Lead PLC Technician

Job Description

Job Description

Position Summary

The Lead PLC Controls Technician serves as the technical lead for the installation, maintenance, troubleshooting, commissioning, and repair of industrial control systems, automation equipment, and related electrical components. In addition to performing hands-on technical work, this position coordinates daily field activities, provides technical direction to assigned technicians and electricians, monitors work quality and progress, and serves as a primary point of contact for customers, supervisors, project managers, and engineering teams.

The ideal candidate has advanced experience with programmable logic controllers (PLCs), control panels, motor controls, instrumentation, and industrial electrical systems. This individual must be able to independently diagnose complex control-system issues, make authorized programming and configuration adjustments, guide team members through technical challenges, and help ensure projects and service activities are completed safely, accurately, and on schedule.

This is a working lead position and requires active participation in fieldwork. The role may provide day-to-day direction and technical oversight to assigned employees but does not necessarily have formal hiring, disciplinary, or performance-management authority unless specifically designated by management.

Key Responsibilities

• Serve as the onsite technical lead for assigned control-system installations, service calls, maintenance activities, startups, and commissioning projects.

• Coordinate daily work assignments, priorities, materials, tools, and technical activities for assigned technicians, electricians, subcontractors, and other project personnel.

• Provide hands-on technical guidance, coaching, and troubleshooting support to less-experienced technicians and team members.

• Monitor work quality, productivity, safety, and project progress, and promptly communicate concerns, delays, scope changes, or resource needs to the appropriate supervisor or project manager.

• Verify that assigned work is completed in accordance with project specifications, electrical drawings, customer requirements, company standards, and applicable codes.

• Install, maintain, troubleshoot, and repair PLC-based control systems and industrial automation equipment.

• Diagnose complex electrical, control, communication, and programming issues affecting equipment performance.

• Connect to PLCs to monitor system operation, review logic, identify faults, and make authorized programming changes.

• Troubleshoot and configure human-machine interfaces (HMIs), variable frequency drives (VFDs), motor controls, sensors, relays, instrumentation, and control devices.

• Install, terminate, test, and label control wiring, communication cables, instrumentation, and electrical components.

• Read and interpret electrical drawings, control schematics, ladder logic, panel layouts, process diagrams, equipment manuals, and project specifications.

• Perform and lead startup, commissioning, functional testing, and validation of new or modified control systems.

• Assist with and provide technical oversight for PLC, HMI, and VFD programming, configuration, backups, and documentation.

• Troubleshoot industrial communication networks and connectivity between control-system components.

• Lead root-cause analysis efforts for equipment failures and recommend corrective and preventive actions.

• Maintain current backups of PLC programs, HMI applications, and equipment configurations in accordance with company procedures.

• Coordinate work with customers, supervisors, project managers, engineering teams, electricians, vendors, subcontractors, and other trades.

• Serve as a primary onsite contact for technical questions, work coordination, customer updates, and issue escalation.

• Provide clear and timely status updates regarding work completed, outstanding items, technical risks, system conditions, and recommended next steps.

• Assist with training, onboarding, and skills development for technicians and other assigned team members.

• Lead or participate in pre-task planning, job hazard analyses, toolbox talks, and other required safety activities.

• Follow and reinforce all company, customer, OSHA, NFPA 70E, lockout/tagout, and jobsite safety requirements.

• Stop work and immediately report unsafe conditions, practices, or equipment when necessary.

• Participate in scheduled maintenance, emergency service, after-hours support, and on-call rotations when needed.

• Perform additional duties as assigned.

Lead Role Responsibilities

• Provide day-to-day technical leadership and work direction to assigned technicians, electricians, and project personnel.

• Delegate tasks based on project priorities, employee experience, safety requirements, and operational needs.

• Ensure team members understand job assignments, technical expectations, project scope, and required completion timelines.

• Support the supervisor or project manager in planning work, coordinating resources, monitoring labor hours, and meeting project milestones.

• Inspect work in progress and completed work to confirm quality, functionality, accuracy, and compliance with applicable standards.

• Help resolve technical and operational issues before escalating them to management, engineering, or the customer.

• Mentor team members in PLC troubleshooting, system diagnostics, programming practices, commissioning procedures, documentation, and safe work methods.

• Provide objective feedback to management regarding employee training needs, technical capabilities, work quality, and performance concerns.

• Maintain effective communication between field personnel, customers, project management, engineering, and company leadership.

• Model professional behavior, sound judgment, technical excellence, and a strong commitment to safety.

Required Qualifications

• Minimum of five years of experience working with PLC controls, industrial automation, or electrical control systems, including experience leading field activities, projects, or technical teams.

• Advanced hands-on experience connecting to, monitoring, programming, and troubleshooting PLC-controlled equipment.

• Demonstrated ability to provide technical direction, coordinate work, and support the development of less-experienced technicians.

• Strong working knowledge of ladder logic, control circuits, motor controls, and industrial electrical systems.

• Experience troubleshooting HMIs, VFDs, sensors, relays, motor starters, instrumentation, and control panels.

• Ability to independently diagnose complex control-system failures and lead root-cause analysis efforts.

• Ability to read and interpret electrical schematics, control drawings, project specifications, and technical documentation.

• Experience using electrical testing and diagnostic equipment, including digital multimeters.

• Understanding of industrial communication protocols and networks.

• Strong planning, organization, troubleshooting, decision-making, and root-cause analysis skills.

• Ability to prioritize assignments, coordinate multiple work activities, and respond effectively to changing project or customer needs.

• Ability to work independently and communicate clearly and professionally with employees, customers, vendors, and project teams.

• Ability to provide constructive technical guidance and hold assigned team members accountable for safety, quality, and task completion.

• Valid driver’s license and an acceptable driving record.

• Ability to pass all required pre-employment and customer-mandated screenings.

• Willingness to work overtime, weekends, alternate shifts, participate in an on-call rotation, or travel when required.

Preferred Qualifications

• Technical degree, certification, or completed apprenticeship in industrial electricity, automation, instrumentation, controls, or a related field.

• Previous experience serving as a lead technician, crew lead, foreman, project lead, or senior controls technician.

• Experience planning field activities, coordinating labor and materials, and monitoring project schedules.

• Experience with one or more major PLC platforms, such as Allen-Bradley/Rockwell Automation, Siemens, Schneider Electric, Mitsubishi, or AutomationDirect.

• Experience with Rockwell Studio 5000, RSLogix 500, FactoryTalk View, Siemens TIA Portal, or comparable programming software.

• Experience developing or modifying PLC and HMI programs.

• Experience with industrial Ethernet, EtherNet/IP, Modbus, DeviceNet, ControlNet, or similar communication protocols.

• Experience with control-panel installation, wiring, testing, and commissioning.

• Experience with distributed I/O, safety PLCs, servo systems, robotics, instrumentation, or process controls.

• Experience in manufacturing, water/wastewater, material handling, food and beverage, processing, utility, or other industrial facilities.

• Journeyman Electrician license or relevant controls certification.

• OSHA 10, OSHA 30, or NFPA 70E training.

Knowledge and Skills

• Technical and field leadership

• Work planning and task coordination

• Employee coaching and skills development

• PLC programming and troubleshooting

• Ladder logic and control-system operation

• HMI configuration and troubleshooting

• VFD setup and diagnostics

• Motor controls and control circuits

• Industrial electrical systems

• Instrumentation and field devices

• Industrial communication networks

• Control drawings and electrical schematics

• System startup and commissioning

• Quality control and work verification

• Root-cause analysis

• Technical documentation

• Project and customer communication

• Customer service and professional communication

Physical Requirements

• Ability to lift and carry up to 50 pounds.

• Ability to stand, walk, bend, kneel, climb, reach, and work in confined or elevated areas for extended periods.

• Ability to climb ladders and use aerial lifts.

• Ability to work indoors and outdoors in varying temperatures and weather conditions.

• Ability to safely use hand tools, power tools, computers, and electrical testing equipment.

• Ability to wear required personal protective equipment.

Work Environment

This position may work in active industrial facilities, manufacturing plants, processing facilities, warehouses, utility facilities, construction sites, and other commercial or industrial environments. Work may involve exposure to heights, confined spaces, moving machinery, electrical hazards, noise, dust, and varying environmental conditions. Compliance with all company and customer safety requirements is mandatory.

Equal Employment Opportunity

Norlee Group is an equal opportunity employer. Employment decisions are made without regard to race, color, religion, sex, pregnancy, national origin, age, disability, genetic information, veteran status, or any other status protected by applicable federal, state, or local law.