Key Responsibilities and Required Skills for Plant Technician

🎯 Role Definition

Are you a hands-on problem-solver with a passion for keeping complex systems running at peak performance? This role requires a dedicated and skilled Plant Technician to join our operations team. As the backbone of our facility, you will be instrumental in ensuring the reliability, safety, and efficiency of our production equipment and infrastructure. This role involves diagnosing and repairing mechanical and electrical issues, performing preventative maintenance, and driving continuous improvement initiatives. You are not just fixing machines; you are a crucial partner in our mission to achieve operational excellence and deliver high-quality products. If you thrive in a dynamic environment and enjoy the challenge of troubleshooting sophisticated machinery, this is the opportunity for you.

📈 Career Progression

Typical Career Path

Entry Point From:

Maintenance Helper or Apprentice
Skilled Machine Operator with a mechanical aptitude
Military Veteran (e.g., Mechanical, Electrical, or Avionics specialties)
Graduate of a Technical or Vocational School program

Advancement To:

Lead Maintenance Technician or Maintenance Team Lead
Maintenance Supervisor or Manager
Reliability Engineer or Specialist
Facilities Manager

Lateral Moves:

Process Technician
Quality Control (QC) Technician
Instrumentation & Controls (I&C) Technician

Core Responsibilities

Primary Functions

Perform routine, preventive, and predictive maintenance on all production equipment, including conveyor systems, pumps, motors, packaging lines, and processing machinery.
Diagnose and troubleshoot complex mechanical, electrical, pneumatic, and hydraulic system failures in a timely and efficient manner to minimize production downtime.
Execute emergency breakdown repairs with a strong sense of urgency while adhering strictly to all safety protocols and procedures (LOTO, etc.).
Read and interpret technical manuals, electrical schematics, blueprints, and parts diagrams to effectively identify and resolve equipment issues.
Install, set up, and commission new machinery and equipment, ensuring it meets operational standards and integrates seamlessly into existing production lines.
Calibrate and adjust machinery settings to ensure optimal performance, product quality, and compliance with manufacturing specifications.
Conduct regular inspections of facility infrastructure, including HVAC, compressed air systems, and water systems, identifying potential issues before they become critical failures.
Fabricate or modify machine parts and guarding using shop equipment such as welders, grinders, lathes, and milling machines as needed for repairs and improvements.
Perform advanced electrical work, including troubleshooting PLCs (Programmable Logic Controllers), VFDs (Variable Frequency Drives), sensors, and control circuits up to 480V.
Safely operate mobile equipment such as forklifts, scissor lifts, and boom lifts to access and repair machinery at various heights and locations.
Document all maintenance activities, repairs, and parts usage accurately and thoroughly in the Computerized Maintenance Management System (CMMS).
Respond to immediate production needs and service calls from operators to address equipment malfunctions and operational disruptions.
Participate actively in root cause analysis (RCA) investigations for recurring equipment failures to develop and implement long-term corrective actions.
Ensure all work is performed in compliance with OSHA, EPA, and other local, state, and federal regulations, as well as internal company safety policies.

Secondary Functions

Assist in maintaining a critical spare parts inventory by identifying needed parts, sourcing suppliers, and submitting purchase requisitions.
Support engineering teams with equipment modifications, capital projects, and continuous improvement initiatives aimed at enhancing safety, quality, and productivity.
Provide technical guidance and informal training to machine operators on proper equipment operation, setup, and minor maintenance tasks (Autonomous Maintenance).
Participate in plant-wide safety committees and contribute to the development and enhancement of safety procedures and job hazard analyses.
Maintain a clean, organized, and safe work environment in maintenance shops and around all job sites within the facility.
Champion continuous improvement by suggesting and implementing innovative ideas to enhance equipment reliability and reduce maintenance costs.

Required Skills & Competencies

Hard Skills (Technical)

Mechanical Systems: Proficient in troubleshooting and repairing mechanical components such as gearboxes, bearings, belts, chains, pumps, and conveyors.
Electrical Troubleshooting: Strong ability to diagnose and repair electrical systems, including motors, control circuits, sensors, and 3-phase power (up to 480V).
PLC & VFD: Foundational knowledge of Programmable Logic Controllers (PLCs) and Variable Frequency Drives (VFDs) for troubleshooting and minor programming adjustments.
Pneumatics & Hydraulics: Solid understanding of pneumatic and hydraulic systems, including reading schematics, and repairing valves, cylinders, and pumps.
Welding & Fabrication: Basic to intermediate skills in welding (e.g., MIG, TIG, Stick) and metal fabrication for repairs and custom part creation.
CMMS Software: Experience using a Computerized Maintenance Management System (e.g., SAP PM, Maximo, eMaint) to log work orders and track assets.
Blueprint & Schematic Reading: Ability to read and interpret complex electrical, mechanical, and pneumatic drawings and schematics.

Soft Skills

Problem-Solving: Exceptional analytical and diagnostic skills to quickly identify the root cause of complex technical problems under pressure.
Attention to Detail: Meticulous approach to repairs, installations, and documentation to ensure accuracy and safety.
Communication: Clear and effective communication with operators, supervisors, and engineers to coordinate repairs and provide status updates.
Teamwork & Collaboration: Ability to work effectively as part of a maintenance team and cross-functionally with other departments.
Adaptability: Flexibility to handle changing priorities, unexpected breakdowns, and varying work schedules (including overtime and on-call rotations).

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED.

Preferred Education:

Associate's Degree or Technical Certificate in a relevant field.
Completion of a recognized apprenticeship program in industrial maintenance.

Relevant Fields of Study:

Industrial Maintenance Technology
Mechatronics or Electromechanical Technology
Electrical or Mechanical Engineering Technology

Experience Requirements

Typical Experience Range: 3-7 years of hands-on maintenance experience in an industrial, manufacturing, or production environment.

Preferred:

Experience in a fast-paced manufacturing setting (e.g., food & beverage, consumer goods, automotive).
Proven track record of working with PLCs, robotics, and automated packaging equipment.
Experience working within a GMP (Good Manufacturing Practices), ISO, or other regulated environment.