ROLE IN ON JOB TRAINING(OJT-1)

AS ASSEMBLER

In the first On Job Training(OJT-1) we gained knowledge about the

component forming and the proper stuffing of components in
polarized place.

The Basics of Printed Circuit Board Assembly

Printed circuit board assembly, also known as “stuffing” or “populating
the bare printed circuit board is quite an intricate process involving many
different phases.
Substrate -This is the base material of a PCB. It gives the PCB its
rigidity.

Copper - A thin layer of conductive copper foil is added to each

functional side of the PCB on one side if it's a single-sided PCB, and on
both sides if it's a double-sided PCB. This is the layer of copper traces.

Through-Hole PCB Assembly -Works well on components with leads or

wires that have to be mounted on board by plugging them through holes
on board. The extra lead part has to be soldered on the other side of the
board. This technology is applied on PCB assemblies containing large
components such as capacitors, resistors etc to be assembled.

Step 1: Components Placement - This step is achieved manually by

professional engineering staff. Engineers need to quickly, yet precisely
place components on corresponding positions based on client's PCB
design files. Component placement must conform to regulations and
operation standards of thru-hole mounting process to guarantee high
quality end products. For example, they have to clarify polarity and
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orientation of components, to stop operating component from affecting
ambient components, to make completed component placement
compatible with corresponding standards and to wear anti-static
wristbands when dealing with static-sensitive components like ICs.

Step 2: Inspection & Rectification - Once component placement is

completed, the board is then placed in a matching transport frame where
board with components plugged in will be automatically inspected so as
to determine whether components are accurately placed. If issues
concerning component placement are observed, it's easy to get them
rectified immediately as well. After all, this takes place prior to soldering
in PCBA process.

Step 3: Wave Soldering - Now the THT components should be

accurately soldered onto circuit board. In the wave soldering system, the
board moves slowly over a wave of liquid solder at high temperature,
approximately 500°F. Afterwards, all leads or wires connections can be
successfully obtained so that thru-hole components are firmly attached to
the board.

Solder Paste -Solder paste is a combination of flux, a chemical created to

assist in the bonding and melting of the metal, and small fragments of
metal (solder) in order to apply the electronic components to the printed
circuit board. The paste is placed on the board in specific places along the
board in exact amounts with the use of a Solder Stencil and a paste
application machine, automatically.

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Silkscreen -A white silkscreen is the final layer on a PCB board. This
layer adds labels to the PCB in the form of characters and symbols. This
helps indicate the function of each component on the board.

Rigid PCB: The most common type of PCB base is a rigid one that
accounts for majority of PCBAs. The solid core of a rigid PCB gives the
board rigidity and thickness. These inflexible PCB bases consist of a few
different materials. The most common is fiberglass, otherwise designated
as "FR4". Less expensive PCBs are made with materials like epoxies or
phenolics, though these are less durable than FR4.

Flexible PCB: Flexible PCBs offer a bit more pliability than their more
rigid counterparts. The material of thesePCBs tends to be a bendable,
high-temperature plastic like Kapton.

Metal Core PCB: These boards are yet another alternative to the typical
FR4 board. Made with a metal core, these boards tend to spread heat
more efficiently than others. This helps dissipate heat and protect more
heat sensitive board components.

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Accessories required to manufacture PCB's

1. Forming Machine

This is an automatic cut & form machine dedicated for processing Axial
components, right from 1/8 watt to 2watt resistors and other devices in
this range. This is a table-top machine capable of handling both, loose
and taped components. A special geared motor serves as the drive for the
cut-form operation.High-Speed-Steel pick-up-wheels and tool-set
provides an almost infinite tool-life to the machine. The machine is fully
adjustable for different pitch size and cut-to-bend lengths. Change-over
from one component geometry to the other takes just 5 minutes, making it
ideal for production on lot basis.A unique loose feeding hopper system is
the heart of the machine, providing a trouble-free feed of components
from the feeding hopper to the machine.For changing over from loose-
feed to Tape-feed (axials), one has to simply interchange the loose-feed
tool module to Tape-feed tool module. Or replace the hopper feeding
system with Tape-feeding system.

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2. Zig's

For cutting electronic components in proper size

3. Magnifier

This is a very practical loupe magnifier in an engineers life. It is designed

especially for extra sharpness and clarity. It can enlarge fine detail in
circuit boards, components, soldering and also in jewelry, maps,
newspapers, directories, legal documents, coins, stamps and antiques etc.
When it is not currently being used,, the lens can be retracted in the body.
The design, it is so compact and lightweight that it can be easily put into
your pocket/small bag wherever you go.

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The tool that is seen on every electronics workbench. The third-hand
holds a PCB board as you solder it. Its arms are fully adjustable in all
directions and help to give you maximum flexibility. Its bottom arm has
two alligator clips on either side which can be used to fix boards. Also,
the third hand comes in handy when you have to tin wire ends, solder
parts, etc. A high-power magnifying glass magnifies the point being
soldered. The magnifying glass can also be rotated and adjusted to any
desired position. The whole tool is fixed onto a heavy base which gives
maximum stability. This Item comes with an Inbuilt LED light and
Soldering Stand.

4. Wave Soldering Machine

Wave soldering is a bulk soldering process that enables one to

manufacture many circuit boards in a very short amount of time. It works
by passing each circuit board over a pan of molten solder. A pump in the
pan creates a “wave” of solder that washes over the board, soldering the
components to the board. The PCB then receives a water spray or air
blowing to safely cool it and fix the parts in place.

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5. Soldering Station with Solder Gun

A soldering iron is a hand tool used in soldering. It supplies heat to

melt solder so that it can flow into the joint between two workpieces.

A soldering iron is composed of a heated metal tip (the bit) and an

insulated handle. Heating is often achieved electrically, by passing an
electric current (supplied through an electrical cord or battery cables)
through a resistive heating element. Cordless irons can be heated by
combustion of gas stored in a small tank, often using a catalytic
heater rather than a flame. Simple irons, less commonly used today than
in the past, were simply a large copper bit on a handle, heated in a
flame.Solder melts at approximately 185 °C (365 °F). Soldering irons are
designed to reach a temperature range of 200 TO 480 Celcius

6. De-Soldering Pump

A desoldering pump, also known as a solder sucker, is a device used to

remove molten solder from a joint. To use it effectively, you must heat up
the solder joint with a soldering iron until the solder melts. Then, position
the tip of the desoldering pump close to the joint and press the button to
activate the vacuum. Once you release the button, the solder will be

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ejected from the pump and you should clean the tip with a damp sponge.
This process should be repeated until all of the solder is removed from
the joint.

7. Automated Torque Machine

A screw that’s been tightened may either lose its thread or be ruined. In
any event, it is not repairable. The optimal/optimally solution would be to
restore the damaged or broken threads. This endeavor might be achieved
by employing a automatic screw sharpening machine.

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8. Automated Punching Machine

9. Magazine’s, Stackers and Bins

ESD bins and ESD totes diminish the risk of damage from electrostatic
discharge, making it easier to handle, transport and store static-sensitive
components and materials. ESD bins are made of polypropylene with
conductive material that prevents the buildup of electrostatic charge.
They are permanently conductive and are not affected when washed with
normal cleaners.

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5’S HOUSE KEEPING

In English, these words are often translated to:

 Sort
 Set in Order
 Shine
 Standardize
 Sustain
5S began as part of the Toyota Production System (TPS), the
manufacturing method begun by leaders at the Toyota Motor Company in
the early and mid-20th century. This system, often referred to as Lean
manufacturing in the West, aims to increase the value of products or
services for customers. This is often accomplished by finding and
eliminating waste from production processes.

Benefits of 5S
Over time, the 5S methodology leads to many benefits, including:
 Reduced costs
 Higher quality
 Increased productivity
 Greater employee satisfaction
 A safer work environment

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