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.

2. 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.

3. 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.

4. 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.

5. 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.

6. 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.

7. 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.

8. 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.

9. 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.

10. 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.

11. 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.

12. 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.

13. 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.

14. 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.

15. 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.

16. 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.

17. 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.

18. 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.

19. 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.

20. 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