1. Global Engineering On-boarding Program

2. Objectives Learn who we are Why you are here
Understand Valued Quality. Delivered.
Identify our culture and behaviors
Understand the Commercial and Electrical Business
Understand what is in it for you
At the end of the day, you should be able to interpret and discuss the
important points of each lesson.
- PG 231

3. Agenda
Thursday- Electrical Evaluation Skills
- PG 234

4. Quiz Review
Wednesday Evening LMS Quiz Results
- PG 232

5. Review Review Talking Points: Click to initiate animation
Briefly Review- ask for participants to provide brief overview of stages we have covered thus far
Scheduling-Locate Job
Quote
Construction Evaluation
Testing
Report
Testing Data Sheets
CDR
- PG 189

6. Testing Skills Measure Voltage Measure Current Measure Leakage Current
Dielectric Withstand Test (DWT)
Temperature Test
Thermocouple
Change of Resistance
Talking Points
As you know, we’re heading off to the lab to perform hands-on testing. First, let’s review some of the
types of testing we will be performing.
- PG 192

7. Voltage Measurement We measure voltage for the following reasons:
To determine correct types of connections to power supply
To determine shock hazards
To determine spacing in products that is based on voltage
To find locations where circuit becomes compliant with requirements to allow no further evaluation
- PG 193

8. Current Measurement We measure current for the following reasons:
Because the amount of current used will determine the size of supply conductors and wiring used
Determine if a unit is operating properly (does the current match the ratings)
To determine the existence of a fire hazard
To find areas (along with voltage) which are considered safe so no further evaluation is needed
- PG 194

9. Leakage Current Measurement
We measure leakage current for the following reasons:
Leakage current is the current available from parts which a user can touch. We measure this to make sure values are not high enough to hurt (or even feel in some cases) someone who can touch the product.
Your lab should have a variety of leakage networks, and perhaps a variety of test circuit boxes. Be sure you ask somebody how to set them up, such as measurement to ground or measurement between parts of the equipment.
Note that testing sometimes must be performed after environmental conditioning
Be sure to follow sequence
Example is provided in guide
a) With switch S1 open, the appliance is to be connected to the measurement circuit.
Leakage current is to be measured using both positions of switch S2, and with the
appliance switching devices in all their normal operating positions.
b) Switch S1 is then to be closed, energizing the appliance. Within 5 seconds, the
leakage current is to be measured using both positions of switch S2 and with the
appliance product switching devices in all their normal operating positions.
c) Leakage current is to be monitored until thermal stabilization. Both positions of
switch S2 are to be used in determining this measurement. Thermal stabilization is to
be obtained by operation as in the normal temperature test.
- PG 195

10. Dielectric Voltage Withstand Test
What is DWT? A high voltage, low current test to find breakdowns in the insulation of a product
- PG 196

11. Dielectric Voltage Withstand Test
When is a DWT indicated?
Indicated where spacings are not sufficient
Indicated when there are nicks or cuts in insulation of wire
Indicated where there issues with insulation becoming conductive
when heated
Simple test to find these issues that need to be looked at further
- PG 196

12. Temperature Testing
Temperature Testing is a basic test performed on all products to make sure the product will operate properly for the expected length of time
Testing tab
Talking Points
Measuring temperatures involves judgments as to:
Where to measure temperature
How to measure temperature
How to compare to the standard
Why we measure temperature.
If a part gets too hot it can burn someone
If a part gets too hot it can cause a fire
If a part gets too hot it can malfunction
If parts of a unit get too hot their life is reduced and can that cause a hazard?
If insulation gets too hot it will not do its job of insulation.
- PG 197

13. Creepage & Clearances
Creepage Distance- Shortest path that follows surface between two points Clearance- Shortest path between two points through air
Talking Points
Measuring temperatures involves judgments as to:
Where to measure temperature
How to measure temperature
How to compare to the standard
Why we measure temperature.
If a part gets too hot it can burn someone
If a part gets too hot it can cause a fire
If a part gets too hot it can malfunction
If parts of a unit get too hot their life is reduced and can that cause a hazard?
If insulation gets too hot it will not do its job of insulation.
- PG 198

14. Creepage & Clearances Talking Points
The clearance between line and neutral on PCB. Creepage is the same distance as clearance for this measurement.
- PG 198

15. Creepage & Clearances Talking Points
Clearance between phases of bus bur assembly. Measuring creepage distance follows structure of insulating material between adjacent phase bus bars.
- PG 198

16. Measurement Uncertainty
Utilize calibrated test equipment in lab
If you use non Intertek calibrated equipment, then verification of measurement equipment is required
In the US, we follow CTL Decision Sheet 251B to comply
There is a more formal course on the detailed rules which is available upon request. This course will be needed if you ever work in the UK or Europe.
Talking Point
All measured values are subject to error. Factors for measurement uncertainty include stability, human judgment and environmental conditions. All of these circumstances can affect the result of a measured value. Intertek equipment is routinely calibrated by an accredited lab because the equipment is calibrated and complies with the CTL provisional decision sheet number 251B, typically no further action is required in day to day evaluations.
- PG 200

17. Single Stress Model Class Exercise Talking Points 1 10 100 1000 1000050
150
200
250
Push Force
Life (Cycles)
Life
Test one
Test two
Test three
Talking Points
This exercise is to demonstrate how variations exist in testing and the importance of recording test data. Additionally, this exercise demonstrates concepts outside of Safety Testing, which is the primary focus of this training.
Resources
SOP Non-Standard Testing
Key Points of Form Standard document
Instructions
Materials: One business card.
The following will be demonstrated in class. Fold business card, crease business card, reverse fold, crease and straighten business card. Straighten the business card with gentle finger sliding tug.
Groups are assigned in class. Each group will be provided the number X for their group.
Every X cycles place one figure tip of water on fold, spread from edge to edge.
Record cycles to failure.
Example Math Models
Arrhenius-Weibull Model
F(t;T) = 1 –exp{-[t exp[-0-(1 /T)]]
Power-Lognormal Model
F(t,V)={[log(t)- (x)]/}
Cox (Proportional Hazards) Normal
R0(t) = exp[-0t h0(t)dt]
All models from “Accelerated Testing”, Wayne Nelson, 1990
Single Stress Model
Notes:
- PG 200

18. Customer Focus
What does this image say to you?
- PG 204

19. Complete Project Management
Customer Focus
Customer Complaints
Complete Project Management
RFQ Process (Sales Interface)
Contact Client
PCD Deadlines and Queue Times
- PG 205

20. Customer Service Good Customer Service = Lasting relationships
Average Customer Service = Steady relationships that could be lost
Poor Customer Service = Lost business
- PG 206

21. Customer Service – Why bother?
Statistics
For every one customer that complains, seven do not!
Many customers move away without telling you why.
An unhappy customer is likely to tell 30 other people about their experience.
Take a look at this cartoon. While it is a bit exaggerated, it does hold some truth.
Finding new customers is a lot more difficult than keeping old customers.
<click>
Statistics show that for every one customer that complain, seven do not.
What does that tell you?
The next point…many customer move away without telling you why.
This last point is the most damaging. An unhappy customer is likely to tell 30 other people about their experience. That makes your job more difficult as there could now be potential customer that have heard negative things about Intertek and may have negative opinions.
- PG 207

22. How can complaints be made?
What is a complaint?
How can complaints be made?
Let’s begin with a definition. What is a complaint?
A complaint is an expression of dissatisfaction about the standard or delivery of service by Intertek. A complaint may or may not be justified and can reference an action, or lack of action, that affects an individual service user or group. It might also reference a policy of Intertek.
We need to be clear. A complaint is not a query about a service or a request for information.
<click>
How can complaints be made?
Typical complaints can be made by telephone, in person, in writing, , fax, complaints leaflets and so on.
A complaint might also be represented by a third party…the worst case being a lawyer!
- PG 208

23. Complaints and SOP 7.14.1 Use SOP 7.14.1 for significant complaints
Validity of test data is questioned
Threat of lawyer or lawsuit
Examples of lower-level complaints:
Customer disputes a bill
Customer did not receive deliverable
Customer has not heard back from engineer or sales person…
Customer PO does not match our invoice
Customer has not received a quote
- PG 209

24. Internal Request for Quote Template
Internal Request for Quote (IRFQ)
Benefits to Engineering and Operations
Sales is training to do quotes
PC uses RFQ to schedule time
All information in one form
Benefits to Sales
Twenty four (24) hour turn-around time from Operations
PC uses RFQ to schedule based on time need and not $$ quoted
Able to quote faster and more independent
An Internal Request for Quote, or IRFQ, is used when Sales is requesting a quote from Engineering. An example is show in your Participant Guide.
<show example of IRQ form>
The idea is for Sales to complete as much as the form as they can.
Engineers will complete the remaining items and add notes as necessary.
The use of this form has benefits to both Sales and Engineering. Let’s first look at the benefits to Engineering and Operations.
<click>
Sales learns to do their own quotes
PC schedules time based on the RFQ, not based on a dollar amount
The form provides a summary to Operations and Engineering on what is being quoted, rather than receiving multiple s and attachments, which could result in missed information such as a model number or special instructions.
The benefits to Sales are that Operations guarantees a 24-hour turn-around time for properly completed RFQs
Sales learns to quote more independently from Operations
Sales has an additional knowledge base for their tool belts
When sending this form to Sales, please copy your PC on all s.
- PG 210

25. Contact your reviewer and client
Signed Order Template
Contact your reviewer and client
Signed Order Template
After a project is scheduled, the client is sent an notifying them that work will begin on their project. When you receive information for a project that you will be working on, it is necessary to contact your reviewer and the client.
<click>
The image on the screen is an example template for a Signed Order. You have a copy of this template in your Participate Guide.
The template is used to contact your client and ask for any additional information that may be required. You should send this correspondence within a day or two of the project start date, or at the latest on the start date. An should also be sent in the middle of the project.
If you have past experience working with the client, a modified template or can be used.
- PG 211

26. Promised Completion Dates
Promised Completion Dates (PCDs)
Set five (5) days after the last day of the project
Important to meet all PCDs
Notify PC if a project need to be pushed out for some reason, such as extra testing
Waiting for Client Information – More than 48 hours
Ensure the communication process was followed
Write a Letter Report so the project can be invoiced
A PCOR will be at the discretion of Sales and Operations
Queue Time – 2 day times
Use of the Network
Lab Safety Presentation should follow after this slide- unless schedule does not permit.
- PG 212

27. Class Exercise
Typical Testing Locate the standards noted in your Participant Guide and identify the difference in how testing is presented When you get to UL 1598, please leave the standard open and accessible on your computer
Testing Tab
Instructions
Review instructions
Upon completion of UL 1598, see where they are in noting a number of tests… and if they conclude “common sense engineering”.
- PG 237

28. Typical Test Program How to create a Test Program
Discuss data sheet creation
Examine the overall program
Consider the order in which tests are performed
Instructions
Some standards identify a specific test order.
Most people do tests in the order identified in the standard which is always a good
basic rule, unless the words are different.
Consider the time it takes to perform the test and plan accordingly.
For, example, let’ say you have two tests that require one hour each to complete and
another test that requires 8 hours to complete. If you perform the two short tests first,
on a Friday, you would be unable to complete the lengthier test during normal
working hours. Therefore, delaying the 8 hour test until Monday. The end result, you
lose a day in the process.
However, if you began the 8 hour test on a Friday, you could complete the other two
tests on Monday morning and gain half a day.
- PG 238

29. Why do we perform tests? Compliance with the standard
Allows the manufacturer more latitude in how he/she designs products rather than simply defining the construction of the product to meet safety requirements
Talking Points
Some standards identify a specific test order.
Most people do tests in the order identified in the standard which is always a good basic rule, unless the words are different.
Consider the time it takes to perform the test and plan accordingly.
For, example, let’ say you have two tests that require one hour each to complete and
another test that requires 8 hours to complete. If you perform the two short tests first,
on a Friday, you would be unable to complete the lengthier test during normal
working hours. Therefore, delaying the 8 hour test until Monday. The end result, you
lose a day in the process.
However, if you began the 8 hour test on a Friday, you could complete the other two
tests on Monday morning and gain half a day.
- PG 239

30. When there is more than one standard
Sometimes, there is more than one standard in a report
Talking Points
Clients want to have more than one standard on product due to selling the same product in more than one country.
We can use multiple standards when the products complies with all the requirements in all standards used!
- PG 241

31. Reasons
Clients want to have more than one standard on a product due to selling the same product in more than one country
We can use multiple standards when the product complies with all the requirements in all standards used
Talking Points
Example: If the Temperature limits on the enclosure were: US 70C and Canada 65C.
then as long as the product was less than 65C it would pass both items.
Example: If the cord length requirements were: US 6-10’ and Canada min 10’.
The product could be listed to both standards.
- PG 241

32. When can we use more than one standard?
We need a separate report when the requirements in the standard conflict
Talking Points
We need separate report when the requirements in the standards conflict:
For Curling Irons, US standards says input is wattage at constant operating temperature,
Canada standard indicated input is wattage during the first 30 seconds of operation
For PTC type heater, the results are very different and so products cannot be listed for
both standards.
If one standard is quiet on a subject then whatever the other standard indicates is the
requirement. Therefore, we can have French markings on a US product because the US
standard only indicates the markings are needed and does not say English ONLY.
- PG 241

33. Separate Reports US and Canadian Standards
Two Construction Reviews (unless standards are harmonized)
When we can include two standards in a report
When we are required to create separate reports
French Markings for Canada
- PG 241

34. Class Discussion What standards are commonly used in your lab?
Special circumstances in Safety Testing
What if I don’t have all of the materials that I require when I start a job?
Talking Points
Ask feedback from participants from their personal experience- challenges- for example products that resemble toys.
- PG 242

35. Summary Review of Job Process Flow Testing Paperwork
Voltage Measurement
Current Measurement
Leakage Current Measurement
Dielectric Voltage Withstand Test
Creepage and Clearances
Measurement Uncertainty
When to use more than one standard
Typical Testing
Typical Standard Use
Talking Points
Summarize talking points above for participants

36. That’s a Wrap
Thank you for your participation today!

37. Questions