Control panel assembler

Control panel assemblers are primarily employed within the manufacturing industry and are skilled in reading schematic drawings to assemble wiring, switches, cables, and other mechanical or electrical pieces. They work on electrical and mechanical components that are designed as a power point for operating electronic or technological equipment.

Control panel assemblers commonly work with electrical engineers in problem-solving solutions as it relates to the assembly process and the functioning of the panels and components. These professionals can also install the completed product, or panel, on a client’s site. Panels can include such things as computer circuitry or breaker boxes.

A control panel assembler has the following duties (the list is not exhaustive):

• Interpret blueprints, diagrams and schematic drawings to determine materials required for control panel and/or electrical equipment assembly on a daily basis
• Locate positions for all electrical apparatus, including brackets, cables, switches and wiring, per the engineering schematics, and mark their location on control panels and/or electrical equipment daily
• Use marks as a guide and drill or tap holes per quality control standards for electrical apparatus on control panels and/or electrical equipment daily
• Fabricate electrical apparatus per specifications and quality control standards using calipers, cutters, drills or saws daily
• Mount fabricated electrical apparatus to the control panels and/or equipment per specifications and quality control standards daily
• Test control panels and/or equipment upon completion to ensure they are fully functional daily
• Troubleshoot control panels and/or equipment if not operating as per engineering schematics daily
• Make necessary adjustments to electronic apparatus and test equipment again to ensure the issue has been repaired daily

Most control panel assemblers work in manufacturing plants, and working conditions vary by plant and by industry. Many physically difficult tasks, such as tightening massive bolts or moving heavy parts into position, have been automated or made easier through the use of power tools. Assembly work, however, may still involve long periods of standing, sitting, or working on ladders.

Some control panel assemblers come into contact with potentially dangerous chemicals or fumes, but ventilation systems usually minimize any harmful effects. Other assemblers come into contact with oil and grease, and their work areas may be noisy.

Most control panel assemblers work full time. Some assemblers work in shifts, which may require evening, weekend, and night work.

The following job titles also refer to control panel assembler:

electrical control panel assembler
monitoring panel assembler
electrical control panel technician
control panel assembly technician
fabricator of electrical control panels
control panel fabricator
assembler of electrical control panels
control panel technician
control panel production assembler
panel wirer
panel board assembler
process control panel assembler
fabricator of control panels
assembler of control panels

A high school diploma is generally required to work as control panel assembler; although some companies require some form of technical or vocational education training, such as an associate’s degree or certificate in electronics technology or a similar discipline.

Common topics covered in a degree or certificate program in this field include semiconductor or electromechanical devices, electrical or industrial motor controls or circuitry, digital or analog circuits, soldering techniques, fundamentals of electronics, or blueprint reading. These programs typically take one to two years to complete and can also provide or require students to complete an internship, or prepare individuals for entering an apprenticeship program.

A prior experience of electrical equipment assembly is a serious asset, as well as the knowledge of specific tools such as National Instruments LabVIEW, SAP, or Sage 100 ERP.

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Control panel assembler is a Skill level 2 occupation.

These occupations, although different, require a lot of knowledge and skills similar to control panel assembler.

wire harness assembler
electrical equipment assembler
electrical cable assembler
control panel tester
battery assembler

These occupations require some skills and knowledge of control panel assembler. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of control panel assembler with a significant experience and/or extensive training.

electrical engineering technician
electrical equipment production supervisor
electromechanical engineering technician
instrumentation engineering technician
sensor engineering technician

This knowledge should be acquired through learning to fulfill the role of control panel assembler.

• Electrical equipment regulations: The national and international regulations with regards to the use and manufacture of electrical equipment on the workfloor. These regulations provide rules and guidelines on topics such as general risk management, electrical equipment manufacture, electrical equipment testing, electrical equipment installation, warning labels, and certificates.
• Electromechanics: The engineering processes that combine electrical and mechanical engineering in the application of electromechanics in devices that need electricity to create mechanical movement or devices that create electricity by mechanical movement.
• Wire harnesses: Assemblies of wires or cables that are bound together by cable ties, tape, or lacing, and are able to transfer signals or electricity. Through binding the wires together, the wires are better protected against damage, are more compact, and require less time to install.
• Electrical wire accessories: Electrical wire and cable products and accessories, such as electrical connectors, splices, and wire insulation.
• Power electronics: The functioning, design, and usage of electronics that control and convert electric power. Power conversion systems are usually categorised as AC-DC or rectifiers, DC-AC or inverters, DC-DC converters, and AC-AC converters.
• Switching devices: Devices that are able to open and close electrical circuits, such as disconnecting switches, interrupter switches, and circuit breakers.
• Power engineering: Subdiscipline of energy and electrical engineering which specialises in the generation, transmission, distribution, and usage of electrical power through the connection of electrical devices to motors, generators, and transformers, such as an AC-DC power adapter.
• Electrical wiring diagrams: The visual schematic representation of an electrical circuit, its components, and the connections between these components.
• Control panel components: The elements present in control panels, such as wires, circuit breakers, DIN rails, switches, programmable logic controllers (PLC), contactors, and transformers.

These skills are necessary for the role of control panel assembler.

• Organise wires: Apply wire markers and cable labels to identify and organise the wire. Use tie-wrap or cable lace to keep the wires together.
• Apply coating to electrical equipment: Prepare and apply coating, such as conformal coating, to electrical equipment and its components to protect the equipment against moisture, high temperature, and dust.
• Read assembly drawings: Read and interpret drawings listing all the parts and subassemblies of a certain product. The drawing identifies the different components and materials and provides instructions on how to assemble a product.
• Troubleshoot: Identify operating problems, decide what to do about it and report accordingly.
• Wire control panel: Strip the wire ends to ensure proper connections and attach wires to the components on the control panel. Pay attention to the wire label, colour, and size. Organise the wire by using a wire duct or cable tie.
• Align components: Align and lay out components in order to put them together correctly according to blueprints and technical plans.
• Use electrical wire tools: Use tools to manipulate wire which will be used for electrical purposes, such as wire strippers, crimpers, soldering irons, torque wrenches, and heat guns.
• Mount control panel components: Connect electrical components, such as circuit breakers, DIN rails, and switches, directly onto the surface of a printed circuit board.
• Bind wire: Bind cables or wire together using cable ties, conduit, cable lacing, sleeves, spot ties, cable clamps, or straps.
• Meet deadlines: Ensure operative processes are finished at a previously agreed-upon time.
• Strip wire: Strip the wire ends using wire strippers to ensure proper connections.
• Report defective manufacturing materials: Maintain required company records and forms in order to report any defective materials or questionable conditions of manufacturing machinery and equipment.
• Install electric switches: Prepare wires for installation in a switch. Wire the switch. Install it securely in the right location.
• Fasten components: Fasten components together according to blueprints and technical plans in order to create subassemblies or finished products.
• Collect control panel components: Select the appropriate control panel components, such as wires and circuit breakers, to meet the specified requirements.
• Ensure conformity to specifications: Ensure that the assembled products are conform to the specifications given.
• Interpret electrical diagrams: Read and comprehend blueprints and electrical diagrams; understand technical instructions and engineering manuals for assembling electrical equipment; understand electricity theory and electronic components.

This knowledge is sometimes, but not always, required for the role of control panel assembler. However, mastering this knowledge allows you to have more opportunities for career development.

• Energy: Power capacity in the form of mechanical, electrical, heat, potential, or other energy from chemical or physical resources, which can be used to drive a physical system.
• Engineering control theory: The interdisciplinary branch of engineering that deals with the behaviour of dynamical systems with inputs and how their behaviour is modified by feedback.
• Electrical engineering: Understand electrical engineering, a field of engineering that deals with the study and application of electricity, electronics, and electromagnetism.
• Programmable logic controller: Programmable logic controllers or PLC’s are computer control systems used for the monitoring and control of input and output as well as the automation of electromechanical processes.
• Waste removal regulations: Know and understand the regulations and legal agreements governing the performance of waste removal activities.
• Microprocessors: Computer processors on a microscale that integrate the computer central processing unit (CPU) on a single chip.
• Electronics: The functioning of electronic circuit boards, processors, chips, and computer hardware and software, including programming and applications. Apply this knowledge to ensure electronic equipment runs smoothly.
• Hybrid control systems: Control systems containing both subsystems with continuous dynamics as well as subsystems with discrete dynamics.
• Electricity: Understand the principles of electricity and electrical power circuits, as well as the associated risks.
• Automation technology: Set of technologies that make a process, system, or apparatus operate automatically through the use of control systems.

These skills and competences are sometimes, but not always, required for the role of control panel assembler. However, mastering these skills and competences allows you to have more opportunities for career development.

• Apply soldering techniques: Apply and work with a variety of techniques in the process of soldering, such as soft soldering, silver soldering, induction soldering, resistance soldering, pipe soldering, mechanical and aluminium soldering.
• Inspect quality of products: Use various techniques to ensure the product quality is respecting the quality standards and specifications. Oversee defects, packaging and sendbacks of products to different production departments.
• Resolve equipment malfunctions: Identify, report and repair equipment damage and malfunctions. Communicate with field representatives and manufacturers to obtain repair and replacement components.
• Inspect electrical supplies: Check electrical supplies for damage, moisture, loss or other problems.
• Measure electrical characteristics: Measure voltage, current, resistance or other electrical characteristics by using electrical measuring equipment such as multimeters, voltmeters, and ammeters.
• Carry out measurements of parts: Operate measurement instruments to measure parts of manufactured objects. Take into consideration specifications of manufacturers to perform the measuring.
• Maintain electrical equipment: Test electrical equipment for malfunctions. Take safety measures, company guidelines, and legislation concerning electrical equipment into account. Clean, repair and replace parts and connections as required.
• Oversee logistics of finished products: Ensure that the processes of packing, storage and shipment of finished products meet the requirements.
• Perform test run: Perform tests putting a system, machine, tool or other equipment through a series of actions under actual operating conditions in order to assess its reliability and suitability to realise its tasks, and adjust settings accordingly.
• Use specialised tools in electric repairs: Use of a variety of specialised tools, instruments and machines, such as presses, drills and grinders; employ them to carry out repairs in a safety manner.
• Wear appropriate protective gear: Wear relevant and necessary protective gear, such as protective goggles or other eye protection, hard hats, safety gloves.
• Replace defect components: Remove defective parts and replace them with functioning components.
• Adjust voltage: Adjust voltage in electrical equipment.
• Repair wiring: Find faults in wires or cables by using specialised equipment and repair these faults depending on type of wiring.
• Apply technical communication skills: Explain technical details to non-technical customers, stakeholders, or any other interested parties in a clear and concise manner.
• Keep records of work progress: Maintain records of the progress of the work including time, defects, malfunctions, etc.
• Adjust manufacturing equipment: Regulate and monitor the manufacturing equipment settings and process parameters, such as its temperature and power level. Review the manufacturing process and equipment and suggest improvements.
• Crimp wire: Attach the electrical connector to the wire using crimping tools. Here the connector and the wire are joined together by deforming one or both so they fit into each other. The electrical connector may connect the wire to an electrical terminal or may join two lengths of wire together.
• Operate soldering equipment: Use soldering equipment to melt and join together pieces of metal or steel, such as a soldering gun, soldering torch, gas-powered iron, and others.

8212 – Electrical and electronic equipment assemblers

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References

1. ESCO
2. U.S. Bureau of Labor Statistics
3. Job Description of a Panel Assembler – BestAccreditedColleges.org
4. Professional Electrical Equipment Assembler Job Description Template | Mighty Recruiter
5. Featured image: Photo by Emmanuel Ikwuegbu from Pexels