I&E Technician (End Plant)

About the role

Our Waco, TX facility manufactures aluminum ends/lids for beverage cans used in soft drinks, beers, energy drinks, teas, and non-carbonated beverages. This high-speed manufacturing environment uses state-of-the-art end-making technology. The Instrumentation & Electronics (I&E) Technician is a specialized maintenance role responsible for the installation, maintenance, calibration, and troubleshooting of all plant instrumentation, electrical control systems, Programmable Logic Controllers (PLCs), Human-Machine Interfaces (HMIs), and advanced sensing/inspection equipment. This role ensures machine uptime, product quality, and data integrity by maintaining the reliability of critical control systems.

Responsibilities

• Control Systems and Programming
  • Troubleshoot, diagnose, and repair complex faults within PLC hardware (e.g., Allen-Bradley, Siemens) and software (Ladder Logic, Function Block).
  • Utilize programming software (e.g., RSLogix 5000) to monitor I/O, modify logic, and upload/download programs safely.
  • Diagnose and resolve issues within industrial control networks (e.g., EtherNet/IP, ControlNet).
  • Ensure reliable communication between PLCs, HMIs, VFDs, and plant data systems.
  • Maintain and verify current backup copies of all critical PLC programs, HMI applications, and configuration files.
• Instrumentation and Calibration
  • Execute routine and preventative maintenance calibration procedures for key process instruments, including pressure, temperature, flow, level, and analytical transmitters (e.g., 4-20mA, HART protocol).
  • Repair, replace, and install various field devices such as photo-eyes, proximity sensors, solenoids, limit switches, and control valves.
  • Maintain, troubleshoot, and calibrate specialized high-speed sensors used in the process, such as Compound Weight, Buckle Resistance, and Curing Oven controls.
• Electrical and Power Systems
  • Expertly troubleshoot electrical circuits up to 480V.
  • Identify and repair faults in motor control centers (MCCs), power distribution panels, and complex wiring harnesses.
  • Install, configure, and troubleshoot Variable Frequency Drives (VFDs) and Servo systems to optimize machine speed and positioning.
  • Strict adherence to all electrical safety protocols, including Lockout/Tagout (LOTO) and NFPA 70E (Arc Flash) procedures.
• Machine Vision and Quality Systems
  • Maintain and troubleshoot high-speed camera and inspection systems (e.g., Pressco, Sencon) used for end-of-line quality checks (compound, cut edge, lacquer coverage).
  • Assist Quality and Production teams with optimizing vision system recipes and thresholds to reduce false rejects while maintaining required quality standards.
• General Skills and Experience
  • Understand manufacturing processes, including data collection and analysis in a high-volume automated environment.
  • Interpret technical manuals, 2D drawings, P&IDs, fluid and electrical schematics, and other engineering documentation.
  • Develop manufacturing documentation and identify critical process parameters.
  • Apply statistics to process measurement and control.
  • Develop and qualify tooling/equipment.
  • Maintain accurate, detailed records for periodic audits.
  • Train personnel inside and outside the work group.
  • Identify and execute improvement opportunities through process and system enhancements.

Requirements

• Education & Experience
  • High School Diploma or GED equivalent.
  • 3–5 years of specialized experience maintaining instrumentation and electronic controls in a high-speed manufacturing or continuous process environment.
• Technical Skills
  • Proficient in reading electrical schematics, P&IDs, and ladder logic.
  • Experience with Allen-Bradley PLC hardware.
  • Ability to use precision electrical test equipment and hand tools.
• Operational Support
  • Commitment to a continuous shift rotation (including nights, weekends, and holidays).
  • Availability for on-call emergencies regarding critical utility failures that threaten production continuity.
• Preferred Qualifications
  • Experience in high-speed manufacturing (beverage, food, or pharma).
  • Prior experience in metal forming, packaging, or high-volume consumer goods (FMCG).
  • Associate degree in Electronics, Instrumentation, or Electrical Technology.
  • ISA Certified Control Systems Technician (CCST) or equivalent professional certification.
  • Experience with Ignition SCADA or similar industrial software platforms.
  • Familiarity with Lean Manufacturing or Six Sigma principles.
  • Experience using precision measurement tools (calipers, micrometers).
• Software/Computer Skills
  • Intermediate knowledge of Microsoft Office (Word, Excel, OneNote, PowerPoint, Visio), Google Workspace, Outlook/Gmail, and website software.
  • Ability to learn new software systems and data management systems quickly.
  • Proficient keyboarding and typing skills.

Environmental & Physical Factors

• Works primarily in a warehouse/manufacturing facility with daily contact with other departmental personnel.
• Occasionally works in all weather conditions, extreme temperatures, around chemicals and chemical fumes/emissions, and dusty or clean environments.
• Frequently works with electrical and mechanical hazards.
• May work outside or in an un-air-conditioned warehouse when handling surplus and scrap materials.
• Continuous use of vision, hearing, and speech.
• Frequent sitting, standing, walking, and occasional bending.
• Lifts, carries, pulls, pushes, and reaches for supplies, occasionally lifting up to 50 lbs.
• Climbs stairs and ladders, requires manual dexterity, and repetitive use of keyboard/computer devices, power tools, and machining equipment.
• Wears safety equipment, such as earplugs, goggles, and steel-toed shoes.

Schedule

• 12-hour rotating shifts: 4 days on and 4 days off, including night shifts.
• Schedule may vary depending on plant operational needs, requiring flexibility for long days, evenings, weekends, holidays, and overtime.
• Regular and predictable attendance is an essential function of this position.