Model Curriculum · 11/30/2018 · form, package mould, simulation and plating systems Automatic...
Transcript of 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
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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
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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
Corresponding NOS Code
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
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(hh:mm)
20:00
Practical Duration
(hh:mm)
30:00
Corresponding NOS Code
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
Automatic wire bonders, multi axis welding machine, manual wire bonders, table top wire bonders, solder reflow systems and PPEs
4. Set up Solder Paste Stencil printer, Mounter and Solder Paste Inspector
Theory Duration
(hh:mm)
20:00
Practical Duration
(hh:mm)
30:00
Corresponding NOS Code
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
Automatic wire bonders, multi axis welding machine, manual wire bonders, table top wire bonders, solder reflow systems and PPEs
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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
Corresponding NOS Code
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
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
6. Control SMT Material and Consumable
Theory Duration
(hh:mm)
20:00
Practical Duration
(hh:mm)
30:00
Corresponding NOS Code
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
SMT machines, circuit boards, soldering equipment, feeders, carriages and stencil printer
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
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
SMT machines, circuit boards, soldering equipment, feeders, carriages and stencil printer
Soldering unit, stencils, epoxy and soft solder bonders, high precision
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(hh:mm)
20:00
Practical Duration
(hh:mm)
30:00
Corresponding NOS Code
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
Automatic wire bonders, multi axis welding machine, manual wire bonders, table top wire bonders, solder reflow systems and PPEs
8. Control and Monitor PCB Quality
Theory Duration
(hh:mm)
20:00
Practical Duration
(hh:mm)
30:00
Corresponding NOS Code
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)
SMT machines, circuit boards, soldering equipment, feeders, carriages and stencil printer
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
9. Maintain SMT Full Line Process and Machines
Theory Duration
(hh:mm)
20:00
Practical Duration
(hh:mm)
30:00
Corresponding NOS Code
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
SMT machines, circuit boards, soldering equipment, feeders, carriages and stencil printer
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
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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
Corresponding NOS Code
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
Corresponding NOS Code
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
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Theory Duration
(hh:mm)
07:00
Practical Duration
(hh:mm)
09:00
Corresponding NOS Code
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
SMT machines, circuit boards, soldering equipment, feeders, carriages and stencil printer
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
Grand Total Course Duration: 500 Hours 00 Minutes (This syllabus/ curriculum has been approved by Electronics Sector Skills Council of India)
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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.
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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
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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
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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
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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
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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