Senior Controls Technician

About the role

The Senior Controls Technician provides leadership in preventive maintenance (PM) capability, work order (WO) completion, breakdown elimination, and technical support to deliver the team’s operational targets such as safety, quality, and efficiency. While focused on controls, instrumentation, and electrical systems, this role also supports mechanical WOs and issues as needed. The technician proactively identifies and mitigates risks to safety, food safety, quality, and production, leads root cause problem-solving with Make and Pack Technicians, communicates priorities, and escalates issues across shifts.

Responsibilities

• Develop a deep understanding of site control systems, including PLCs, VFDs, and other controlled equipment.
• Help Reliability Technicians understand site control equipment to improve troubleshooting and eliminate unplanned downtime.
• Act as a resource for problem-solving and root cause analysis on controls-related systems.
• Troubleshoot, repair, and overhaul equipment within close tolerances.
• Calibrate site instrumentation, including temperature, pressure, vacuum, pH, level, and flow devices.
• Document work orders (WO) and preventive maintenance (PM) tasks using SAP PM.
• Communicate daily with machine operators, peers, supervisors, and management.
• Support additional duties as assigned by the Reliability Manager.
• Engage in Total Productive Maintenance (TPM) theory, participate in Pillar Teams, train fellow mechanics/operators in autonomous maintenance (AM), and conduct breakdown analysis.
• Participate in the Mars Supply Excellence program to drive reliability improvements and support autonomous maintenance.
• Adhere to Lock-Out/Tag-Out (LOTO), confined space procedures, and all plant safety, GMP, quality, and food safety standards.
• Maintain and troubleshoot electrical and control systems, including 480V power distribution, instrumentation, motor controls, VFDs, servos, I/O devices, PLCs, HMIs, and control networks.
• Troubleshoot machine breakdowns using control system programs, electrical schematics, PLC/HMI/VFD software, and test equipment.
• Identify and recommend control system improvements; modify PLC logic, HMI programs, and servo controller logic to enhance equipment performance.

Requirements

• High School Diploma or equivalent (required).
• Technical degree/trade certification or 5–10 years of equivalent work experience (required).
• 5+ years of maintenance experience at Mars or similar manufacturing environment (preferred).
• Technical degree in industrial electrical/controls or related field (preferred).
• 5–10 years of experience in a TPM/technical manufacturing environment.
• Demonstrated experience in quality and safety.
• Functional knowledge of HACCP concepts.

Skills

• Working knowledge of electrical, hydraulic, and pneumatic schematics and mechanical drawings.
• Ability to troubleshoot AC/DC electrical components (e.g., motor starters, switches, sensors) using multimeters and amp probes.
• Ability to troubleshoot pneumatic and mechanical drive systems (e.g., sorting systems, palletizing robots).
• Flexible schedule to support production needs; ability to multitask in a fast-paced environment.
• Willingness to develop technical skills in welding, machining, and fabrication.
• Good PLC and instrumentation troubleshooting skills.
• Advanced understanding of AC/DC electrical systems (up to 480V 3-phase), hydraulics, and pneumatics (preferred).
• Technical/trade certification in welding, advanced machining, fabrication, or blueprint interpretation (preferred).

Physical Requirements

• Frequent lifting/carrying (10–50 lbs).
• Frequent pushing/pulling (50–200 lbs).
• Frequent handling, gripping, bending, and stooping.
• Ability to work at elevated heights (ladders/platforms), climb stairs, and lean over equipment.
• Ability to stand/work on feet for extended periods (minimum eight hours per shift).
• Ability to work under stressful conditions (heat, cold, confined spaces) and full mobility to climb stairs/ladders.

Benefits

• Best-in-class learning and development support, including access to Mars University.
• Industry-competitive salary and benefits package, including company bonus.
• Work with over 130,000 diverse and talented associates guided by the Five Principles.
• Join a purpose-driven company striving to build the world we want tomorrow, today.

Pay

The base pay range for this position is USD 43.37 – USD 59.63 per hour, applicable to all US locations listed within the job posting. Base pay may vary depending on job-related knowledge, skills, and experience. The total compensation package includes variable pay, medical and dental benefits, 401k participation, and paid time off.