Controls Maintenance Technician

Controls & Maintenance Technician

Reporting to the Engineering & Maintenance Manager, the Controls & Maintenance Technician will be responsible for supporting manufacturing operations through troubleshooting, repair, equipment reliability improvements, and control system support. This position combines industrial maintenance and controls responsibilities with a focus on equipment uptime, corrective maintenance, automation support, operator-driven equipment care, and continuous improvement initiatives.

The Controls & Maintenance Technician will work closely with Maintenance, Engineering, Production, and external vendors to diagnose equipment issues, implement corrective actions, support capital projects, and improve overall equipment performance. The position will also support the facility's transition from a traditional Preventative Maintenance (PM) program to a Total Productive Maintenance (TPM) system by developing equipment care standards, training operators, improving equipment ownership at the production level, and driving reliability improvements throughout the organization.

This role is hands-on and requires strong mechanical, electrical, pneumatic, hydraulic, and controls troubleshooting skills.

Note: This position is not responsible for performing scheduled Preventative Maintenance (PM) activities. Preventative Maintenance scheduling and execution responsibilities remain assigned through the Maintenance Planning and Scheduling function. This role focuses on equipment reliability, corrective maintenance, TPM implementation, and operator engagement.

Key Responsibilities

• Controls System Support
• Troubleshoot and repair PLC, HMI, VFD, servo, and industrial control systems.
• Assist with modifications to existing control programs and machine interfaces.
• Support commissioning, startup, and validation of new equipment and systems.
• Diagnose communication issues involving Ethernet/IP, Modbus, and other industrial protocols.
• Work with Engineering and external vendors to resolve complex controls issues.
• Maintain and update electrical schematics and controls documentation.
• Equipment Reliability & Corrective Maintenance
• Respond to equipment breakdowns and perform corrective maintenance activities.
• Troubleshoot mechanical, electrical, hydraulic, pneumatic, and process-related equipment failures.
• Identify root causes of recurring equipment issues and implement corrective actions.
• Repair and maintain production equipment, support systems, and facility infrastructure.
• Support machine rebuilds, equipment upgrades, and reliability improvement projects.
• Assist in maintaining spare parts inventories and identifying critical replacement components.
• Document repairs, troubleshooting findings, and corrective actions within the CMMS system.
• Utilize equipment history and failure analysis to improve equipment reliability and reduce unplanned downtime.
• Total Productive Maintenance (TPM)
• Support the transition from Preventative Maintenance (PM) to Total Productive Maintenance (TPM) methodologies.
• Develop and implement operator-based equipment care standards.
• Train and coach operators on basic equipment inspections, cleaning, lubrication, adjustment, and condition monitoring activities.
• Assist in establishing autonomous maintenance programs throughout manufacturing operations.
• Identify opportunities to improve Overall Equipment Effectiveness (OEE), equipment reliability, and asset utilization.
• Develop visual controls, inspection standards, TPM documentation, and equipment ownership processes.
• Participate in focused improvement activities targeting chronic equipment losses and downtime.
• Collaborate with Production to establish equipment ownership and accountability at the operator level.
• Support predictive and condition-based maintenance initiatives where applicable.
• Manufacturing & Continuous Improvement
• Analyze equipment performance and identify opportunities to reduce downtime.
• Support continuous improvement initiatives focused on safety, quality, productivity, and reliability.
• Collaborate with Production and Engineering to improve equipment performance and process capability.
• Assist with installation and integration of new manufacturing equipment.
• Participate in root cause investigations and corrective action implementation.
• Support Lean Manufacturing, TPM, Operational Excellence, and reliability improvement initiatives.
• Project Support
• Assist Engineering and Maintenance Management with capital projects and equipment installations.
• Coordinate contractor activities during equipment upgrades and maintenance projects.
• Support project planning, equipment layout reviews, and startup activities.
• Maintain project documentation and technical records.
• Participate in equipment acceptance testing, commissioning, and validation activities.

Qualifications

• Associate degree, technical certification, or equivalent experience in Industrial Maintenance, Electrical Technology, Mechatronics, Controls Technology, or related field.
• Minimum 35 years of industrial maintenance and troubleshooting experience in a manufacturing environment.
• Strong knowledge of electrical systems, motor controls, VFDs, PLCs, sensors, and industrial automation.
• Ability to read and interpret electrical schematics, mechanical drawings, and technical manuals.
• Experience troubleshooting hydraulic and pneumatic systems.
• Familiarity with CMMS systems and maintenance work order processes.
• Working knowledge of TPM principles, autonomous maintenance, equipment reliability, and continuous improvement practices preferred.
• Working knowledge of industrial safety standards including Lockout/Tagout procedures.
• Experience with Allen-Bradley, Siemens, or similar PLC platforms preferred.
• Welding, machining, fabrication, and machine rebuilding experience is a plus.

Other Requirements

• Strong troubleshooting and problem-solving abilities.
• Ability to train and mentor operators in TPM and equipment care activities.
• Ability to work independently and prioritize multiple tasks in a fast-paced manufacturing environment.
• Capable of lifting up to 50 pounds and working in industrial environments.
• Ability to work occasional overtime and support emergency equipment repairs as required.
• Strong communication and teamwork skills.
• Positive attitude, good judgment, and commitment to continuous improvement.
• Performs all other duties as assigned.

Position Objectives

Success in this role will be measured by:

• Reduction in unplanned equipment downtime.
• Improvement in equipment reliability and Overall Equipment Effectiveness (OEE).
• Increased operator participation in TPM and autonomous maintenance activities.
• Reduction in recurring equipment failures.
• Improved equipment availability and manufacturing throughput.
• Successful implementation of TPM principles throughout manufacturing operations.
• Enhanced collaboration between Maintenance, Engineering, and Production.