Assembling and wiring electronic equipment and systems

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This standard identifies the competences you need to assemble and wire up electronic products, inclusive of components, sub-assemblies, or completed equipment/systems, in accordance with approved procedures. You will be required to interpret the associated working instructions, to obtain and prepare all resources for any essential pre-wiring assembly aspects of the product, to obtain and prepare the resources to be used specifically for electronic wiring, then to wire up, interconnect and conduct limited preliminary checks on finished items. You will also be expected to maintain a record of the work undertaken and to hand over the work on completion of the assembly activities. Your responsibilities will require you to comply with organisational policy and procedures for the electronic assembly and wiring activities undertaken and to report any related problems that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking full responsibility for your own actions and for the quality and accuracy of the work that you carry out. Your underpinning knowledge will provide a good understanding of your work and will also provide you with an informed approach to applying the correct assembly and wiring procedures. You will understand the principles of electronic wiring and assembly work, in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the safety precautions required when working in an electronic assembly and wiring environment and with the associated equipment and tools. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.

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1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines
2. follow the relevant instructions, assembly drawings and any other specifications
3. ensure that the specified components are available and that they are in a usable condition
4. assemble the components in their correct positions, using appropriate methods and techniques
5. secure the components using the specified connectors and securing devices
6. check the completed assembly to ensure that all operations have been completed and it meets the required specification
7. deal promptly and effectively with problems within your control and report those that cannot be solved
8. ensure that work records are completed, stored securely and available to others, as per organisational requirements
9. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements

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1. the specific safety precautions to be taken whilst carrying out the  activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
2. the health and safety requirements of the work area  and the activities, and the responsibility these requirements place on you
3. the hazards associated with  the activities, and how to minimise them and reduce risks
4. the personal protective equipment and clothing (PPE) to be worn during the activities
5. voltage ranges, what constitutes a hazardous voltage and how to reduce the risks of a phase to earth shock
6. how to recognise and deal effectively with victims of electric shock (to include methods of safely isolating the power source and methods of first aid resuscitation)
7. regulations and standards relevant to electronic wiring and assembly (the latest electronics wiring regulations, directives, environmental legislation)
8. how mechanical assembly instructions are represented and how to interpret them
9. the general principles of wiring and assembly, the range of methods used and key features of each (such as tin/lead soldering, lead-free soldering systems, no-wash fluxing, crimping)
10. how the different types of electronic wiring and insulation are coded and specified
11. how information on wiring interconnections is specified, with particular reference to the role of wiring schedules, wire-running lists, backplane net interconnect lists
12. the various methods used for securing electronic wiring (such as heat shrink sleeves, strapping, cable ties, p-clips)
13. the care and selection of tools and aids used in wiring and assembly work (soldering tools and equipment, crimp tools, testing and checking equipment for continuity, short circuit testing, joint/crimp `pull-off' security, insulation resistance)
14. how to recognise wiring types and sizes, their identification, coding and range of termination methods
15. how to identify the types, and read the values, of electronic components (resistors, capacitors, diodes, integrated circuits) with particular reference to their polarity, orientation, colour coding, value, tolerance, working voltage/current
16. how to take electrostatic discharge precautions in relation to component handling during the wiring and assembly of electronic products and when such precautions are needed
17. the handling requirements and termination methods used for fibre-optic links
18. the range of checks and tests used within wiring and assembly work (such as insulation resistance, flashover testing, continuity, short circuit testing)
19. calibration requirements for tools and equipment used in wiring (such as crimp tool test and selection for wire sizes, `pull-off' limits, meters for continuity and insulation resistance checks)
20. the problems that can occur with wiring and assembly work and how they can be avoided
21. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
22. how to access, use and maintain information to comply with organisational requirements and legislation

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1. Carry out all of the following activities during the assembly and wiring of the electronic equipment/systems:

   1. use the correct issue of drawings, job instructions and specifications
   2. adhere to health and safety regulations, systems and  procedures to realise a safe system of work
   3. follow clean work area protocols, where appropriate
   4. comply with organisational procedures
   5. create and store records of the activities, in accordance with  appropriate procedures

2. Use two of the following documents during the assembly activities:

   1. assembly drawings and charts              
   2.  interconnection net diagrams
   3. schedules of specified components     
   4. wiring specifications
   5. wire running lists

3. Complete the preparatory assembly, to include carrying out all of the following:

   1. use hand tools/automated tools for securing all fastenings
   2. assemble sub-units to support housings/brackets
   3. assemble connectors and allied devices

4. Obtain, check and prepare consumables and specialised tools for the wiring and interconnection, to include all of the following:

   1. solder and any associated fluxes (such as sufficient quantity, right type, good condition)
   2. wire strippers and cutters (such as right size, good condition)
   3. authorised crimp tooling and attachments (such as checked for sizes, calibration and condition)
   4. cables and individual wiring/fibre optic links (such as correct  sizes and types, good condition)
   5. cable strapping obtained and cut to nominal length (such as right sizes and sufficient quantities)

5. Assemble and wire the equipment, using five of the following methods and techniques:

   1. set up, programme and use automated wiring termination equipment (where appropriate)                  

   2. attach wire terminations by appropriate method/s (such as soldering, crimping)

   3. set out/position interconnection wiring             
   4. bundle/strap/tie wiring looms and cables
   5. cut wires to required length                     
   6. set out and terminate any fibre optic links
   7. strip insulation from ends of wires

6. Check the completed work meets all of the  following requirements for:

   1. security of all assembled and interconnected items
   2. insulation resistance between housing assembly and interconnection wiring
   3. continuity of all interconnections
   4. unwanted short circuits between wires

7. Check assembled equipment complies with one of the following quality and accuracy standards:

   1. current industry standards, codes of practice and procedures
   2. customer standards and requirements
   3. company standards and procedures
   4. other international standards

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2

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31 Mar 2023

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Current

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Original

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Semta

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SEMEEE3-17

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians, Maintenance Team Technician, Manufacturing Technologies, Production and Process Engineers

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3113

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Engineering; electrical; electronic; assembling; wiring; manual; soldering; termination; techniques; methods

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