PCB Manufacturing Jobs Vs. Circuit Board Assembly Jobs: A Detailed Comparison

Introduction

Printed circuit boards (PCBs) form the backbone of electronics products. Their fabrication and assembly provides employment to hundreds of thousands globally. PCB manufacturing involves creating the bare printed circuit boards. PCB assembly populates the boards with components to produce functional printed circuit assemblies (PCAs). While interconnected, PCB manufacturing and circuit board assembly involve distinct processes and require different skills.

This article examines and compares various roles and responsibilities in PCB fabrication jobs versus circuit board assembly jobs. It provides insights into the work environment, technical skills, qualifications, training, and career growth opportunities associated with each area.

Overview of PCB Manufacturing Jobs

PCB fabrication transforms base materials like laminates and copper foils into complex, multi-layer circuit boards ready for component mounting. Manufacturers employ operators, technicians and engineers across these key departments:

PCB Processing

Involves equipment operation for processes like:

• Drilling – Creates holes for vias and component leads
• Plating – Deposits copper in drilled holes and on surfaces
• Coating – Applies photoresist for imaging conductors
• Etching – Chemically etches away unwanted copper
• Stripping – Removes photoresist
• Outer layer/solder masking – Applies solder resist layer
• Legend printing – Prints white markings for component designators

Quality/Inspection

Examines PCBs at each process step to detect defects using:

• Visual inspection
• Optical and imaging systems
• Electrical testing
• Dimensional metrology
• Testing of characteristics like solderability

Engineering

Handles activities like:

• Research and development
• Product engineering
• Process engineering
• Equipment engineering
• Quality/reliability engineering

Materials

Involves procurement, handling and inventory management of:

• Base materials like laminates and prepregs
• Consumables like photoresists and etchants
• Metals including copper foils
• Plating chemicals like copper sulfate and formaldehyde
• Solder masks and legend inks

Planning

Covers production scheduling, capacity planning, process flow development and productivity management.

Maintenance

Performs preventive and corrective maintenance on all PCB fabrication equipment.

Key PCB Manufacturing Roles and Responsibilities

Here are typical roles and duties involved in PCB manufacturing jobs:

Equipment Operators

• Set-up, operate and monitor PCB fabrication equipment
• Follow standard operating procedures for each process
• Perform machine checks and calibrations
• Load boards and materials into equipment
• Review process data and track production
• Troubleshoot issues and make minor machine adjustments
• Segregate defective boards after inspection
• Maintain cleanliness of tools and work areas

Process Technicians

• Prepare chemistry and solutions for processes
• Mix, test and replenish chemicals
• Take samples and conduct tests to validate chemistry concentration
• Maintain chemical logs with preparation details
• Transport materials like dry film and chemicals
• Assist engineers with process troubleshooting and improvement
• Support changeovers between PCB designs and orders

Inspection Technicians

• Perform visual inspection of PCBs at each process step
• Use optical systems to measure conductor widths, spacing and hole sizes
• Execute electrical testing like continuity checks and isolation resistance
• Document inspection results on travelers and logs
• Generate discrepancy reports for failed boards
• Prepare certification packages with inspection data

Quality Engineers

• Develop inspection plans and sampling criteria
• Create procedures for measurements, testing and reporting
• Conduct failure analysis on defective boards
• Identify root causes and corrective actions
• Monitor process performance and quality metrics
• Lead continuous improvement initiatives

Maintenance Technicians

• Execute preventive maintenance like cleaning and lubrication
• Diagnose and troubleshoot equipment failures
• Repair or replace defective components
• Align and calibrate machines to specifications
• Document all maintenance and repair activity
• Support equipment installations and upgrades

Key Skills Needed for PCB Manufacturing Jobs

Essential skills for PCB manufacturing roles include:

Equipment Operation: Knowhow to correctly operate and control equipment like drilling machines, plating tanks, exposure units and solder mask screen printers.

Process Knowledge: Understand chemistry, parameters and procedures for processes like developing, etching, stripping and legend printing.

Inspection: Able to perform visual inspection and use tools like microscopes, calipers and electrical testers.

Testing: Skills in testing PCB characteristics like solderability, electrical properties and chemical concentrations.

Quality Systems: Know techniques like sampling, SPC, root cause analysis and corrective actions.

Math: Must apply math for calculations like solution concentrations, production yields and process capability ratios.

Technical Documentation: Can read and interpret specifications, procedures, drawings and datasheets.

Communication: Able to share information clearly between shifts, teams and departments.

Troubleshooting: Diagnose and debug issues with equipment, processes and materials.

Safety: Follow all chemical, electrical and machine safety procedures.

Education and Training for PCB Manufacturing Jobs

Typical education and training pathways into PCB manufacturing include:

• High school diploma or GED
• Technical certification in electronics manufacturing
• Associate degree in electronics engineering technology
• On-the-job training on equipment and processes
• IPC training for standards like IPC-A-600, IPC-A-610, IPC J-STD-001
• OEM training on proprietary equipment and procedures
• Certifications like CIT (certified IPC trainer) and CIS (certified IPC specialist)

Advanced roles like process engineering or quality engineering require bachelor’s or master’s degrees in engineering disciplines.

Continual skills upgrading through refresher training is essential due to evolving PCB technology.

Career Growth in PCB Manufacturing

Typical career growth paths in PCB fabrication include:

Operator > Lead Operator > Supervisor > Production Manager

Operators can progress to lead roles with coaching skills. Further advancement possible into production supervision and management.

Technician > Senior Technician > Engineer

Technicians can transition into senior tech roles with additional training on new processes and equipment. Some progress into process engineering positions.

Engineer > Senior Engineer > Principal/Chief Engineer > Engineering Manager

Engineers can evolve from working on a process to leading entire new product introduction or manufacturing engineering. Management roles possible for senior engineers.

Manager > Director > VP Operations

Managers expand scope from one department to multiple departments or site leadership. Progression into executive roles like VP operations possible with experience.

Overview of Circuit Board Assembly Jobs

Printed circuit board assembly (PCBA) involves mounting and soldering electronic components onto PCBs using both automated and manual processes. Key departments are:

SMT (Surface Mount Technology) Assembly

• Screen printing to apply solder paste on SMT pads
• Pick-and-place machine operation to mount components
• Reflow soldering to form SMT joints
• Automated optical inspection (AOI)

Through-Hole Assembly

• Component preparation like wire cutting/forming
• Insertion of through-hole parts either manually or using automation
• Wave soldering to form solder joints on inserted components
• Manual soldering to fix or rework joints
• Testing assembled boards

Conformal Coating

• Coating application through spraying, dipping or brushing
• Coating touch-up and repair

Quality and Inspection

• In-process inspection at process steps
• ICT (in-circuit test) for electrical testing
• AXI (automated x-ray inspection)
• Burn-in stress testing
• Final QA and packaging

Materials and Warehouse

• Stocking and kitting components
• Management of solder paste, solder, fluxes and other materials

Planning

• Production planning and scheduling
• Line layouts and assembly workflows

Maintenance

• Upkeep of all production and test equipment

Key Circuit Board Assembly Roles and Responsibilities

Common roles and responsibilities in PCB assembly include:

SMT Operators

• Load solder paste stencils and PCBs into printers
• Operate pick-and-place machines for automatic component mounting
• Run conveyorized reflow ovens
• Changeover equipment for different PCBs
• Perform visual checks of solder paste, placed components and reflowed boards

SMT Technicians

• Change solder paste and adhesives for new production
• Clean stencils and monitors paste prints for quality
• Set up feeders and component tapes on pick-and-place machines
• Maintain inventory of components at line side
• Troubleshoot issues with misprints, tombstoning, skew parts, etc.

Through-Hole Operators

• Kit components required for assembly
• Insert, clinch and solder components either manually or using mechanisms
• Perform hand soldering to correct issues
• Visually inspect solder connections and rework as needed
• Operate automated wave soldering equipment

Conformal Coating Operators

• Prepare coating materials like mixing, pot life monitoring, viscosity checks
• Load boards onto conveyorized coating equipment
• Apply coating through spraying, brushing, dipping or selective dispensing
• Inspect coating for uniformity, thickness and coverage
• Touch up coating using brushes, swabs and other tools

Quality/Inspection Technicians

• Perform in-process inspection of materials, processes and workmanship
• Execute electrical testing like in-circuit tests, functional tests, and burn-in
• Use x-ray inspection to examine internal solder joints
• Verify coating properties like thickness, cure, surface finish
• Document all inspection and test results

Test Engineers

• Develop test plans, procedures and criteria for assembled boards
• Create test programs, fixtures and scripts for automated testing
• Analyze data from inspections and tests
• Identify and drive root cause analysis and corrective actions

Materials Coordinators

• Receive, stock and kit parts required for assembly
• Maintain inventory levels through cycle counts and monitoring
• Issue material kits to lines based on production requirements
• Track material consumption and order replenishments proactively

Key Skills Needed for Circuit Board Assembly Jobs

Critical skills needed for PCBA roles include:

Soldering: Manual soldering techniques for through-hole and repairs.

Hand Tools: Component trimming, forming and bending tools.

Equipment Operation: Running printers, pick-and-place, conveyors and wave soldering machines.

Inspection: Techniques like visual inspection, in-circuit testing, x-ray, and functional testing.

Conformal Coating: Selecting and applying protective coatings.

Materials Management: Inventory control and material planning.

ESD Control: Following proper electrostatic discharge avoidance procedures.

Documentation: Read and follow assembly drawings, work instructions, testing documents.

Teamwork: Coordinate activities within and across production lines.

Troubleshooting: Identify and quickly resolve assembly issues.

Education and Training for Circuit Board Assembly Jobs

PCB assembly roles require education like:

• High school diploma or equivalency certification
• Associate degree in electronics manufacturing technology
• Hands-on training on assembly processes and machinery
• IPC training and certification for IPC-A-610, J-STD-001 and IPC-7711/7721
• ESD control training
• Some test engineering roles need bachelor’s degree in electrical/electronics engineering

On the job experience is essential to gain competency in processes like soldering, inspection, conformal coating and troubleshooting assembly issues.

Career Growth in Circuit Board Assembly

Here are some common career advancement paths in PCB assembly:

Operator > Senior Operator > Lead hand > Line Supervisor

Operators can progress to lead and supervisory roles with skills development and leadership abilities.

Technician > Senior Technician > Supervisor > Quality Manager

Technicians gain broad knowledge of processes which prepares them to advance to supervision and management.

Test Engineer > Senior Engineer > Engineering Manager

Engineers grow skills in test program development, tooling design and product qualifications. Senior roles possible leading groups of engineers.

Materials Coordinator > Buyer > Materials Manager

Materials roles expand from line side to central planning and procurement roles with experience.

Supervisor > Production Manager > Operations Director

Proven supervisors move into production management and leadership of multiple departments.

Comparison Between PCB Manufacturing and Circuit Board Assembly Jobs

	PCB Manufacturing Jobs	Circuit Board Assembly Jobs
Processes	Board fabrication steps like imaging, etching, plating, solder mask, AOI.	SMT assembly, through-hole insertion, soldering, conformal coating, electrical test.
Work Environment	Cleanroom environment for many processes. Chemical usage.	Production floor environment. ESD control required.
Qualifications	High school diploma or IPC training certification. Associate degree preferred.	High school diploma. IPC training a plus. Associate degree helpful for test engineering roles.
Critical Skills	Operating fabrication equipment. Performing process steps like developing and stripping. Conducting inspection and testing.	Operating SMT and through-hole assembly equipment. Manual soldering techniques. Conducting inspections and testing like ICT and AXI.
Training	On-the-job training on specific equipment. IPC programs for standards knowledge.	Training on assembly procedures. IPC-A-610 and J-STD-001 certification. ESD control.
Career Growth	Progression from operators to technicians and engineers. Advancement into management roles.	Evolution from operators to senior operators, supervisors and managers. Test engineers can advance through engineering levels.
Work Schedule	Generally first shift. Overtime possible.	Primarily first shift but sometimes second and third shifts needed. Weekend work possible.
Hazards	Chemical handling. Equipment operation.	Repetitive strain injuries. Fatigue from standing.

Summary of Key Differences

In summary, key differences between PCB manufacturing versus circuit board assembly work:

• PCB fabrication involves chemical processing while PCBA is primarily mechanical assembly.
• More significant chemical and contamination controls required in PCB manufacturing.
• PCB manufacturing relies heavily on operating specialized equipment for each process step.
• PCBA depends more on manual skills like soldering, inspection, and conformal coating.
• Foundation for PCB manufacturing roles is IPC standards knowledge while IPC-A-610 and J-STD-001 training is more essential for PCBA.
• PCB manufacturing provides opportunities to progress from operators to engineers while advancement in PCBA is generally on the operations management track.
• Hazards are more related to chemical exposure in PCB fabrication while ergonomic issues are prevalent in PCBA.

Conclusion

In conclusion, PCB manufacturing and PCBA both offer rewarding careers with good advancement potential within electronics manufacturing. While the day-to-day roles and responsibilities differ significantly between the two areas, fundamental skills like quality focus, technical aptitude, communication and problem-solving are critical throughout. With the growth in cutting-edge products needing advanced PCBs and rising volumes requiring large-scale assembly, there are continuing job opportunities in both PCB fabrication and circuit board assembly.

FAQ

1. What are the main process steps involved in PCB manufacturing?

The key PCB fabrication process steps include:

• Imaging – Applying photoresist and exposing conductive patterns.
• Developing – Removing unexposed areas of photoresist.
• Etching – Chemically removing unwanted copper.
• Plating – Electroplating copper on through holes and surfaces.
• Stripping – Taking off remaining photoresist.
• Solder mask – Applying epoxy layer over conductors.
• Legend – Printing white markings.
• AOI – Automated optical inspection.

2. What key inspection and testing activities are performed during PCB fabrication?

Typical PCB manufacturing inspections and testing:

• Visual inspection of materials and boards at each step
• Measurement of hole sizes, conductor widths, spacing
• Plating thickness and adhesion tests
• Electrical testing like continuity, resistance, insulation
• Solderability testing
• AOI during imaging and after final legend print
• Ionic contamination testing

3. What are the critical processes involved in SMT circuit board assembly?

Key SMT assembly process steps:

• Solder paste printing – Depositing paste on pads
• Pick and place – Mounting surface mount components
• Reflow soldering – Melting paste to form solder joints
• AOI – Checking component placement and solder joints
• Conformal coating – Applying protective coating
• ICT – In-circuit testing functionality

4. What types of circuit board assembly defects can be detected through inspection and testing?

Common PCBA defects found through inspection and testing:

• Missing or misoriented components
• Insufficient solder fillets, shorts between joints
• Cold solder joints, tombstoned components
• Solder bridges, skewed parts, billboarding
• Wrong components, bent leads, damaged parts
• Insufficient coating coverage or non-uniformity
• Electrical opens, intermittent connections
• Functionality failures or marginal performance

5. How are career growth opportunities different between PCB manufacturing versus circuit board assembly?

• PCB manufacturing provides path from operators to engineers.
• PCBA careers typically progress from operators to supervisors and managers.
• PCB manufacturing offers opportunities to advance through engineering levels.
• PCBA provides growth from machine operation roles to production leadership roles.
• Both offer ways to expand scope and responsibility with experience.

Is Salary of PCB Assembly Jobs Good ?

PCBs or print Circuit boards are crucial tech components. Almost every high-tech component ranging from smartwatches to phones requires a PCB to function. They have proven that you can rely on them regarding quality delivery and efficiency. However, you know that PCBs go through a manufacturing process to create the final product you use? For this process to become successful, human resources and intelligence become essential. However, you cannot just wake up one day and decide that you are a PCB assembler. You have to follow some steps to reach the top, and that is what this article is all about. We shall review PCB assembly jobs, what it takes to become a PCB assembler and why you should consider becoming a PCB assembler.

What do PCB assembly Jobs entail?

Well, a circuit board assembly job entails using electronic components to build PCBs and prepare them for use by consumers. In this particular profession, your responsibilities are to:

• Read wiring diagrams
• Follow the sample boards
• Select some electrical components
• Finalizing the PCB using special hand tools

Other responsibilities that come with the first responsibilities include:

• Inserting wires
• Utilizing heat guns
• Applying sealers
• Heat sink installation
• Dealing with faceplates and sockets
• Press-fitting component leads to the PCBs

PCB assemblers work with:

• Resistors
• Relays
• Integrated circuits
• Capacitors
• Transistors

PCB assembly jobs salary and Job growth

PCBs bear extensive use in the tech industries, and with the growing tech popularity, we can only expect more uses to arise. Therefore, we can predict that job opportunities in the PCB assembly sector are looking to grow as the days go by.

Since 2012, job opportunities in this particular field have grown by about four percent.

Can you guess the annual salary of a PCB assembler? If so try it out and then compare your answer with the salaries that we shall go through in a bit.

PCB assemblers earn different salaries. We can attribute this to:

• Experience differences
• Category differences, etc.

Here is a basic breakdown of how PCB assemblers earn. I hope you got one of them right:

1. 25^th percentile – They earn 30,000 USD annually, which translates to 2,500 USD monthly
2. Average percentile – They earn 33,382  USD annually which translates to2,781 USD monthly
3. 75^thpercentile –  They earn 36,500 USD annually, which translate to 3,041 USD monthly
4. Top Earners – They earn 41,500 USD which translate to 3,458 USD monthly

 It takes some time to become a top earner, but with a lot of determination and resilience, you can get there.

So now you know what a PCB assembly job entails; it’s now time to help you become one.

How can you become a PCB Assembler?

If you wish to become a PCB assembler, then you will need these academic qualifications:

1. A high school diploma – You can also use a GED certificate in this case. These certificates prove that you have gone through and understood everything taught in high school. High school education helps you understand the basics of PCB assembly. You, however, still need to undergo further studies to become a PCB assembler.
2. Studies in manufacturing high-tech gadgets – It helps prepare you to work with complex PCBs. What’s more, you gain an associate degree or a certificate.
3. In the process of further studies in the manufacturing of high-tech gadgets, you get to learn about:
4. Component identification
5. Inspection techniques
6. Soldering skill
7. PCB assembly
8. All these skills help you become a great PCB assembler. They also boost your confidence, which motivates you to do your job perfectly.

However, besides just educational qualifications, you also need to have:

• Excellent eye-to-hand coordination
• Manual dexterity, and
• Blueprint reading skills.

It is also good to note that you will be working with color-coded wires; this means that color deficiency might lower your performance.

PCB Assembly Jobs

We have gone through what PCB assembly jobs entail, how to become a PCB assembler, and the salary to expect. Now let us look at some PCB assembly jobs that can come your way:

1. Technician
2. Inspector
3. Shipment specialist

Some employees construct PCBs while others work with robotics to create more sophisticated board configurations. Remember that different clients require varying designs. Hence the configurations keep on changing to deliver the required end products.

Technician gig

If you are looking to work as a technician, then here is what to expect.

Technicians place specific electronic components onto a new circuit board. They then solder these components to keep the print circuit board together permanently.

From cellphones to kitchen ovens, a lot of consumer devices use PCBs. It is the job of a technician to:

• Interpret circuit schematics
• Construct PCBs that provide user-defined functions

The end product is what you use in your day-to-day devices.

However, consumers cannot get their PCB directly from the technician. And that is where a shipment specialist comes in.

A Shipment Specialist Gig

Shipment specialist package PCB for, you guessed it, shipment. They wrap PCBs in packaging that’s static resistant, which protects the PCB from both electrical and physical damage.

The shipment specialist’s job is crucial as any PCBs that incur damage during shipment must be recycled or discarded. Unfortunately, these two processes, recycling and discarding, incur extra costs to the manufacturer. Thus the manufacturer tries as much as possible to minimize shipment damages.

Moreover, goods that incur damage during transportation are of no use to the consumer. Therefore, they cannot pay for them; this adds to the net loss due to bad shipment.

However, some customers fake good damages to avoid paying for PCBs. So, how can we deal with this case? That is where the inspector comes in.

The inspector’s gig

Before initializing the shipment process, the inspector must visually inspect the PCB to ensure that they are in good condition. They then have to test the PCBs to ensure they function properly. The inspector inserts the PCB inside a “test fixture” and then powers it to test each function. However, because PCB production happens in bulk, testing each PCB becomes pretty much impossible. They hence select some PCB samples, test them, and then make their conclusion.

And those are some of the jobs you can score having PCB assembly knowledge.

Conclusion

PCBs are a great part of technology; therefore, if you love tech, you will probably love PCB assembly jobs. The jobs come in many different variations; all meant to assemble a PCB to completion and deliver it to the consumer. Each job is unique in its own way; you can hence look for one specific area, major in it, and become a pro to start earning big.