Maintenance Controls Technician

Controls & Automation

• Serve as the primary Maintenance Department technical resource for PLCs, HMIs, VFDs, servo systems, motion controls, industrial networks, sensors, instrumentation, machine safety systems, and automated manufacturing equipment.
• Provide advanced technical support to Maintenance Technicians, Maintenance Tech Leads, and Maintenance Supervisors.
• Review PLC and HMI programs, machine sequences, alarms, interlocks, inputs, outputs, and safety circuits to identify equipment failure root causes.
• Connect to, monitor, and troubleshoot PLC, HMI, VFD, servo, and other control systems using approved software and procedures.
• Perform approved programming and parameter changes in accordance with Thorne's change control, Quality, Validation, IT, and documentation requirements.
• Maintain current and secure backups of PLC, HMI, VFD, servo, robotics, vision system, and other critical equipment programs and parameters.
• Support the configuration, installation, replacement, and commissioning of controls components, including PLC processors, I/O modules, HMIs, VFDs, sensors, encoders, servomotors, power supplies, safety relays, and communication devices.
• Troubleshoot industrial communication networks and protocols used throughout Thorne's manufacturing operations.
• Develop and maintain controls standards for hardware, software, programming, naming conventions, backups, system access, spare parts, and technical documentation.
• Identify obsolete controls hardware and software and recommend appropriate upgrades or migration strategies.
  
  

Advanced Troubleshooting & Equipment Reliability

• Lead advanced troubleshooting efforts during significant, complex, or recurring equipment downtime.
• Apply systematic troubleshooting methodologies using equipment symptoms, alarms, machine sequences, electrical drawings, program logic, historical work orders, and previous corrective actions.
• Identify technical root causes rather than relying on repeated component replacement or temporary corrective measures.
• Partner with Maintenance leadership to determine when Engineering, IT, equipment manufacturers, system integrators, or other external resources should be engaged.
• Provide assigned after-hours or on-call technical support for critical equipment failures, shutdowns, startups, and projects.
• Ensure equipment is returned to service safely and in accordance with applicable Quality, Validation, Production, and cGMP requirements.
• Communicate significant equipment failures, controls risks, safety concerns, and extended downtime promptly to Maintenance leadership.
• Maintain accurate troubleshooting, repair, modification, and preventive maintenance records within eMaint.
• Support effective shift transitions by documenting equipment conditions, troubleshooting completed, corrective actions, and outstanding follow-up requirements.
  
  

Technical Leadership & Team Development

• Serve as a technical mentor and resource for Maintenance Technicians, Maintenance Tech Leads, and Maintenance Supervisors.
• Provide technical direction during controls-related troubleshooting and repair activities.
• Help develop the team's capabilities in electrical troubleshooting, controls systems, equipment operation, root cause analysis, and safe diagnostic practices.
• Support Maintenance Supervisors in evaluating repair complexity, technical requirements, safety risks, resources, and estimated repair durations.
• Assist Maintenance leadership in assessing technician controls and electrical troubleshooting capabilities and recommending development opportunities.
• Promote consistent troubleshooting, repair, and documentation standards across maintenance shifts.
• Share technical lessons learned and best practices to improve team effectiveness.
• Provide recommendations to the Maintenance Manager regarding equipment risks, controls obsolescence, critical spare parts, and improvement priorities.
  
  

Reliability & Continuous Improvement

• Lead or support root cause analysis for major and recurring equipment failures.
• Develop lessons learned and apply structured problem-solving methodologies, including 5 Whys, to identify and address recurring equipment issues.
• Analyze downtime data, CMMS history, PLC information, alarms, equipment trends, and technician observations to identify improvement opportunities.
• Support reliability initiatives, equipment criticality assessments, failure mode analysis, and preventive maintenance optimization.
• Partner with Production, Engineering, Quality, Validation, IT, EHS, and other stakeholders on equipment reliability and continuous improvement initiatives.
• Improve controls-related preventive and predictive maintenance activities to strengthen equipment safety, reliability, maintainability, availability, and operational performance.
• Support improvements in preventive maintenance completion, mean time between failures (MTBF), mean time to repair (MTTR), equipment availability, and planned and unplanned downtime.
  
  

Preventive Maintenance & Technical Documentation

• Review and verify preventive maintenance procedures for electrical, instrumentation, and controls systems.
• Create and maintain troubleshooting guides, technical work instructions, inspection checklists, standard equipment settings, and controls documentation.
• Maintain accurate electrical drawings, control panel drawings, I/O lists, network diagrams, manuals, program backups, and related technical records.
• Document work performed, time spent, materials used, failure symptoms, troubleshooting steps, root causes, corrective actions, equipment settings, and follow-up recommendations.
• Partner with Maintenance Supervisors and storeroom personnel to maintain appropriate controls-related spare parts inventory.
• Evaluate spare parts requirements based on equipment criticality, failure history, obsolescence, cost, and lead time.
  
  

Equipment Projects & Commissioning

• Support new equipment installations, controls upgrades, system integrations, equipment relocations, and capital projects.
• Participate in project design reviews and provide technical recommendations regarding controls standards, component selection, maintainability, equipment access, safety, documentation, and spare parts.
• Participate in Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), commissioning, startup, qualification, and performance verification as required.
• Review vendor controls designs and verify receipt of required programs, backups, passwords, software licenses, electrical drawings, manuals, parameter lists, and technical documentation.
• Maintain required programming software, communication cables, test equipment, licenses, and controls troubleshooting tools.
• Verify that controls modifications are appropriately reviewed, risk-assessed, tested, approved, backed up, and documented before implementation.
• Provide technical support during planned shutdowns and equipment improvement projects.
  
  

Safety, Quality & Compliance

• Perform all work in accordance with Thorne's safety policies, Lockout/Tagout procedures, electrical safety requirements, and applicable OSHA and NFPA 70E standards.
• Ensure machine safety circuits, guards, emergency stops, safety interlocks, and protective devices remain operational and are not bypassed without an approved, documented process.
• Identify and promptly report safety incidents, near misses, unsafe conditions, and equipment hazards.
• Follow applicable SOPs, cGMP requirements, change control procedures, and documentation standards when working in production and controlled environments.
• Ensure contractors performing controls or electrical work comply with applicable safety, Quality, documentation, and technical requirements.
• Maintain controls work areas, maintenance tools, programming equipment, and control panels in accordance with cleanliness and 5S standards.
• Support continuous improvement in workplace safety, environmental practices, equipment reliability, operational processes, and waste reduction.

Education & Experience

• Associate degree or technical diploma in Industrial Automation, Electrical Technology, Mechatronics, Instrumentation, or a related discipline, or an equivalent combination of education and relevant experience.
• 7+ years of industrial maintenance experience, including at least 5 years of advanced controls and automation troubleshooting within a manufacturing environment
• Demonstrated experience troubleshooting PLCs, HMIs, VFDs, control power, instrumentation, industrial networks, and machine electrical systems to root cause.
• Experience reading and interpreting electrical schematics, ladder logic, P&IDs, sequence-of-operations documentation, and technical manuals.
• Experience using a Computerized Maintenance Management System (CMMS) and maintaining accurate electronic technical records.
• Previous experience within cGMP nutraceutical, pharmaceutical, biotechnology, or food manufacturing preferred.
• Experience with reliability methodologies, Failure Mode and Effects Analysis (FMEA), Root Cause Analysis (RCA), and Total Productive Maintenance (TPM) preferred.
• Experience with high-speed encapsulation equipment is a plus.
  
  

Technical Knowledge

• Advanced knowledge of industrial automation, electrical controls, and automated manufacturing equipment.
• Strong troubleshooting expertise across PLCs, HMIs, VFDs, servo systems, motion controls, industrial networks, instrumentation, and machine safety systems.
• Ability to interpret and troubleshoot PLC ladder logic, equipment sequences, alarms, interlocks, I/O signals, and electrical control circuits.
• Knowledge of controls hardware installation, configuration, replacement, commissioning, and approved programming modifications.
• Understanding of industrial communication networks and protocols.
• Ability to read and interpret electrical schematics, P&IDs, control panel drawings, network diagrams, and technical manuals.
• Knowledge of controls software backups, version management, equipment parameters, and technical documentation practices.
• Understanding of preventive and predictive maintenance principles, equipment reliability, and structured troubleshooting methodologies.
• Working knowledge of electrical safety requirements, Lockout/Tagout, OSHA, NFPA 70E, and machine safety systems.
• Understanding of cGMP, change control, equipment qualification, and validation requirements within regulated manufacturing.
• Proficiency with CMMS systems, including accurate documentation of maintenance activities, equipment history, and corrective actions.
• Ability to use programming software, diagnostic equipment, test instruments, and technical tools required for industrial controls troubleshooting.
  
  

Core Competencies

• Advanced Technical Expertise: Demonstrates deep knowledge of industrial controls, automation, and electrical troubleshooting.
• Root Cause Problem Solving: Uses systematic diagnostic methods to identify and resolve complex equipment failures.
• Technical Leadership: Provides guidance, mentorship, and technical support to maintenance teams without direct supervisory authority.
• Equipment Reliability: Proactively identifies opportunities to reduce downtime, prevent recurring failures, and improve equipment performance.
• Safety & Compliance: Maintains high standards for electrical safety, machine protection, cGMP compliance, and controlled equipment modifications.
• Analytical Thinking: Interprets complex equipment data, program logic, alarms, trends, and technical documentation to make informed decisions.
• Communication: Clearly communicates technical findings, equipment risks, corrective actions, and recommendations to technicians, supervisors, and cross-functional partners.
• Collaboration: Builds effective working relationships across Maintenance, Engineering, Production, Quality, Validation, IT, and external technical partners.
• Accountability: Takes ownership of technical troubleshooting and follows complex issues through to sustainable resolution.
• Judgment & Escalation: Recognizes significant equipment, controls, safety, or operational risks and escalates concerns appropriately.
• Organization & Documentation: Maintains accurate technical records, equipment documentation, program backups, and troubleshooting information.
• Continuous Improvement: Identifies opportunities to strengthen equipment reliability, maintenance processes, technical standards, and team capabilities.
• Adaptability: Effectively responds to changing manufacturing priorities, critical equipment failures, and evolving automation technologies.
• Initiative: Works independently with minimal direction while maintaining strong communication and alignment with Maintenance leadership.
  
  

Physical Demands

• Ability to remain stationary and move throughout manufacturing, maintenance, warehouse, and administrative environments as required.
• Ability to safely access and inspect manufacturing equipment, electrical panels, controls systems, and related machinery.
• Ability to operate diagnostic equipment, programming tools, and other technical equipment required for assigned responsibilities.
• Ability to communicate effectively with employees, supervisors, contractors, and cross-functional stakeholders.
• Ability to read and interpret detailed electrical schematics, technical manuals, equipment documentation, and electronic displays.
• Ability to work in manufacturing environments with moderate noise levels.
• Ability to work the assigned 12-hour overnight rotating 2-2-3 schedule, from 5:00 p.m. to 5:30 a.m., and provide additional technical support as business needs require.