SMT: ICT (In-Circuit Testing) Operator (Chandigarh)

Job Description:

1. ICT Machine Operation

• Operate ICT equipment according to approved SOPs, work instructions and test procedures.
• Load and run the correct ICT test program for the respective PCB/PCBA model.
• Verify product part number, revision and test program before starting testing.
• Perform equipment start-up and shutdown according to defined procedures.
• Load/unload PCBAs carefully into/from the ICT fixture.
• Ensure correct positioning and orientation of assemblies before initiating test cycles.
• Monitor test equipment for alarms, abnormal conditions and interruptions.

1. ICT Test Execution

• Execute approved ICT test sequence for manufactured PCBAs.
• Verify electrical parameters as defined in the released test specification/program.
• Perform PCBA testing for applicable checks such as:

• Open circuits
• Short circuits
• Resistance
• Capacitance
• Diode characteristics
• Connectivity
• Component presence/orientation where supported
• Other electrical checks defined by the approved test program

Ensure the complete defined test sequence is executed before product release. Never bypass failed tests or modify test limits without authorization.

1. PASS / FAIL Verification

• Review ICT test results and correctly identify PASS and FAIL PCBAs.
• Ensure only PASS assemblies move to the next process.
• Clearly segregate failed assemblies according to the defined procedure.
• Prevent mixing of tested, untested, PASS, FAIL, Hold and Rework material.
• Escalate unclear or abnormal test results to the responsible Engineer.
• Never manually override a FAIL result without authorized technical disposition.

1. Defective PCBA Segregation

• Place failed PCBAs in identified NG/Hold/Rework locations.
• Attach or record appropriate failure identification.
• Maintain linkage between failed PCBA and ICT failure information.
• Prevent defective products from progressing to subsequent operations or dispatch.
• Ensure rejected boards are transferred only through the defined rework/analysis process.
• Maintain proper physical and system control of failed assemblies.

1. Failure Identification & Feedback

• Record the failure code/type generated by ICT equipment.
• Identify repetitive/common failures and immediately inform Production/Quality/Test Engineering.
• Provide accurate failure information for root-cause analysis.
• Highlight abnormal increases in specific failure types.
• Support containment when repetitive failures suggest a process problem.
• Communicate suspected upstream SMT issues to the responsible team.

1. Rework & Retest Control

• Receive repaired/reworked PCBAs only through the approved process.
• Retest reworked assemblies using the released ICT program.
• Ensure the complete required test sequence is repeated before release.
• Maintain traceability of original failure and subsequent retest result.
• Segregate PCBAs that fail repeatedly and escalate to the responsible Engineer.
• Never repeatedly retest failed boards simply to obtain a PASS result without investigation.

1. ICT Fixture Handling

• Handle ICT fixtures carefully to avoid damage to:

• Test probes/pogo pins
• Connectors
• Cables
• Alignment pins
• Clamping mechanisms
• Interface boards

Ensure the correct fixture is used for the specific PCB/PCBA model. Keep test fixtures clean and protected when not in use. Report bent, damaged, worn or contaminated probes immediately. Store fixtures at designated locations with clear identification.

1. Test Fixture & Contact Monitoring

• Monitor for contact-related false failures.
• Visually inspect accessible fixture contact points as permitted by the work instruction.
• Report recurring contact problems to Test/Maintenance Engineering.
• Do not make unauthorized modifications to fixtures or test probes.
• Support scheduled fixture cleaning and preventive-maintenance activities.
• Help differentiate probable fixture-contact issues from genuine product failures.

1. First-Off / Start-Up Testing

• Support first-piece/first-off testing after product changeover or production start.
• Verify the correct program and fixture before testing.
• Ensure first-off results are reviewed according to defined approval requirements.
• Do not release serial production based on incomplete or abnormal first-off results.
• Escalate unexpected failures immediately.
• Support Quality/Engineering during initial production verification.

1. Product Changeover

• Support ICT product/model changeovers.
• Ensure previous product and associated identification are cleared from the test station.
• Install/select the correct fixture and test program for the new product.
• Verify product, revision, fixture and program before testing begins.
• Support changeover checklist completion.
• Prevent wrong-program/wrong-fixture testing.

1. PCBA Traceability

• Maintain complete traceability of tested assemblies.
• Scan or record serial number, barcode, batch/lot and production order as applicable.
• Ensure ICT test results remain linked to the correct PCBA where traceability systems are implemented.
• Follow MES/barcode-system procedures where available.
• Report unreadable or missing traceability codes.
• Prevent testing or release of untraceable PCBAs without authorized disposition.

1. Test Data & Record Maintenance

• Maintain accurate records of:

• Quantity tested
• PASS quantity
• FAIL quantity
• Failure codes
• Retest results
• Fixture used
• Product/model
• Machine stoppage or abnormalities

Complete manual/system records at the time of testing. Ensure records are accurate for quality investigations and audits. Protect test records from unauthorized alteration.

1. FPY & Defect Monitoring

• Support monitoring of First Pass Yield (FPY) at ICT.
• Communicate repetitive failure trends to Production/Quality/Test Engineering.
• Provide accurate test data for defect Pareto analysis.
• Support improvement actions aimed at reducing ICT failures.
• Monitor retest volume and recurring test failures.
• Participate in daily quality/production reviews when required.

1. Basic Equipment Monitoring

• Monitor ICT equipment condition during operation.
• Report:

• Equipment alarms
• Communication failures
• Fixture-contact issues
• Sensor problems
• Abnormal noises
• Test interruptions
• Software/test sequence abnormalities

Stop testing if equipment behavior may compromise result validity. Coordinate with Maintenance/Test Engineering for restoration.

1. Basic Autonomous Maintenance

• Perform authorized operator-level daily checks and cleaning.
• Maintain cleanliness of ICT equipment and test station.
• Clean fixtures only using approved methods.
• Complete equipment daily-check sheets.
• Report damaged cables, connectors, switches or safety mechanisms.
• Support basic TPM/autonomous maintenance activities.
• Do not conduct electrical repairs without proper authorization.

1. ESD & PCBA Handling

• Follow defined ESD controls at all times.
• Use required ESD wrist straps, footwear, garments and grounded workstations.
• Use ESD-safe trays/racks for handling assemblies.
• Avoid unnecessary contact with components, solder joints and connector pins.
• Protect PCBAs against mechanical damage during loading/unloading.
• Report ESD-control abnormalities immediately.

1. Safety Compliance

• Follow equipment and electrical safety instructions.
• Operate the tester only after required training and authorization.
• Never bypass safety interlocks or guards.
• Do not access energized electrical sections beyond operator authorization.
• Use appropriate PPE where specified.
• Immediately report unsafe equipment conditions.
• Follow emergency-stop procedures where applicable.

1. 5S & Workplace Discipline

• Maintain 5S standards around the ICT test station.
• Clearly define locations for PASS, FAIL, Hold, Rework and untested PCBs.
• Keep fixtures, cables, tools and documents at designated locations.
• Prevent accumulation of unidentified PCBAs.
• Maintain a clean and organized workstation.
• Participate in periodic 5S audits.

1. Shift Handover

• Provide clear handover to the next-shift operator covering:

• Running product/model
• Tested/PASS/FAIL quantities
• Major failure types
• Rework/retest status
• Fixture condition
• Equipment problems
• Pending Quality/Engineering decisions

Complete required records before end of shift. Highlight unresolved repetitive failures.

1. Continuous Improvement & Training

• Participate in Kaizen, TPM, FPY and defect-reduction activities.
• Provide practical feedback on recurring ICT failures and fixture issues.
• Support trials under Engineer guidance.
• Complete product/tester-specific operator training.
• Develop basic understanding of electronic components, PCB circuits and common SMT defects.
• Participate in periodic competency evaluation and multi-skilling activities.

Key Skills / Competencies

• ICT equipment operation
• PCBA electrical testing
• PASS/FAIL interpretation
• Basic understanding of resistor, capacitor, diode and circuit connectivity
• ICT fixture handling
• Test probe/pogo-pin awareness
• Defective-PCBA segregation
• Rework/retest control
• FPY and failure-code monitoring
• PCBA traceability
• Barcode/MES operation
• ESD-safe handling
• Basic TPM/autonomous maintenance
• 5S and shop-floor discipline
• Basic computer and test-data entry skills