

09:00


Bridge Module

Inspect the work area to ensure safety of employees, machinery etc

Follow waste management practices as per company standards

Follow processes pertaining to organizational record management systems, reporting systems, HR policies and the escalation matrix

Total Duration Theory Duration

(hh:mm)

200:00 Practical Duration

(hh:mm)

300:00

Unique Equipment required:

Computers




Grand Total Course Duration: 500 Hours 00 Minutes (This syllabus/ curriculum has been approved by Electronics Sector Skills Council of India)

EMS Engineer

8

Trainer Prerequisites for Job role: “EMS Engineer” mapped to Qualification Pack: “ELE/Q5312” Version 1.0

Sr. No.

Area Details

1 Job Description To deliver accredited training service, mapping to the curriculum detailed above, in accordance with the Qualification Pack “ELE/Q5312 version1.0”.

2 Personal Attributes A Trainer should be free from socio-economic preferences and prejudice. He/ she should be safety conscious and proficient in handling and use security/ safety equipment. Besides being knowledgeable, he/ she should be energetic, motivating, innovative and good at communication. The trainer should be able to establish rapport with the trainees and employ innovative methods to impart instructions.

3 Minimum Educational Qualifications

B. Tech/Diploma in Electronics and Communication Engineering

4a Domain Certification Certified for Job Role: “EMS Engineer” mapped to QP: “ELE/ Q5312 version1.0”. Minimum accepted score is 80%

4b Platform Certification Recommended that the Trainer is certified for the Job Role: “Trainer”, mapped to the Qualification Pack: “MEP/Q0102”with scoring of minimum 80%

5 Experience Minimum 2 years of relevant industry experience along with min 1 year of training delivery experience.

EMS Engineer

9

Assessment Criteria for “EMS Engineer”

Job Role EMS Engineer

Qualification Pack ELE/Q5312, Version1.0

Sector Skill Council Electronics Sector Skills Council of India

Guidelines for Assessment

1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance

Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of

marks for Theory and Skills Practical for each PC.

2. Each NOS will have assessed both for theoretical knowledge and practical

3. The assessment will be based on knowledge bank of questions created by the SSC.

4. Individual assessment agencies will create unique question papers for theory and skill practical part for each

candidate at each examination/training center

5. To pass the Qualification Pack, every trainee should score a minimum of 70% in every NOS

6. In case of successfully passing only certain number of NOS's, the trainee is eligible to take subsequent

assessment on the balance NOS's to pass the Qualification Pack.

7. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.

Compulsory NOS Total Marks: 450

Marks Allocation

Assessment outcomes

Assessment Criteria for outcomes Total Marks

Out of

Theory Skills

Practical

ELE/N5313 Manage SMT Machine

PC1. set magazine loader to supply PCB to the screen printer for production

100

4 2 2

PC2. set un-loader to unload the assembled PCB 4 2 2

PC3. set solder paste printer 4 2 2

PC4. prepare screen printer parameter setup chart 3 1 2

PC5. prepare the specification of stencil mask and order the new stencil

3 1 2

PC6. set pick-and-place (Mounter) 3 1 2

PC7. select feeder and nozzle as per the product 3 1 2

PC8. prepare part library as per standards 4 2 2

PC9. prepare shift data as per standard guidelines 3 1 2

PC10. prepare program as per standard procedure 4 2 2

PC11. perform program optimization 4 2 2

PC12. run the program and clear errors if machine gets stuck due to any reason

3 1 2

PC13. control machine droppage (components) 3 1 2

PC14. set the reflow oven 3 1 2

PC15. set soaking temperature profile for glue, Pb 3 1 2

EMS Engineer

10

and Pb free products

PC16. set the temperature for air reflow oven and N2 reflow oven

4 2 2

PC17. prepare the model-wise dummy PCB as per procedure

4 2 2

PC18. modify the temperature of reflow oven as per output defects to control the quality of product

4 2 2

PC19. set Automated Optical Inspector (AOI) 4 2 2

PC20. observe the feedback for any defects and take required corrective actions

4 2 2

PC21. set the solder paste inspector 4 2 2

PC22. modify inspection part library for solder short, missing, shift, etc.

3 1 2

PC23. modify program and debug it for false call 5 2 3

PC24. check critical operating check points as per the standard check sheet

3 1 2

PC25. plan for changeover as per production planning

3 1 2

PC26. adhere to the model changeover procedure while changeover

3 1 2

PC27. ensure that the machine is in good working condition and maintenance is carried over as per the schedule

3 1 2

PC28. prepare preventive maintenance schedule 3 1 2

PC29. prepare required documents as per the company policy

3 1 2

100 42 58

ELE/N5314 Manage production process, material quality and machines

PC1.prepare material supply process

100

2 1 1

PC2.prepare Bill of Material (BOM) 2 1 1

PC3.prepare material In/Out process 2 1 1

PC4.set the kitting system 3 1 2

PC5.prepare material control procedure 2 1 1

PC6.prepare In/Out Process 3 2 1

PC7.check storage check point 2 1 1

PC8.prepare consumable control Procedure 3 2 1

PC9.setup line and facilitate installation of equipment

3 1 2

PC10.check for equipment levelling 2 1 1

PC11.prepare IQC Process 3 1 2

PC12.prepare equipment history Card 2 1 1

PC13.prepare equipment & spare parts master list 3 1 2

PC14.manage the equipment & spare parts 3 1 2

PC15.check the line production capability including operational loss

3 1 2

EMS Engineer

11

PC16.prepare product wise production plan 4 1 3

PC17.control processes and machine down time 3 1 2

PC18.control product efficiency 3 1 2

PC19.control product capacity (Operational efficiency)

3 1 2

PC20.ensure that the quality data is controlled in PPM not in Percentage

2 1 1

PC21.prepare quality standards 3 2 1

PC22.collect and maintain the quality data 3 2 1

PC23.prepare quality monitoring reports as per company policies

3 2 1

PC24.prepare quality control process flow 3 2 1

PC25.take corrective action in case of any quality accidents (defects)

3 1 2

PC26.check for quality defects to achieve highest quality standards

3 1 2

PC27.monitor each defect and take corrective actions

3 1 2

PC28.prepare immediate feedback of any quality accidents

3 1 2

PC29.take corrective measures of the defective 3 1 2

PC30.monitor and manage the production process from loading bare PCB in loader to screen printer printing, Solder Paste Inspection, mounting of components, Soldering in reflow oven, inspection by AOI and un-loading of populated PCB in magazine rack

4 2 2

PC31.verify defects in process and take immediate corrective action on any accidents during process 3 1 2

PC32.verify that there should not be any shut down of machine due to improper maintenance 3 1 2

PC33.perform regular cleaning and lubrication process as prescribed by manufacturer of the machine

3 1 2

PC34.maintain properly all the reports 2 1 1

PC35.prepare reports, procedures, work instructions, setup chart and check-sheets

3 2 1

PC36.ensure that correct & accurate production quantity is entered in the report

2 1 1

Total 100 44 56

EMS Engineer

12

ELE/N5312 Follow safety rules and procedures

PC1.work safely at all times complying with company’s health and safety and environmental guidelines

100

15 5 10

PC2.wear suggested Personal Protective Equipment (PPE) before entering the production shop floor

12 5 7

PC3.assess possible risks associated with the work and implement necessary safety control measures to prevent injury to self and others

15 5 10

PC4.identify and work in electrostatic protected areas while working with ESD sensitive parts

15 5 10

PC5.ensure that appropriate ground paths are established to reduce electrostatic charge generation and accumulation as per relevant occupational health and safety guidelines

15 5 10

PC6.comply with electrical safety practices while handling power tools and equipment

15 5 10

PC7.verify that static control materials are used while handling assembly parts

13 5 8

Total 100 35 65

ELE/N9909 Coordinate with colleagues

PC1.assess work requirements

100

5 2 3

PC2.carry out targets and calculate incentives 5 2 3

PC3.identify new operating procedures and constraints

8 3 5

PC4.report problems in the field 5 2 3

PC5.resolve personnel issues 5 2 3

PC6.receive feedback on work standards and customer satisfaction

5 2 3

PC7.communicate any potential hazards at a particular location

8 3 5

PC8.meet given targets 8 3 5

PC9.deliver work of expected quality despite constraints

8 3 5

PC10.receive positive feedback on behaviour and attitude shown during interaction 8 3 5

PC11.interact with colleagues from different functions and understand the nature of their work 8 3 5

PC12.receive spares from tool room or stores; deposit faulty modules and tools to stores 8 3 5

PC13.pass on customer complaints to colleagues in a respective geographical area 5 2 3

EMS Engineer

13

PC14.assist colleagues with resolving field problems resolve conflicts and achieve smooth workflow 8 3 5

PC15.resolve conflicts and achieve smooth workflow

3 1 2

PC16. follow the company policy during cross functional interaction

3 1 2

Total 100 38 62

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Model Curriculum · 11/30/2018 · form, package mould, simulation and plating systems Automatic...

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