Electrical, Controls

Job title: Electrical, Controls and Maintenance Technician

Reports to: Maintenance Manager

Direct reports: n/a

Back up position: Maintenance Technician, Maintenance Manager

Department: Maintenance Department

Work location: Evansville, IN

Exempt/Non-Exempt: Non-Exempt

Job Description date: June 2024

I - Job Purpose and Summary:

The Electrical, Controls and Maintenance Technician coordinates and executes maintenance automation and controls functions safely in the facility so the plant equipment and services perform at maximum levels and minimize unscheduled interruption of the plant operation. This position also trains, coaches, teaches and counsels others on electrical controls maintenance procedures and best practices. Strong skills in planning and organizing are required. Knowledge of programmable logic controllers, electrical systems, and process control systems is required. The Electrical & Controls Technician is a key contributor to the continuous improvements of critical plant performance metrics in the areas of safety, quality and productivity

II - Key Accountabilities:

1. HSE: Promote a safe work environment at all times through the adherence to all PGPI’s Health & Safety and Environmental policies and procedures as well as to all relevant Indiana OSHA regulations in order to achieve ZERO workplace incidents and injuries. Follows the plant safety process and ensures that good safety habits are instilled. Maintains an awareness of all safety issues within area of responsibility and responds with appropriate urgency to correct safety issues identified. Designs program safety into the electrical systems. The site lead for electrical compliance
2. QA & FOOD SAFETY: Ensure compliance with rigorous standards of food safety, quality, legality, and authenticity, playing a crucial role in maintaining the highest standards throughout the entire food production process. Maintains BRC and regulatory compliance within the maintenance regulations
3. Maintenance & Troubleshooting: Installs, repairs and tests electrical systems on industrial equipment including PLC control systems, power distribution, lighting, fire and security alarms and communication systems to National Electrical Code specifications. Ensures operation of machinery and electrical equipment by completing preventive maintenance requirements on drives, backup power systems, motors, pneumatic tools, conveyor systems, and other electrical related systems, following diagrams, sketches, operations manuals, manufacturer's instructions, and engineering specifications. Maintains electrical control software in support of programming for the facility. Programs HMIs, PLCs, Servos, and other electrical systems. Makes timely and appropriate decisions when an emergency or breakdown occurs so that production interruption is minimized.

For equipment or processes where maintenance costs are high, where reliability is low, or where chronic problems exist, performs additional analysis to identify appropriate maintenance practices (e.g., Root Cause Failure Analysis, Failure Modes and Effects Analysis, Reliability-centered maintenance analysis). Diagnoses electrical problems and determines how to correct them, checking schematics, repair manuals, and parts catalogs as necessary. Supports the Maintenance department by defining who can use PLC and computer interfaces for troubleshooting.

1. Maintenance Project Management: Accountable for keeping the Maintenance Manager appraised of electrical equipment conditions so that situations of major significance can be planned for to avoid major production downtime. Prepares electrical maintenance reports by collecting, analyzing, and summarizing information and trends. Coordinates and executes maintenance electrical functions in the facility so the plant equipment and services perform at maximum levels and minimize unscheduled interruption of the plant operation. Provides technical information to support planned electrical preventive maintenance to minimize production downtime. Tracks electrical maintenance costs and failures. Specifies electrical parts, supplies, and equipment from catalogs and suppliers. Defines electrical spare parts needs, such that inventories are maintained at appropriate levels. Plans and lays out repair work, using diagrams, drawings, maintenance manuals, and schematic diagrams. For planned new equipment purchases and installations where no maintenance history exists, applies maintenance and repair best practices to assure maximum reliability. Ensures all equipment and site electrical drawings are kept up to date.
2. Continuous Improvement: Understand, implement, and review maintenance and plant availability systems associated with the site infrastructure and production environment to the agreed safety, technical and work standards. Ensure KPI’s are monitored and presented to allow identification of improvement plans. Leading and owning the evaluation of electrical risks prior to the introduction of and establishment of controls of a new maintenance practice, process or equipment installation.
3. Training & Development: Participate in all trainings related to the job in order to gain knowledge/skills/abilities needed for exceptional performance. Together with Maintenance Manager, prepare personal development plan in order to identify areas for improvement.

III - Internal and External Contacts:

Internal: All employees in Operations, Maintenance, Warehouse Department, HSE & QA

External: Outside contractors and vendors.

Education

• Minimum high school diploma or GED, and electrical ability. Testing may be conducted.

Related Experience

• Efficient in sizing conductors, conduits and using NEC Code Book.
• Experienced in handling low to high voltage up to 480 VAC
• Competent with installing, wiring and programming of VFDs and DC drives.
• Competent with troubleshooting PLCs and Ladder Logic.
• Experienced in Process Controls
• Diagnose and apply results using: Voltmeters, ammeters, IR and megger.
• Familiar with current Arc Flash regulations.
• Position may require employee to work around and troubleshoot energized equipment.

Competencies

• Safety: First aid for shock victims, National Electrical Code, static electricity, grounding, double-insulated tools, National Fire Protection Association (NFPA) - 70e, and hazardous electrical locations.
• Programmable Logic Controllers: PLC components, I/O Systems, instructions, PLC programming, communication protocols, drivers, power supplies, expansion/retrofits, and system development (Allen Bradley Suite preferred).
• Electrical Systems: servos, variable frequency drives, measuring systems, DC circuits, batteries, transformers, AC circuits, DC equipment/controls, three-phase systems, wiring, DC shunt motors, control relays, across-the-line starters, limit switches, electronic switching and electrical energy and power relationships.
• Process Control Systems: speed and rotation sensors, human machine interfaces, control loop operations, data transmission, PID controller/loop tuning, final control elements, process modeling, instrumentation, measurement level detectors, and transducers.
• Electrical Maintenance: voltmeters, ammeters, wattmeters, digital meters; schematics and symbols; short circuits, reversible motors, current probes, and relays
• Mechanical Systems: Pneumatic control systems, air-piloted valves, and hydraulics

Technical Skills

• Computer skills to include Microsoft Suite products and CMMS
• Proof of the completion of formal training. Formal technical school training or some college, combined with 5 years of Industrial Electrician or Industrial Maintenance experience or equivalent certifications. Certifications in any additional related discipline are added factors to consideration.

Certifications, Licenses, Registrations

• Certification or license as an electrician.

Language(s)

• Fluency in English Required.
• Fluency in Spanish Preferred

Other Qualifications

• HACCP, Good Manufacturing Practice (GMP)

V – Work/Employment Conditions and Other Requirements:

Work Environment

This job operates in a manufacturing warehouse environment. This role routinely uses manufacturing equipment. The environment is hot, cold, wet, dusty and loud. Must be able to don personal protective equipment on the manufacturing floor (hearing protection, hard hat, safety glasses, beard/hair nets, safety shoes).

Physical and Sensory Demands

• While performing the duties of this job, the employee is required to stand; walk; use hands to handle, or feel objects, tools or controls; reach with hands and arms overhead and grip; climb stairs, work from heights up to 40 feet; talk or hear. The employee must occasionally lift or move products and supplies, up to 55 pounds.
• Good Vision (corrected to ~20/20), and good color vision because workers frequently must identify electrical wires and electronic components by color.? Good hearing, ability to communicate by speaking clearly, a good sense of smell, taste, and touch is necessary to do the work.??

Position Type and Working Schedule

RFT – Regular Full Time, working schedule based on production demands.

Travel Requirements

n/a

VI - Other Duties:

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.