Chapter

PCB Assembly and Testing
CHAPTER 1
ABOUT PODRAIN
Podrain is an Electronics Manufacturing Services company, specialising in high quality PCB

assembly, box build/system integration and cable assemblies. They also have a boutique
hardware design unit.
They also undertake turn-key PCB assembly services for prototypes and mid volume production.
The company has a network of sales and service offices comprising regional offices located at
Bangalore, Mumbai, Kolkata, Delhi, Lucknow, Chennai and a number of sub-offices under each
region, to represent the company in every significant town. In line with the business strategy, the
entire activities of the company are now re-organized as independent business group with
manufacturing facility at Bangalore, Mankapur and Palakkad. Transmission Business group with
manufacturing facility at Bengaluru and Naini, terminal equipment Business group with
manufacturing facility at Bengaluru and Naini.
The company has a strong in-house R&D infrastructure attached to the independent business
group. The main R&D division are at Bengaluru and Naini forward looking at technology, the
R&D s engaged in continuous development and absorption of technology.
Dept of ECE, TOCE 1 2019-2020

CHAPTER 2
INTRODUCTION
2.1 Introduction
The company has a strong in-house R&D infrastructure attached to the independent business
group. The main R&D division are at Bengaluru and Naini forward looking at technology, the
R&D s engaged in continuous development and absorption of technology.
The company lays a strong foundation on quality, which is taken as a corporate management
foundation under an independent execution director reporting to chairman and managing director.
The company has adopted ISO 9001: 2015 certified, taking it as a tool for organizational change
and work redesign. They are planning to get ISO 13485 by year end. We are also in the future
going to be Aerospace certified - AS9100 and ISO 14001.
Human Resource Development is another trust in a company involving professional and

organization development activities. Their idea is to help startups realize their POC (Proof of
Concept). We would like to engage with startups from the time they do the first prototype and
then go from POC to alpha build to beta build to pre-production and then mass production.
They are mainly focussed on complex PCB Assembly. They have experience with Qualcomm, TI,
Freescale, Renesas and Broadcom chipsets. They have helped multiple design houses with their SOM
assemblies and they also have experience with POP assemblies. Their USP is that we deliver
complex PCB Assembly job work in less than 72 hours once we have received the complete kit and
all clarifications. Their facility is like an extension for a lot of design house where they do the first
boards bring up and do the initial testing.

2.2 Highlights
• They Deliver complex PCB without compromise on quality.
• High customer retention rate.
• They always return e-mails and calls within time.
• Affordable pricing offers – depending on the customer and their potential we can work
within budget.
• They always like a challenge. Any new technology, they are always interested to help and
learn.
• Also willing to invest in new technology and in automation.
2.3 Main Area of Business
Assembly:
• PCB Assembly
• System Integration
• Order fulfillment and RMA Logistics

2.4 Services Provided By Podrain
 PCB Assembly – Prototype as well as small to mid-volume
 System Integration
 Mechanical Box Build
 Chassis and Rack Level Assembly,
 Plastic Enclosure Assembly
 Basic test/functional level test Order Fulfilment & RMA Logistics
 Quick turn rework and re-balling
 BGA/QFM Removal and replacement
 Through-hole or SMT
 Repair and maintain broken traces or pads to its original
 Warehousing for electronics assembly for Just in time delivery
 At Podrain we have invested in the best
 Top of the line Yamaha production line capable of placing components up to Chip
(01005), BGA (0.25 mm), LGA, QFN, DFN, QFP
 Fully Automatic Ball Grid Array Rework Station

 X-Ray Machine
 We strive to bring the best on all 3 fronts – Quality, Cost and Delivery Time in the work
that We do.
2.5 Journey At Podrain
My Internship at Podrain electronics pvt.Ltd started on the forenoon of 6th January, 2020. It
started with a campus tour across all the sections of the company, where it began with
the,Desoldering, PCB assembly section ,went along to component placement , heating, error
detection, quality check, store, cleaning and ended at the physical product assembly section. I
have been given a brief introduction to all the processes that the product undergoes. There was a
presentation regarding the actual reasons behind the efficient functioning of the organisation.
There were short lectures given by the senior engineers on different terminologies and techniques
used by great companies in their evolution, which are the primary needs for development. The
majorly acquired knowledge through these lectures is regarding 5S technique. I have been finally
allocated to the product assembly section, where I am assigned with various tasks like
programming, key injection, testing ,labelling, stickering, scanning, packing of the swiping
machines like FG peak device and RMA 180s. switch assembly, programmable controller
flashing, testing of the functionality using an android app and EZETAP labelling.
I have also been assigned with certain non technical managerial tasks like stock verification
and product dispatch listing. Hence, after a rigorous work experience of 55 days for 9 hours a
day, which has been concluded on 29th February, 2020,I confidently say that I have been
evolved as a part of professionally superior and ethically strong global power.

CHAPTER 3
COMPANY PRINCIPLES
3.1 PRINCIPLE OF PODRAIN
Fig 1.1 Company Principles
The 5S concept might sound a little abstract at this point, but in reality it's a very practical,
hands-on tool that everyone in the workplace can be a part of.
5S involves assessing everything present in a space, removing what's unnecessary, organizing

things logically, performing housekeeping tasks, and keeping this cycle going. Organize, clean,
repeat.
3.1.1 Sort
The first step of 5S, Sort, involves going through all the tools, furniture, materials, equipment,
etc. in a work area to determine what needs to be present and what can be removed. Some
questions to ask during this phase include:
 What is the purpose of this item?
 When was this item last used?

 How frequently is it used?
 Who uses it?
 Does it really need to be here?
These questions help determine the value of each item. A workspace might be better off
without unnecessary items or items used infrequently. These things can get in the way or take
up space.
Keep in mind the best people to assess the items in a space are the people who work in that
space. They are the ones who can answer the above questions.
When a group has determined that some items aren't necessary, consider the following
options:
• Give the items to a different department
• Recycle/throw away/sell the items
• Put items into storage
For cases when an item's value is uncertain—for example, a tool hasn't been used recently, but
someone thinks it might be needed in the future—use the red tag method. Red tags are usually
cardboard tags or stickers that can be attached to the items in question. Users fill out information
about the item such as:
 Location

 Description
 Name of person applying the tag
 Date of application
Then the item is placed in a “red tag area” with other questionable items. If after a designated
amount of time (perhaps a month or two) the item hasn't been used, it's time to remove it from
the workspace. It's not worth hanging onto things that never get used since they just take up
space.
3.1.2 Set in Order
Once the extra clutter is gone, it's easier to see what's what. Now work groups can come up with
their own strategies for sorting through the remaining items. Things to consider:
• Which people (or workstations) use which items?
• When are items used?
• Which items are used most frequently?
• Should items be grouped by type?
• Where would it be most logical to place items?
o Would some placements be more ergonomic for workers than others?
o Would some placements cut down on unnecessary motion?
• Are more storage containers necessary to keep things organized?

During this phase, everyone should determine what arrangements are most logical. That will require
thinking through tasks, the frequency of those tasks, the paths people take through the space, etc.
Businesses may want to stop and think about the relationship between organization and larger
Lean efforts. What arrangement will cause the least amount of waste?
In Lean manufacturing, waste can take the form of:
 Defects
 Waiting time
 Extra motion
 Excess inventory
 Overproduction
 Extra processing
 Unnecessary transportation
 Unutilized talents
3.1.3 Shine
Everyone thinks they know what housekeeping is, but it's one of the easiest things to overlook,
especially when work gets busy. The Shine stage of 5S focuses on cleaning up the work area,
which means sweeping, mopping, dusting, wiping down surfaces, putting tools and materials
away, etc.

In addition to basic cleaning, Shine also involves performing regular maintenance on equipment
and machinery. Planning for maintenance ahead of time means businesses can catch problems
and prevent breakdowns. That means less wasted time and no loss of profits related to work
stoppages.
Shining the workplace might not sound exciting, but it's important. And it shouldn't just be left
up to the janitorial staff. In 5S, everyone takes responsibility for cleaning up their workspace,
ideally on a daily basis. Doing so makes people take ownership of the space, which in the long
run means people will be more invested in their work and in the company.
3.1.4 Standardize
Once the first three steps of 5S are completed, things should look pretty good. All the
extra stuff is gone, everything is organized, spaces are cleaned, and equipment is in good
working order.
The problem is, when 5S is new at a company, it's easy to clean and get organized…and then
slowly let things slide back to the way they were. Standardize makes 5S different from the
typical spring-cleaning project. Standardize systematizes everything that just happened and
turns one-time efforts into habits. Standardize assigns regular tasks, creates schedules, and
posts instructions so these activities become routines. It makes standard operating procedures
for 5S so that orderliness doesn't fall by the wayside.
Depending on the workspace, a daily 5S checklist or a chart might be useful. A posted schedule
indicating how frequently certain cleaning tasks must occur and who is responsible for them is
another helpful tool.
Initially, people will probably need reminders about 5S. Small amounts of time may need to be
set aside daily for 5S tasks. But over time, tasks will become routine and 5S organizing and

cleaning will become a part of regular work.
3.1.5 Sustain and safety
Once standard procedures for 5S are in place, businesses must perform the ongoing work of
maintaining those procedures and updating them as necessary. Sustain refers to the process of
keeping 5S running smoothly, but also of keeping everyone in the organization involved.
Managers need to participate, as do employees out on the manufacturing floor, in the
warehouse, or in the office. Sustain is about making 5S a long-term program, not just an event
or short-term project. Ideally, 5S becomes a part of an organization's culture. And when 5S is
sustained over time, that's when businesses will start to notice continuous positive results.
Some companies like to include a sixth S in their 5S program: Safety. When safety is included,
the system is often called 6S. The Safety step involves focusing on what can be done to
eliminate risks in work processes by arranging things in certain ways.
This might involve setting up workstations so they're more ergonomic, marking intersections—
such as the places where forklifts and pedestrians cross paths—with signs, and labelling the
storage cabinet for cleaning chemicals so people are aware of potential hazards. If the layout of
the workplace or the tasks people perform are dangerous, those dangers should be reduced as
much as possible. That's what the sixth S focuses on.
Some people consider safety an outcome of performing the other five S's appropriately, and
as a result say a sixth S isn't necessary. They think if the workspace is properly organized and
cleaned and uses helpful visual safety cues, a separate safety step is unnecessary.
Neither approach to safety is right or wrong. But however a business wants to approach
safety, it should be aware that paying attention to safety is important.

CHAPTER-4
SERVICES AND INDUSTRIES
4.1 PICTORICAL REPRESENTATION OF PODRAIN SERVICES AND

INDUSRIES
Fig 4.1 PCB Assembly Board
1. PCB Assembly:
 Complex PBCA with multiple BGA, QFN, LGA etc.

 Flex pcb with components populated by machine
 Flexi – rigid PCB assembly for multiple applications
 Prototypes delivered in 2 to 3 days on acceptance of kit and clarifications
Fig 4.2 PCB Assembly Machine
2. System Integration:
 Box build for complex products – mainly from health care, home automation,
m-POS and other IOT devices. Total area available for box build is 9000 sq ft.

Fig 4.3 System Integration

3. Order fulfilment and RMA Logistics
 Where required we are willing to support warehousing, order fulfilment and RMA
services. Have dedicated warehouse space and staff for the same.
4. Quickturn rework and re-balling
 Rework of QFN, LGA, BGA, Micro BGA – fully automated.
 Re-balling of BGA from 0.3 to 0.65 mm
4.2 INDUSTRIES
Podrain company is working for several industries are mentioned below:
 Medical Industry

Fig 4.4 PCB Board for Medical Industry
 Automotive Industry
Fig 4.5 Automotive Industry
 Telecom Industry

Fig 4.6 PCB Board in Telecom Industry
4.3 Machines and Infrastructure
 Fully Automatic Pick n' Place Machine
 7-Zone Reflow Soldering Machine for both RoHS/ RoHS
 Automatic Optical Inspection (AOI) Machine
 X-Ray Machine
 High end BGA rework Station with Camera and Laser Mechanism
 Soldering Pot
 Soldering Stations

 Microscopes
 Magnifiers
 Hand Crimping Tool for wire harness
 Electric Screw Drivers
Fig 4.7 Box Build Lines 1200 Sq.Ft
Fig 4.8 BGA Rework with X-Ray

Fig 4.9 SMT Assembly Line 4000 Sq.Ft

4.4 Process Flow
Fig 4.10 PCB Assembly Process
 PCB Assembly
There exist various stages in the PCB assembly process including adding solder paste to the
board, pick and place of the components, soldering, inspection and test. All these processes
are required, and needed to be monitored to ensure that the product of the highest quality is

produced.
Pick and place machines are a key element of any PCB assembly line enabling components to
be automatically placed on a printed circuit board quickly and accurately. Each stage of assembly
and production must be compatible with the next, and there must be feedback from the output to
the input to ensure that the highest quality is maintained. Processes involved in PCB Assembly: *
Solder Paste: —> Before the addition of components on the Printed Circuit Board, the solder
paste has to be applied at the appropriate places where the solder is required.Typically these
areas are the component pads and is achieved using solder screen.
The solder paste is a paste of small grains of solder mixed with flux. This can be deposited
into place in a process that is very similar to some printing processes.
Using the solder screen, placed directly onto the board and registered in the correct position , a
runner is moved across the screen squeezing a small amount of solder paste through the holes in
the screen and onto the board.
As the solder screen has been generated from the printed circuit board files, it has holes on the
positions of the solder pads, and in this way solder is deposited only on the solder pads i.e., at
the appropriate places.
a. PCB Assembly
 The amount of solder that is deposited must be controlled to ensure the resulting joints have
the right amount of solder.
b. Pick and Place:
 Pick and place machines are relatively sophisticated machines used for PCB assembly.
As the name indicates the pick components up and place them onto the printed circuit
board. In this way manual placement which is slow and relatively inaccurate is
avoided, thereby hugely increasing the throughput and quality.

 After the addition of solder paste, the board with added solder paste is then passed to
the pick and place assembly process. In this process, a machine loaded with reels of
components picks the components from the reels or other dispensers and places them
onto the correct position on the board.
 The position and component information required to programme the pick and place
machine is derived from the printed circuit board design information. This enables the
pick and place programming to be considerably simplified.
 A machine loaded with reels of components picks the components from the reels or other
dispensers and places them onto the correct position on the board.
c. Soldering:
 Once the components have been added to the board, the next stage of the assembly,
production process is to pass it through the soldering machine.The Soldering machine
performs soldering at the appropriate positions.
d. Inspection:
 Once the board is passed through the soldering machine, it is often subjected to
inspection. Inspection refers to the proper observation to check if the components are
placed properly and to inspect boards and detect poor joints, misplaced components, and
under some instances the wrong component.
 Instead automatic optical inspection is a far more viable solution. Manual inspection
is avoided since all the faults can’t be determined using human eye. Therefore,
machine power is used for accurate inspection.
e. Test:

 It is necessary to test electronic products before they leave the factory. There are
several ways in which they may be tested.
f. Feedback:
 To ensure that the manufacturing process is running satisfactorily, it is necessary to

monitor the outputs. This is achieved by investigating any failures that are detected.
 The ideal place is at the optical inspection stage as this generally occurs immediately
after the soldering stage. This means that process defects can be detected quickly and
rectified before too many boards are built with the same problem.
 Initially the customer provides all the materials required for the manufacture of PCB
that meets the specifications according to the Bill Of Materials(BOM).The Materials
are IGI inspected and is further decided to use them or to discard.
 The materials are then stored which undergo production according to a specified
plan.The XY data file is then basically a list of all the components on the design and
their respective x-y coordinates and rotation.Baking of PCB components is carried out
if required, otherwise solder paste printing is done.
 Immediately after the completion of Solder paste printing, the board is

inspected.If it is OK,Component placement is carried out otherwise the PCB is
cleaned and feedback is given to the technician.
 After placement of various components on the board, the board is inspected at various
stages.If found faulty, an attempt to rectify the fault has to be made.
 Manual inspection is not preferred during inspection as it may lead to inaccuracy and is
time consuming.Once the board is passed through the soldering machine, it is often
subjected to inspection.

 Inspection refers to the proper observation to check if the components are placed
properly and to inspect boards and detect poor joints, misplaced components, and under
some instances the wrong component.Instead automatic optical inspection is a far more
viable solution.
 Manual inspection is avoided since all the faults can’t be determined using human
eye. Therefore, machine power is used for accurate inspection.
 The process after the preparation of the PCB with all the discrete components is the
actual assembly of the concealed box. This process is entirely done by man power.
 This process comprises of different stages wherein different components are

assembled in a plastic covering and is sealed.
 Placing and Fitting of PCB :
 Here the assembled PCB is fitted on a moulded plastic platform with screws.
 Placement and connection of SMPS adaptor :
 A switched-mode power supply (SMPS) is an electronic circuit that converts power

using switching devices that are turned on and off at high frequencies, and storage
components such as inductors or capacitors to supply power when the switching device
is in its non-conduction state.
 Connection of wires for the power supply The power supply wires are then explicitly
connected with a colour code of red for positive, blue for negative and black for
ground.

 Assembly of Unit
 Fitting of the clamp for connection to mains :
 A plastic clamp is connected to isolate the three power supply wires while connecting the
device to the mains.
 Placement of buttons on the side panel:
 The utility buttons are stuck on the side panel of the product with a heavy adhesive.
These buttons are internally connected to the PCB for functioning. An SOS button is
stuck on the front panel which is used by the consumer during an emergency. Finally all
the panels are interlocked together making the product ready for functionality testing.
4.5 Pick and Place Machine
 Troubleshooting is one of the major process that is to be done with all the defective
products, where the faulty products are all rectified and sent for utilisation.
 Products to be troubleshooted are segregated in to two types namely software and

hardware. All the software issues are assigned to the software expert teams for debugging
and all the hardware issues are sent to the lab for close examination and repair.
 The software issues are usually program concerned, hence the devices are preferred to
be flashed using a flashing software called boot loader. The codes are constantly
optimised by the R&D team for further upgradation.

Fig 4.11 Pick and Place Machine

3.6 Testing and Functionality
 Podrain have tied up with the world’s leading inspection, verification, testing and
certification company.
 They have access to a lab dedicated to testing and certifying electrical and electronic
(E&E) products and components in India. They are specialized in evaluating
electromagnetic capability, battery, energy efficiency and safety compliance of products
in dozens of categories — lighting products, solar products, medical devices, home
electronics, office equipment and more. Plus, we can help you develop a strategic testing
program to minimize turnaround time and keep production on schedule.
Fig 4.12 PCB Assembly Machine Outer Layout

 Tests done locally in Bangalore:
1. EMI/EMC Test
2. Safety Tests
3. IP Tests
4. BIS Tests
5. Environmental Testing
6. CE/CB Certification
7. REACH and ROHS
8. Salt Spray Testing
 SERVICES: Risk Assessment , Electrical safety Testing , CE Marking services

[as per Machinery directive 2006/42/EC].
1. Troubleshooting:
I. The hardware issues are sent to labs where all the physical faults are
carefully examined. All the identified faults are rectified either buy
replacing the components through the process of heating and soldering
or by repairing if there exist any minor errors like contact errors or
misconducts caused by dust.
II. All these hardware processes are done in ESD proof enviroments by
personnels wear ESD coats, footwear and wrist bands.
III. Finally all repaired products are dispatched back.

IV. Packing and Dispatch
V. The assembled products are finally set for packaging. The boxes are
stuck with a sticker labelling it with it's respective Mac ID. All the
Mac IDs are then physically noted down and also are scanned using
a barcode scanner, then the information is stored in an excel sheet.
VI. These products are further stored in large cartons with a specific number
of products placed in each carton. These cartons are stored and are then
attended by certain set of personals who pack each product in individual
cartons and pile them up.
VII. These piled up products are set in large packings with bubble wraps for
safety and are all set for dispatch. Each package with specific number of
products are labelled with the destination addresses and are set for target
dispatch. Finally all the products are dispatched via trucks and are
tracked till the acknowledgment from the consumer is received.
2. Packaging
I. The whole point of internship carried out by a student is to get exposure

to the outside world. Technical knowledge can also be acquired sitting in
a library and experimenting in the lab but the actual exposure can be
acquired only through social interactions. It's all about sharing each others
views and ideas.
II. The interaction at PODRAIN is remarkable, where these existed a scope

to converse with people with different backgrounds and status. There was
a chance to know the mindsets of different people existed in the working
community.

III. The nature of thinking of different employees existed in a different ways

for instance, the thinking of an enthusiastic workman always wanted a job
that is work bound but a lazy workman expects a time bound job. A clever
workman opts for a knowledge gain rather than a salary hike, which in
turn makes him flourish financially.
CHAPTER 5
CONCLUSION
5.1 Conclusion
 Company has more concern towards the employees, labour standards and environment by
following the global compact principles and put forward its thoughts by promoting
environment friendly business to the world by its new products. It had succeeded in
balancing its profit making and environmental commitments which are two sides of the
business.
 The company follows the international standards to achieve the utmost customer
satisfaction by timely responding to the customer requirements and resolving their
problems.
 After four weeks of organizational study in Podrain Electronics Private Limited, my

knowledge and thinking has been transformed from theoretical approach to real time
business approach.

5.2 Social Interaction
 My interaction was majorly with the people in the assembly section most of whom were
diploma holders from low middle class income group, who strained themselves for the
sake of their families. Most of them were single earners in the family. Apart from them I
have interacted with the HR Manager and director, Mr. Rajesh R, who’s work made me
realise the importance of a person who mobilises the mob for successful functioning of
an organisation through constant motivation and support. My backbone throughout the
period of internship is my external guide Mr.Boovesh Kumar, Senior Engineer ,who
constantly supported me with moral and technical support to carry out the assigned work
with ease.
 Interaction with the people at all levels gives a greater impact on the way of looking at
life, it gives a motivation while feeling low and disappointed by seeing an age old
watchman who struggles in the hot sun to guard the company; It makes one overcome
the self-pity and motivates to work hard and contribute to the upliftment of lives.
 Major Impact of social interaction happens with the close circle of colleagues, who
are the actual reason for tiresome hard work to go with ease. It's my batch of 6 interns
who made my life at podrain quality joyride and made my two months of internship a
memory of lifetime

REFERNCES
1) www.cse.wustl.edu
2) https://podrain.com/

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PCB Assembly and Testing

Podrain is an Electronics Manufacturing Services company, specialising in high quality PCB

Dept of ECE, TOCE 1 2019-2020

Human Resource Development is another trust in a company involving professional and

Dept of ECE, TOCE 2 2019-2020

• They Deliver complex PCB without compromise on quality.

• High customer retention rate.

• They always return e-mails and calls within time.

• Also willing to invest in new technology and in automation.

2.3 Main Area of Business

• Order fulfillment and RMA Logistics

Dept of ECE, TOCE 3 2019-2020

2.4 Services Provided By Podrain

 PCB Assembly – Prototype as well as small to mid-volume

 Mechanical Box Build

 Chassis and Rack Level Assembly,

 Plastic Enclosure Assembly

 Basic test/functional level test Order Fulfilment & RMA Logistics

 Quick turn rework and re-balling

 BGA/QFM Removal and replacement

 Repair and maintain broken traces or pads to its original

 Warehousing for electronics assembly for Just in time delivery

 At Podrain we have invested in the best

 Fully Automatic Ball Grid Array Rework Station

Dept of ECE, TOCE 4 2019-2020

2.5 Journey At Podrain

Dept of ECE, TOCE 5 2019-2020

3.1 PRINCIPLE OF PODRAIN

Fig 1.1 Company Principles

5S involves assessing everything present in a space, removing what's unnecessary, organizing

 What is the purpose of this item?

 When was this item last used?

Dept of ECE, TOCE 6 2019-2020

 How frequently is it used?

 Who uses it?

 Does it really need to be here?

• Give the items to a different department

• Recycle/throw away/sell the items

• Put items into storage

Dept of ECE, TOCE 7 2019-2020

 Name of person applying the tag

3.1.2 Set in Order

• Which people (or workstations) use which items?

• When are items used?

• Which items are used most frequently?

• Should items be grouped by type?

• Where would it be most logical to place items?

o Would some placements be more ergonomic for workers than others?

o Would some placements cut down on unnecessary motion?

• Are more storage containers necessary to keep things organized?

Dept of ECE, TOCE 8 2019-2020

In Lean manufacturing, waste can take the form of:

Dept of ECE, TOCE 9 2019-2020

Dept of ECE, TOCE 10 2019-2020

cleaning will become a part of regular work.

3.1.5 Sustain and safety

Dept of ECE, TOCE 11 2019-2020

SERVICES AND INDUSTRIES

4.1 PICTORICAL REPRESENTATION OF PODRAIN SERVICES AND

Fig 4.1 PCB Assembly Board

 Complex PBCA with multiple BGA, QFN, LGA etc.

Dept of ECE, TOCE 12 2019-2020