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Key Responsibilities and Required Skills for Electrical Assembly Technician

💰 $40,000 - $65,000

ManufacturingElectronicsElectricalAssemblyTechnician

🎯 Role Definition

As an Electrical Assembly Technician you will assemble, wire, test and document electrical and electronic products to specification. Your work will include PCB and cable/harness assembly, hand and machine soldering, component placement, functional and continuity testing, and strict adherence to quality and IPC standards (IPC-A-610, IPC/WHMA-A-620). The ideal candidate combines hands-on assembly expertise, attention to detail, and the ability to interpret electrical schematics and bills of materials (BOM) while working in a production or prototype environment.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Cable Harness Assembler or Wire Harness Technician
  • Electronics Assembler or Production Assembler
  • Military electronics technician or technical trade apprenticeship

Advancement To:

  • Senior Electrical Assembly Technician
  • Lead Assembler / Team Lead
  • Manufacturing Supervisor or Production Manager
  • Test Engineer or Electrical Technician Specialist

Lateral Moves:

  • Quality Inspector (IPC/QA)
  • Maintenance or Facilities Technician
  • Process Improvement / Lean Manufacturing Specialist

Core Responsibilities

Primary Functions

  • Read and interpret electrical schematics, assembly drawings, wiring diagrams and bills of materials (BOM) to perform accurate PCB, cable harness, and final product assembly according to engineering specifications and customer requirements.
  • Perform precision soldering operations (through-hole and surface mount) using hand soldering, soldering irons, reflow or wave solder processes to assemble electronic circuits while meeting IPC-A-610 workmanship criteria.
  • Build and assemble wire harnesses and cable assemblies including cutting, stripping, crimping, ferruling, and routing wires to exact lengths and specifications using hand tools and semi-automated crimping equipment.
  • Inspect incoming components for correct part numbers, orientation, and physical condition and report discrepancies to purchasing or quality to prevent defective assemblies.
  • Conduct in-process and final visual and dimensional inspections using magnification, microscopes, and measurement tools to verify solder fillets, component placement, and connector seating in compliance with IPC-A-610 standards.
  • Perform continuity, insulation resistance and basic functional testing using multimeters, continuity testers, oscilloscopes and bench test fixtures, documenting results and flagging failures for rework or engineering review.
  • Execute first-article builds and prototype assemblies from engineering kits, documenting deviations and providing feedback to design and manufacturing engineers for manufacturability improvements.
  • Use torque drivers and calibrated tools to install fasteners, terminals and connectors with specified torque values to ensure mechanical reliability and electrical contact integrity.
  • Apply Electrostatic Discharge (ESD) controls including wrist straps, grounded mats and ESD-safe storage to protect sensitive components throughout the assembly and handling process.
  • Follow standardized work instructions, travelers, work orders and manufacturing routers in an ERP or MES system to track build status, part consumption and traceability for serialized assemblies.
  • Perform component placement and manual rework of PCBs including removing and replacing ICs, resistors and capacitors with soldering and desoldering techniques while preventing PCB damage.
  • Calibrate and maintain hand tools and test fixtures, report tool failures, and perform basic troubleshooting on jigs, fixtures and test equipment to minimize downtime.
  • Participate in process improvement initiatives such as 5S, Kaizen and lean manufacturing projects to reduce waste, improve cycle time and increase assembly throughput.
  • Execute in-circuit and functional test procedures, record test data, and interpret failure modes to support corrective action and continuous quality improvement.
  • Complete detailed assembly and inspection documentation, including lot codes, serial numbers, work order sign-offs and nonconformance reports, ensuring full traceability for audits.
  • Collaborate with engineering and quality teams to review design changes, provide manufacturability feedback and implement process changes on the production floor.
  • Troubleshoot wiring faults, intermittent connections and connector issues using systematic techniques and test equipment to diagnose and recommend fixes or rework.
  • Operate semi-automated assembly equipment (crimp machines, press-fit machines, bench presses) and support setup/adjustment for small production runs and prototypes.
  • Adhere to all safety, regulatory and company compliance requirements including PPE, lockout/tagout and hazardous materials handling when working with batteries, capacitors or adhesives.
  • Perform controlled rework and repair of assemblies per authorized procedures, documenting corrective actions and returning repaired units to testing and inspection.
  • Maintain a clean and organized workstation, manage component inventory levels at the point-of-use and request replenishment to prevent production delays.
  • Train and mentor junior assemblers on soldering techniques, wiring best practices, test procedures and IPC workmanship standards to raise team competency and consistency.

Secondary Functions

  • Support engineering by assembling prototypes and producing samples for design validation and customer demonstrations.
  • Assist with BOM reconciliation and kitting to enable smooth production runs and reduce build errors.
  • Participate in cross-functional meetings to communicate assembly issues, lead-times and potential quality risks to stakeholders.
  • Support periodic audits and supplier quality actions by providing assembly documentation, test records and process descriptions.
  • Contribute to the development and revision of work instructions, SOPs and assembly checklists to reflect best practices and process updates.

Required Skills & Competencies

Hard Skills (Technical)

  • IPC-A-610 and IPC/WHMA-A-620 knowledge and practical application for PCB and cable assembly workmanship.
  • Precision hand soldering (SMT and THT), desoldering and rework skills including use of hot air, soldering irons and micro-soldering tools.
  • Wire harness assembly: cable cutting, stripping, crimping (manual and pneumatic), ferruling and binder/looming practices.
  • Proficient with test equipment: multimeter, oscilloscope, insulation resistance tester, continuity tester and basic bench test fixtures.
  • Ability to read and interpret electrical schematics, wiring diagrams, assembly drawings and BOMs.
  • Familiarity with ESD control procedures and use of ESD-safe tools and storage.
  • Experience with ERP/MRP systems or MES for work order execution, inventory tracking and traceability.
  • Use and maintenance of torque tools, crimp tooling, microscopes and magnification aids.
  • Basic mechanical assembly skills including rivet/fastener installation and use of hand/power tools.
  • Ability to perform in-circuit testing (ICT) and functional verification using test procedures and custom fixtures.
  • Solder paste application, stencil alignment and basic understanding of reflow profiles (for small-run SMT support).
  • Quality inspection and nonconformance reporting, with strong documentation skills for audit readiness.
  • Basic electrical theory: continuity, voltage, current, resistance, polarity and safe handling of DC power systems.

Soft Skills

  • Strong attention to detail and high standard of workmanship to ensure repeatable, high-quality assemblies.
  • Effective verbal and written communication for clear documentation and cross-functional collaboration.
  • Problem-solving mindset with the ability to diagnose root causes and propose corrective actions.
  • Time management and organizational skills to meet production schedules and prioritize tasks in a fast-paced environment.
  • Team player attitude and willingness to train or be trained, participate in continuous improvement and support peers.
  • Adaptability and willingness to work on diverse projects ranging from prototypes to high-volume production.
  • Reliability and strong work ethic with consistent adherence to safety and quality protocols.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED with vocational training or on-the-job experience in electronics/electrical assembly.

Preferred Education:

  • Associate degree, certificate or diploma in Electronics Technology, Electrical Engineering Technology, Mechatronics, or a related technical field.

Relevant Fields of Study:

  • Electronics Technology
  • Electrical Engineering Technology
  • Mechatronics / Industrial Technology
  • Applied Science or Technical Trade Certifications

Experience Requirements

Typical Experience Range:

  • 1 to 5 years of hands-on experience in electronic assembly, PCB soldering, and cable harness fabrication.

Preferred:

  • 3+ years of experience with IPC-A-610/620 compliant assembly, electrical testing and documented production builds; experience in a regulated or aerospace/medical/electronics manufacturing environment is a plus.
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