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 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.

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.
  • Demonstrated ability to use precision electrical test equipment and hand tools.
• Operational Support
  • Commitment to a continuous shift rotation (including nights, weekends, and holidays).
  • Available 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.
  • Prior experience in the aluminum packaging or beverage industry.
  • Familiarity with Lean Manufacturing or Six Sigma principles.
  • Experience using precision measurement tools (calipers, micrometers).
• General Skills
  • Understanding of manufacturing processes, engineering, scientific, and technical information.
  • Experience with data collection and analysis in a high-volume automated manufacturing environment.
  • Ability to interpret technical manuals, 2D drawings, P&IDs, fluid and electrical schematics, and other engineering documentation.
  • Proven understanding of BOMs, manufacturability, process design, process validation, assembly methods, design reviews, and cost reduction methodologies.
  • Strong organizational skills and ability to maintain accurate, detailed records for periodic audits.
  • Excellent communication, negotiation, and training skills for relaying data verbally and in writing.
  • Ability to work on multiple projects with tight deadlines and take ownership with minimal direction.
  • Excellent analytical, problem-solving, and decision-making skills with high integrity.
• 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, dusty and clean environments.
• Frequently works with electrical and mechanical hazards.
• May work outside or in un-air-conditioned warehouses 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, ladders, and uses manual dexterity for repetitive tasks involving keyboards, computers, power tools, and machining equipment.
• Wears safety equipment, such as earplugs, goggles, and steel-toed shoes.

Schedule

This position requires 12-hour rotating shifts on a 4-days-on, 4-days-off schedule, including night shifts, weekends, holidays, and overtime as needed. Flexibility is required to meet plant operational demands, and regular, predictable attendance is essential.