flagship course

Electronics Assembly and Testing

Build and test electronic circuits and boards, read schematics, solder safely, and report faults with measured proof.

about this course

What you will be able to do

L4 Practitioner8 modules · 39 h lessons plus practice

Build and test electronic circuits and boards, read schematics, solder safely, and report faults with measured proof.

Define voltage, current, resistance and power with units.
Apply safe soldering and assembly to a written standard.
Analyse a circuit with a multimeter and an oscilloscope.
Evaluate a board for fit to its specification.
Create a small tested product and its build record.

Task, condition and standard

Task

Assemble a small powered board from a schematic, test it against its specification, and keep a build and test record.

Condition

About 10 weeks part-time. A soldering station, multimeter, bench power supply, oscilloscope or logic probe, a kit of parts, a mentor.

Standard

Joints meet the written solder standard, every test reading has a unit and a limit, faults are proved by measurement, and the build record lets another person repeat the work.

Who it is for: School leavers, ITI and diploma students, repair technicians, makers and small manufacturing staff. Requirements: None; basic arithmetic. Materials: lesson text, templates, rubric, check with answers.

lesson by lesson

8 modules with worked examples

Module 1 Bench safety and basic quantities 4 hDefine

Define voltage in volts, current in amperes, resistance in ohms and power in watts, and give the symbol for each.
Wear eye protection when soldering and cutting leads, and work with ventilation or a fume extractor.
Set the iron in its stand, never on the bench, and switch it off when you leave.
Use an earthed mat and wrist strap when handling chips that static can damage; never work on mains-powered circuits with the supply connected.

Worked example. A 5 V supply drives a 250 ohm resistor. Current is 5 / 250 = 0.02 A, or 20 mA, and power is 5 x 0.02 = 0.1 W, so a quarter-watt resistor is safe.

Activity. Calculate voltage, current and power for three resistor circuits.

Standard to meet. Give all three answers correct units and match a meter reading within 5%.

Module 2 Read schematics and components 5 hExplain

Learn the symbols for resistor, capacitor, diode, LED, transistor and chip.
Read resistor colour bands and capacitor markings, and check with a meter.
Follow a signal from input to output on a schematic with a finger or a highlighter.
Note polarity for diodes, LEDs and electrolytic capacitors before fitting.

Worked example. A resistor with brown, black, orange, gold bands reads 10 x 1,000 = 10 kilo-ohm, plus or minus 5%, so acceptable readings are 9.5 to 10.5 kilo-ohm.

Activity. Identify twelve parts on a kit board and list value, polarity and position.

Standard to meet. Identify all twelve and check that values agree with a meter within the stated tolerance.

Module 3 Solder and assemble 6 hApply

Heat the pad and lead together for about 2 seconds, then feed solder; a good joint is shiny and shaped like a small cone.
Fit parts in order of height: resistors, diodes, chip sockets, capacitors, connectors.
Trim leads flush after soldering and clean flux residue with isopropyl alcohol.
Use lead-free solder where the product must meet RoHS and keep the work area clean.

Worked example. A 40-joint board is built in 55 minutes; an inspection with a magnifier finds 2 cold joints and 1 bridge, which are reflowed; first-pass yield is 37 of 40, or 92.5%.

Activity. Assemble a board and inspect each joint under a magnifier.

Standard to meet. Pass at least 95% of joints against the written standard on first inspection.

Module 4 Measure with a multimeter 5 hApply

Set the meter to the correct mode and range before touching the circuit.
Measure voltage in parallel and current in series; resistance only with power off.
Use continuity beep to check tracks and joints.
Write each reading with its unit and the expected range.

Worked example. A 9 V battery feeds a 5 V regulator. Input reads 8.7 V and output 4.98 V, which is within 5% of 5 V, so the regulator is healthy.

Activity. Take ten readings on a powered board and compare each with its expected value.

Standard to meet. Give each reading a unit, an expected range and a pass or fail.

Module 5 Test with an oscilloscope 5 hAnalyse

Set volts per division and time per division so the wave fills the screen.
Read amplitude, period and frequency from the display; frequency is one divided by period.
Use a x10 probe and compensate it before measuring.
Compare an input and an output wave to see gain, delay or distortion.

Worked example. A square wave spans 5 divisions at 2 ms per division, so period is 10 ms and frequency is 1 / 0.01 = 100 Hz; the height of 2.5 divisions at 2 V per division gives 5 V peak to peak.

Activity. Capture and measure a waveform on a timing circuit.

Standard to meet. Calculate period, frequency and amplitude and match the design within 10%.

Module 6 Find and prove faults 5 hAnalyse

Start with a visual check for burnt parts, cracks and lifted pads.
Measure the supply first, then follow the signal stage by stage.
Change one thing at a time and record the result.
Prove the fault with a reading before replacing the part.

Worked example. A board has no output. The 5 V rail reads 0 V; the input fuse shows no continuity (open); replacing the 1 A fuse restores 5.02 V and the output works.

Activity. Diagnose a board with a seeded fault and write the proof.

Standard to meet. Locate the fault by measurement and confirm the repair with a second reading.

Module 7 Check against specification 5 hEvaluate

Turn the specification into a test sheet with limits for each requirement.
Test under normal and worst-case supply, for example 4.5 V and 5.5 V.
Record pass, fail or marginal, and flag marginal results for review.
Decide to accept, rework or reject, and give the reason.

Worked example. A 5 V supply board must give 4.75 to 5.25 V at 0.5 A load. Tests give 4.98 V at 0.1 A and 4.80 V at 0.5 A, so it passes but the low end is marginal.

Activity. Write a test sheet and test one board against it.

Standard to meet. Give every requirement a limit, a reading and a decision.

Module 8 Capstone: build, test, document 4 hCreate

Choose a small product such as a regulated power supply or an LED timer.
Build it from the schematic and test it fully.
Write the build record with parts, photos, readings and faults.
Present the product and answer questions.

Worked example. A power supply is built in 3 hours with 48 joints, 2 reworked, 12 tests all passed, and a one-page record signed off by the mentor.

Activity. Present the build and test record in five minutes.

Standard to meet. Write the record in enough detail for another person to repeat the build.

assessment

How you are checked

Evidence: the work product from each module, kept in one folder with dates. A mentor and two peers mark it with this rubric. Pass: no criterion at 'Not yet'.

Marking rubric
Criterion	Not yet	Meets	Exceeds
Assembly	Missing or unclear	Meets the stated check	Joints meet the standard and the method is shared
Testing	Guessing	Evidence kept	Every reading has a unit and a limit
Records	Gaps	Complete	Complete and reviewed by a peer
Safety and ethics	Overlooked	Followed	Followed and taught to others

Ten-question check, with model answers

Q1. What is the current through 100 ohms at 5 V?

Model answer: 0.05 A, or 50 mA. (Covered in module 1: Bench safety and basic quantities. To pass that module: Give all three answers correct units and match a meter reading within 5%.)

Q2. What does the gold band mean?

Model answer: A tolerance of plus or minus 5%. (Covered in module 2: Read schematics and components. To pass that module: Identify all twelve and check that values agree with a meter within the stated tolerance.)

Q3. What does a dull, grainy joint show?

Model answer: A cold joint, which can fail; reheat and add fresh solder. (Covered in module 3: Solder and assemble. To pass that module: Pass at least 95% of joints against the written standard on first inspection.)

Q4. Why is current measured in series?

Model answer: The meter must carry the circuit current to measure it. (Covered in module 4: Measure with a multimeter. To pass that module: Give each reading a unit, an expected range and a pass or fail.)

Q5. How do you find frequency from the period?

Model answer: Divide one by the period. (Covered in module 5: Test with an oscilloscope. To pass that module: Calculate period, frequency and amplitude and match the design within 10%.)

Q6. Why change only one thing at a time?

Model answer: Otherwise you cannot tell which change fixed the fault. (Covered in module 6: Find and prove faults. To pass that module: Locate the fault by measurement and confirm the repair with a second reading.)

Q7. What is a marginal result?

Model answer: A reading that passes but sits close to the limit. (Covered in module 7: Check against specification. To pass that module: Give every requirement a limit, a reading and a decision.)

Q8. What belongs in a build record?

Model answer: Parts, steps, readings, faults found and the final decision. (Covered in module 8: Capstone: build, test, document. To pass that module: Write the record in enough detail for another person to repeat the build.)

Q9. Name the first check before powering a new board.

Model answer: Inspect for bridges and wrong polarity, then check resistance across the supply. (Covered in: Task, condition and standard, near the top of this page.)

Q10. Why use a fume extractor?

Model answer: Flux smoke irritates the lungs and eyes. (Covered in: Task, condition and standard, near the top of this page.)

seven levels

Your ladder, L1 to L7

This course sits at L4 Practitioner. Each level adds to the one below.

L1 Basic. Know the safety rules and basic quantities.
L2 Awareness. Read schematics and identify components.
L3 Foundation. Solder and assemble simple boards under supervision.
L4 Practitioner. Test and repair boards alone.
L5 Specialist. Handle complex faults and specification tests.
L6 Advanced. Lead a production line and set test methods.
L7 Super expert. Design test systems and standards for a manufacturer.

Slide by slide

Seven slides, one per level. Open each for the slide text and the speaker notes.

Slide 1 L1 Basic: Bench safety basics

Name 8 bench safety rules and state voltage, current and resistance with their units, with no error.

Speaker notes. Teacher asks for units and rules orally at the bench. Covered in module 1.

Slide 2 L2 Awareness: Read schematics

Identify 12 components on a schematic and match each to its real part on a board.

Speaker notes. Teacher hands over a simple circuit diagram and a board to match. Covered in module 2.

Slide 3 L3 Foundation: Supervised soldering

Solder and assemble a 10-part board under supervision with every joint shiny and no bridges.

Speaker notes. Teacher inspects each joint with a magnifier and a continuity check. Covered in module 3.

Slide 4 L4 Practitioner: Test and repair

Measure with a multimeter and repair 3 faulty boards alone, recording readings before and after the fix.

Speaker notes. Teacher plants a dry joint and checks the learner's readings sheet. Covered in module 4.

Slide 5 L5 Specialist: Complex fault tracing

Trace 2 hard faults using an oscilloscope and prove each against a stated specification with measured values.

Speaker notes. Teacher supplies a board with an unstable signal and reviews the waveform captures.

Slide 6 L6 Advanced: Lead a production line

Lead a line of 5 people, set a 4-step test method and keep the first-pass rate above a target you define.

Speaker notes. Teacher checks the test method sheet and a day's pass and fail count.

Slide 7 L7 Super expert: Design test systems

Design a test system with a fixture, 6 pass criteria and a record format, and validate it on 20 units.

Speaker notes. Teacher reviews the criteria and the 20-unit results for gaps. Check local rules with an expert for product safety marks.

career routes

Roles, routes and subjects

These routes come from the India pathway tables. They show where this course leads, in my own words.

Career role families

Electronics engineer
Circuit board designer
Connected-device integrator
Hardware test engineer
Chip design tools specialist

Ways to work: Employed in manufacturing and assembly units, own small unit, contract design. Who buys: Business to business supply and contract assembly.

jobs this leads to

Where this takes you

Electronics assembly operator
Test technician
Repair technician
Quality inspector
Prototype maker

ten locations and global

Your place

Local rules change licences, data handling, pricing words and names of bodies. Check them for your place before you act.

India (Bengaluru)

Language: English, Hindi, Kannada. Currency: INR. Data rule for what you publish: Digital Personal Data Protection Act 2023. Skills frame to cite: National Skills Qualifications Framework (NSQF) and the national credit framework.

Netherlands (Eindhoven area)

Language: Dutch, English. Currency: EUR. Data rule for what you publish: EU GDPR (Dutch: AVG), supervised by the Autoriteit Persoonsgegevens. Skills frame to cite: the Dutch qualification framework (NLQF) linked to the European Qualifications Framework.

UAE (Dubai and Abu Dhabi)

Language: Arabic, English. Currency: AED. Data rule for what you publish: Federal Decree-Law No. 45 of 2021 (personal data protection). Skills frame to cite: the emirate education and training regulators (for example KHDA in Dubai) and the national qualifications framework.

Brazil (Sao Paulo)

Language: Portuguese (Spanish and English support). Currency: BRL. Data rule for what you publish: LGPD (Lei Geral de Protecao de Dados). Skills frame to cite: the national technical-education catalogue and the national S-system training bodies.

Canada (Toronto)

Language: English, French. Currency: CAD. Data rule for what you publish: PIPEDA, with provincial rules where they apply. Skills frame to cite: the provincial colleges framework and the national credential-recognition guidance.

United States

Language: English, Spanish. Currency: USD. Data rule for what you publish: state privacy laws (for example California), and COPPA for children under 13. Skills frame to cite: state and community-college credit systems.

Singapore

Language: English, Mandarin, Malay, Tamil. Currency: SGD. Data rule for what you publish: Personal Data Protection Act (PDPA). Skills frame to cite: the Singapore national skills frameworks and the national credit system.

Australia

Language: English. Currency: AUD. Data rule for what you publish: the Privacy Act 1988 and the Australian Privacy Principles. Skills frame to cite: the Australian Qualifications Framework (AQF) levels.

Hong Kong (Eastern Asia)

Language: Chinese (Cantonese, Mandarin), English. Currency: HKD. Data rule for what you publish: the Personal Data (Privacy) Ordinance. Skills frame to cite: the Hong Kong Qualifications Framework.

Georgia and Israel (Western Asia)

Language: Georgian, Hebrew, Arabic, English. Currency: GEL or ILS. Data rule for what you publish: the personal data law of the country where the learner lives. Skills frame to cite: the national qualifications framework of that country.

Cayman Islands (Caribbean)

Language: English. Currency: KYD. Data rule for what you publish: the Data Protection Act. Skills frame to cite: the local education and training framework.

Mexico

Language: Spanish, English. Currency: MXN. Data rule for what you publish: the federal law on personal data held by private parties. Skills frame to cite: the national competency certification system and the education ministry levels.

Draft

Draft flagship. Own wording. Not live.

Risk lesson (estimates, not quotes). In India a rough sheet figure is Rs 1,500 per board assembled and tested against a unit cost of Rs 1,000 and a fixed cost of Rs 45,000 a month: a margin of about 33% and a break-even of about 90 units a month. If the price falls 25% to about Rs 1,125, break-even rises from 90 to 360 units a month. Plan a price floor or a lower cost before you launch, and test the plan at the lower price. These sheet figures are separate from the sample numbers in the modules. Check them with a local price expert.