Controls Technician

Job Summary

The Controls Technician is responsible for the maintenance, troubleshooting, and continuous improvement of plant electrical, controls, and automation systems. This role ensures safe, reliable, and efficient plant operations by diagnosing and resolving issues involving PLCs, HMIs, SCADA systems, robotics, servo systems, industrial networks, and associated electrical and electromechanical equipment. The Controls Technician works independently and collaboratively with Maintenance, Engineering, Operations, and external vendors to support equipment reliability and process performance.

Essential Duties & Responsibilities

• Maintain, troubleshoot, and repair plant electrical, controls, and automation systems
• Diagnose electrical, electronic, mechanical, and control system failures using root cause analysis
• Independently perform advanced troubleshooting and implement corrective actions without assistance
• Support PLC-based systems, including program diagnostics, downloads/uploads, and modifications
• Troubleshoot and Support PLC systems (Allen-Bradley preferred)
• Automation & Equipment Troubleshooting
• Troubleshoot and Support HMIs and SCADA systems (e.g., Wonderware, Intellution)
• Servo systems, robotics, and motion control
• PID control loops, heat systems, and process controls
• Identify and resolve issues in sensors, relays, instrumentation, and industrial communication systems
• Installation, Modification & MOC
• Install, modify, and validate electrical wiring and control components in compliance with code
• Execute Management of Change (MOC) processes and maintain accurate documentation
• Support fabrication, installation, and system modifications to meet engineering and regulatory requirements
• Maintenance & Reliability
• Perform preventive and predictive maintenance on electrical and control systems
• Maintain accurate records of repairs, calibrations, and inspections
• Utilize SAP (or equivalent CMMS) for work orders, parts, and maintenance documentation
• Support reliability and waste reduction initiatives across the plant
• Systems & Process Support
• Troubleshoot bulk ingredient systems, refrigeration systems, and process equipment
• Support industrial communication networks (Ethernet/IP, Modbus, DH+, etc.)
• Utilize electrical test equipment to diagnose circuit and component failures
• Safety, Quality & Compliance
• Adhere to all safety standards including Lockout/Tagout, Arc Flash, and electrical safety programs
• Follow GMP, food safety, and environmental compliance requirements
• Perform scheduled safety and environmental inspections and ensure corrective actions are completed
• Identify and escalate safety, compliance, or system design risks
• Collaboration & Training
• Interface with operators, maintenance technicians, engineering, vendors, and contractors to resolve issues
• Provide technical guidance and support during equipment troubleshooting and installations
• Train and mentor maintenance technicians, setup technicians, and operators as needed