PLC Technician

Control Technician

The Control Technician is responsible for maintaining, developing and creating dependable equipment throughout our facility. Implements continuous improvements, supports new system installations, production strategies and plant reliability. Persons must be capable in analyzing conditions, technical troubleshooting thru the process, identify and repair mechanical and electrical issues which prevent meeting the shift or weekly schedules. Assists, trains/coaches' employees in electrical, mechanical, hydraulic, and pneumatic maintenance and the repair of machinery and equipment. The successful candidate must have a passion for safety and be able to foster effective working relationships built upon trust and respect within all levels of the organization.

The ideal candidate will possess expert knowledge of PLCs, HMIs, VFDs, Servos, Vision systems, Control Networks and plant automation systems to troubleshoot all industrial control systems including OEM process control systems.

Responsibilities:

• Ensures operation of equipment by demonstrating senior level abilities to troubleshoot, repair, upgrade and maintain control systems & components on processing, filling, packaging equipment and utility systems by following manuals, diagrams, sketches, digital videos, manufacturer's instructions, SOPs and engineering specifications WITHOUT assistance.
• Troubleshoots and resolves PLC, HMI, VFD, Servo, Vision systems, Control Networks, Instrumentation problems without assistance. Must be able to span, calibrate and replace devices including I/Ps (current to pressure devices), VFDs
• Uses skills and knowledge to assess, repair, replace electrical controls and devices leveraging tools (laptops, meters, meggers, oscilloscopes, pressure calibrators, etc.)
• Uses abilities to program, troubleshoot and repair Ink coders (Video Jet/others)
• Work with Field Service techs to learn new control systems & components for purpose of training other technicians.
• Demonstrated abilities to calibrate temperature, pressure and I/P sensors.
• Must have demonstrated understanding of CIP/SIP and production functions of processing, filling, and packaging equipment in their assigned area and leverage this knowledge in other areas.
• Executes projects by following the Change Management process to develop enhancements of industrial control schemes to drive operational improvements and cost reductions.
• Maintains continuity among work teams by documenting and communicating actions, irregularities, and continuing needs. Writes technical summaries detailing work performed for permanent record keeping.
• Maintains controls related documentation (Programs, OEM manuals, electrical drawings, P&IDs, parameters for control networks, drives, and process databases)
• Provides related technical guidance and expertise; assisting and coaching Maintenance, Operations and QA associates on an ongoing basis.
• Complies with the following initiatives: Maintenance Excellence, Autonomous Maintenance, Management Operating System (MOS), Safe Quality Foods (SQF), 5S, Good Manufacturing Practices (GMP), Process Safety Management (PSM)
• Applies Root Cause Analysis and problem solving regularly in their daily work to eliminate repetitive failures and issues.
• Demonstrated abilities with MVP computer maintenance management system: Parts check out, Parts requisitions, Work Orders, Work Requests, and run scheduled reports.
• All other duties as assigned or become evident

Job Requirements:

• Apprenticeship or experience and demonstrated abilities in related field. Associates in Electrical, Mechanical or related technical fields are preferred. A High School Diploma or equivalent at a minimum.
• 10+ years in maintenance related Field
• Achieve and maintain required certifications
• Certification to operate lifts and other required equipment
• Five years applied industrial controls experience using Allen Bradley control platforms (Studio5000, RSLogix 500, FTView ME & SE, etc.), Siemens S7, Wonderware SCADA systems, Motor Controls (VFD and Servo), and industrial networks including ControlNet, DeviceNet, ProfiBus, and EtherNet preferably in a food/beverage manufacturing environment.

Knowledge, Skills and Abilities:

• All Candidates are required to take the Danone Maintenance Entrance testing (cannot retake within 9 months). Must achieve composite score of 210 or better, with a minimum of 28 on the Electrical test and 36 on the PLC test in the Danone Maintenance Entrance Test
• Expert knowledge of PLCs, VFDs, Servos, vision systems and plant automation systems.
• Proficiency in MS office and Computer skills
• Excellent verbal and written communication skills
• Proven decision-making ability and work well in a team environment
• Ability to prioritize and multitask
• Ability to work various hours and shifts
• Ability to work overtime when required
• Advanced understanding and ability to troubleshoot, replace, and configure sensors and instrumentation such as photo-eyes, proximity switches, pressure, flow, level and temperature sensors.
• Advanced understanding and ability to troubleshoot, configure, and replace non-similar motor control components such as starters, soft-starters, VFDs, and Servos.
• Advanced understanding and ability to troubleshoot, configure, and replace non-similar controls hardware, such as input/output modules, human machine interfaces (HMIs), chart recorders, safety relays, and other industrial controls.
• Working and practical knowledge of plant utility systems is highly desirable, (including boiler systems, ammonia refrigeration systems, compressed air systems, waste water treatment). Working knowledge of National, State, Local building codes, OSHA and standard industry safety rules/regulations.
• Working knowledge of all automation standard practices as defined by the ISA
• Advanced electrical knowledge and understanding of electrical safety (NFPA 70E).
• Able to work on multiple voltages (DC/AC) up to 480V and use appropriate electrical meters and tools required for the task at hand.
• Advanced working knowledge and ability to troubleshoot and interpret Allen-Bradley PLC programs to understand how the machine functions and be able to make recommendations and/or identify the root cause of any issues.
• Ability to read and interpret Domestic and European P&ID drawings, pneumatic, hydraulic and electrical schematics for use in system understanding and troubleshooting.
• Effectively leverage CMMS (MVP) work order system use for PM and storeroom functionality
• Can safely use hand tools, drills, grinders and shop equipment
• Effectively assesses and uses proper tools for job. No adjustable pliers or channel locks used for nuts and bolts.
• Any and all Internal Candidates must have BUL endorsement
• Any and all Internal Candidates are required to have current resume

Tools and Equipment:

• Various predictive maintenance equipment, shop equipment and electrical tools (meters, meggers, calibration tools), hand tools etc.
• Office machinery including: computers, printers, fax machines, copiers, telephones, etc.
• Automation software (Rockwell, Wonderware, Ignition etc), Microsoft Office, CMMS etc.
• Industrial power equipment (Forklift, scissor, boom lift, etc.)