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Key Responsibilities and Required Skills for Universal Technician

💰 $45,000 - $90,000

MaintenanceField ServiceMechanicalElectricalFacilitiesManufacturingHVACInstrumentation

🎯 Role Definition

The Universal Technician is a cross-functional maintenance and field-service professional who maintains uptime, optimizes equipment reliability and delivers safe, compliant repairs across diverse systems — including mechanical, electrical, fluid power, HVAC, PLC/HMI, and instrumentation. This role combines hands-on troubleshooting, preventive and corrective maintenance, installation and continuous improvement activities, while documenting work in a CMMS/SAP system and supporting production, facilities and customers in both shop and field environments.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Maintenance Technician / Maintenance Mechanic
  • Field Service Technician / Service Engineer
  • Electromechanical Technician / Industrial Mechanic
  • HVAC Technician, Millwright, or Instrumentation Technician

Advancement To:

  • Senior Universal Technician / Lead Technician
  • Maintenance Supervisor / Team Lead
  • Field Service Manager / Service Operations Manager
  • Reliability Engineer / Maintenance Planner

Lateral Moves:

  • Calibration Technician / Metrology Specialist
  • Controls Technician / Automation Specialist (PLC/HMI)
  • Quality Technician / Process Technician
  • Facilities Technician / Building Systems Engineer

Core Responsibilities

Primary Functions

  • Conduct thorough diagnostics and perform corrective repairs on electrical systems, including motor controls, starters, VFDs, relays and control panels, using schematics and test equipment to restore equipment to service quickly and safely.
  • Troubleshoot complex mechanical failures on production equipment and conveyors, disassemble/inspect components, perform precision machining or replacement, and verify integrity through operational testing.
  • Execute preventive maintenance (PM) routines across mechanical, electrical, pneumatic, hydraulic and HVAC assets per PM schedules, updating condition records and recommending PM improvements to reduce unplanned downtime.
  • Install, commission, and calibrate sensors, PLCs, HMIs and instrumentation (pressure, temperature, flow, level) and validate signal integrity and alarm settings to ensure accurate process control.
  • Perform pneumatic and hydraulic system maintenance: replace seals, rebuild cylinders, service pumps, set pressures, and diagnose leak paths to restore system performance.
  • Read, interpret and work from electrical and mechanical schematics, PLC ladder logic, P&IDs, wiring diagrams, blueprints and technical manuals to safely and efficiently complete repairs and installations.
  • Support field-service operations including travel to customer sites for emergency breakdowns, scheduled installations, start-ups, and on-site troubleshooting while maintaining professional customer communication and documentation.
  • Use multimeters, oscilloscopes, megohmmeters, thermal cameras and alignment tools to perform root-cause analysis and document findings in detailed service reports and failure analysis logs.
  • Perform equipment alignments, bearing replacements, shaft repairs, belt and chain adjustments, and vibration checks following manufacturer tolerances and best practices.
  • Carry out refrigeration and HVAC repairs, filter replacement, refrigerant handling, system leak tests and thermostat calibration to maintain optimal environmental conditions in facilities.
  • Execute mechanical assembly and fabrication tasks including welding, brazing, fastening, fitting and minor machining to restore or modify equipment per engineering change notices.
  • Program, update and troubleshoot PLC/HMI code (Allen-Bradley, Siemens, Mitsubishi or equivalent) and work with automation engineers to implement logic changes, I/O mapping and firmware updates.
  • Maintain accurate maintenance records in CMMS/SAP including work orders, spare parts used, labor hours, failure codes and recommended corrective actions to support KPIs and audit readiness.
  • Manage spare parts inventory, order replacements, maintain kitting for critical assets and recommend stocking levels to balance availability and cost.
  • Conduct safety inspections, lead lockout/tagout procedures, perform hazard assessments and ensure compliance with OSHA, local regulations and company safety programs.
  • Support continuous improvement initiatives (5S, Kaizen, TPM) by identifying repeat failure modes, proposing corrective actions, and participating in root cause investigations to increase equipment reliability.
  • Perform electrical panel builds, wire harness assembly and termination, including ferrules and proper labeling, to support equipment upgrades and new installations.
  • Participate in startup and commissioning teams for new equipment or upgraded systems, execute FAT/SAT activities and provide training and documentation to operators and maintenance staff.
  • Respond to warranty claims and work with vendors and OEMs to coordinate repairs, replacements, and warranty authorizations while maintaining accurate service records.
  • Provide mentorship and on-the-job training for junior technicians and apprentice-level staff, demonstrating safe work habits, troubleshooting techniques and documentation standards.
  • Conduct scheduled and ad-hoc safety, calibration and compliance inspections to ensure equipment meets ISO/GMP/industry-specific standards and prepare equipment for internal and external audits.
  • Support energy management initiatives by diagnosing energy-inefficient systems and implementing corrective actions (VFD tuning, airflow balancing, insulation, control optimization).
  • Perform software updates for embedded controllers, HMIs and diagnostic tools, backing up code and configuration files before modifications and verifying proper operation post-update.
  • Coordinate with production, engineering and procurement teams to schedule downtime, prioritize work orders and minimize operational impact while maximizing equipment availability.
  • Provide remote troubleshooting support and guided diagnostics via phone or video conferencing to expedite resolution when on-site attendance is not immediately possible.
  • Ensure proper handling, labeling and disposal of hazardous materials and used oils in compliance with environmental and safety regulations.

Secondary Functions

  • Assist with equipment obsolescence planning and recommend modern replacements or retrofits to improve maintainability and safety.
  • Contribute to maintenance SOPs, standard work documents and troubleshooting guides to capture tribal knowledge and accelerate future repairs.
  • Participate in cross-functional projects such as facility upgrades, production line reconfigurations, and continuous improvement sprints.
  • Support predictive maintenance programs by collecting vibration, thermography and oil analysis data and escalating findings to reliability teams.
  • Attend vendor training, technical seminars and certification courses to stay current with new maintenance technologies and safety practices.

Required Skills & Competencies

Hard Skills (Technical)

  • Electrical troubleshooting and repair (AC/DC circuits, motor controls, relays, VFDs)
  • Mechanical systems maintenance (bearings, couplings, chains, belts, gearboxes)
  • PLC and HMI configuration and troubleshooting (Allen-Bradley, Siemens, Mitsubishi — or equivalent)
  • Pneumatic and hydraulic system diagnostics and repair
  • Instrumentation and calibration (pressure, temperature, flow, level sensors)
  • CMMS/SAP work order entry, preventive maintenance scheduling and spares management
  • Use of diagnostic test equipment (multimeter, oscilloscope, thermal camera, vibration analyzer)
  • Reading and interpreting electrical schematics, P&IDs and mechanical drawings
  • HVAC and refrigeration troubleshooting, refrigerant handling and system balancing
  • Welding, brazing, basic machining and mechanical fabrication
  • Motor alignment and vibration analysis for rotating equipment reliability
  • PLC ladder logic debugging and basic scripting for HMI/SCADA elements
  • Field-service skills: commissioning, FAT/SAT and customer-focused troubleshooting
  • Safety certifications and procedures: LOTO, confined space, permit-required entry, hazardous materials handling
  • Basic IT and networking skills for industrial equipment (Ethernet/IP, Modbus, basic switch/router troubleshooting)

Soft Skills

  • Strong problem-solving and analytical thinking with attention to root cause
  • Clear verbal and written communication skills for technical reporting and customer interaction
  • Time management and prioritization under competing requests and production constraints
  • Team collaboration and cross-functional coordination with production and engineering
  • Customer-service orientation with professional demeanor during field visits
  • Adaptability and continuous learning to handle diverse equipment and technologies
  • Detail-oriented documentation and record-keeping for compliance and traceability
  • Initiative and ownership to follow through on repairs and continuous improvement actions

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED with vocational/technical coursework; or equivalent military technical training.

Preferred Education:

  • Associate degree, technical diploma or certificate in Electrical Technology, Mechanical Engineering Technology, Mechatronics, Industrial Maintenance, HVAC, Instrumentation, or related discipline.

Relevant Fields of Study:

  • Electrical Engineering Technology
  • Mechanical Engineering Technology / Industrial Maintenance
  • Mechatronics / Robotics
  • HVAC / Refrigeration Technology
  • Instrumentation & Control

Experience Requirements

Typical Experience Range:

  • 2 to 7 years of hands-on maintenance, field service or multi-disciplinary technician experience.

Preferred:

  • 5+ years supporting diverse equipment in manufacturing, processing, facilities or field-service environments with demonstrated ability in electrical/mechanical troubleshooting, PLCs, CMMS usage and safety compliance.
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