Key Responsibilities and Required Skills for Electro‑Mechanical Technician

🎯 Role Definition

The Electro‑Mechanical Technician is an essential hands-on role responsible for installing, maintaining, troubleshooting, and optimizing electromechanical systems on industrial equipment, production lines, and field assets. This role blends electrical, mechanical, and automation skills — including PLC/HMI troubleshooting, motor and drive maintenance, pneumatics/hydraulics repair, wiring and schematic interpretation, and test/diagnostic procedures — to ensure equipment reliability, safety, and production uptime. Ideal candidates are methodical, safety-focused, and experienced in preventive and corrective maintenance in manufacturing, automation, or field-service environments.

📈 Career Progression

Typical Career Path

Entry Point From:

Maintenance Technician
Electronics Technician
Mechanical Assembler / Machine Operator

Advancement To:

Senior Electro‑Mechanical Technician / Lead Technician
Automation Technician or Controls Engineer
Maintenance Supervisor or Reliability Engineer
Field Service Engineer or Technical Trainer

Lateral Moves:

Instrumentation Technician
Robotics Technician
Controls/PLC Programmer
Field Service Technician

Core Responsibilities

Primary Functions

Diagnose and repair electrical and mechanical faults on production machinery and automated systems using multimeters, oscilloscopes, thermal cameras and diagnostic software, ensuring rapid restoration of operations with minimal downtime.
Perform preventive maintenance on motors, gearboxes, bearings, conveyors, actuators, belts, couplings, and drive systems according to established schedules and condition-based monitoring data to extend equipment life and reduce unplanned outages.
Troubleshoot and program PLCs (Allen‑Bradley, Siemens, Omron, Mitsubishi, etc.), HSIs/ HMIs, and industrial network devices (Ethernet/IP, Profinet, Modbus) to resolve logic errors, communication faults, and I/O issues that impact production.
Install, wire, and commission new machinery, control panels, sensors, and instrumentation, including reading and implementing electrical and mechanical drawings, schematics, and bill of materials.
Calibrate and verify sensors, encoders, torque transducers, temperature controllers and other measurement devices to ensure accurate process control and product quality.
Perform mechanical alignments, belt and chain adjustments, shaft coupling inspections and precision reassembly of subassemblies following manufacturer tolerances and technical manuals.
Replace and repair servo motors, variable frequency drives (VFDs), stepper motors, and motor controllers; diagnose faults, update firmware, and tune control parameters for optimal performance.
Conduct root cause analysis (RCA) for recurring equipment failures, create corrective action plans, and implement design or process changes with engineering to prevent recurrence.
Fabricate and modify mechanical components and electrical assemblies using hand tools, bench tools, soldering equipment, and machine shop tools to support quick turn repairs and prototype modifications.
Maintain accurate maintenance logs, work orders, calibration records, and spare parts inventories in CMMS (e.g., Maximo, SAP PM, UpKeep) to support auditability and spare parts planning.
Adhere to lockout/tagout (LOTO), confined space, and electrical safety procedures while performing live or energized diagnostics when authorised, and report any safety hazards immediately.
Assist engineering and operations teams during equipment upgrades, installation projects, and production changeovers by providing technical input on mechanical and electrical constraints.
Perform end-of-line testing, functional verification and final acceptance testing of repaired and newly installed equipment to meet quality and safety standards.
Coordinate with outside vendors and OEMs for warranty repairs, specialist troubleshooting, and procurement of long lead components to minimize downtime and ensure repair quality.
Support and participate in continuous improvement (Kaizen) initiatives by identifying opportunities to reduce downtime, improve maintainability, and increase throughput through design-for-maintenance changes.
Implement predictive maintenance technologies such as vibration analysis, thermography and ultrasonic inspection, interpret results, and schedule targeted interventions.
Train junior technicians, operators and maintenance staff on equipment safe operation, basic troubleshooting steps, and first-line preventive maintenance tasks to raise overall team capability.
Respond to emergency maintenance calls and participate in on-call rotation, ensuring timely and effective response to critical production-impacting events.
Test and verify electrical protection devices, fuses, breakers and safety interlocks, and repair or replace defective components to maintain machine and personnel safety.
Maintain and update electrical schematics, mechanical drawings and functional documentation after modifications so that build and repair history is current and accessible.
Support root cause investigations of product defects tied to machine performance and collaborate with quality engineers to implement process or equipment corrections that prevent recurrence.
Participate in project planning, materials estimation, and time studies for mechanical and electrical tasks to support accurate budgeting, scheduling, and resource allocation.

Secondary Functions

Contribute to spare parts optimization and vendor-managed inventory strategies by recommending critical spares and lifecycle replacement plans.
Support process documentation by updating standard operating procedures (SOPs), maintenance checklists and troubleshooting guides for production and maintenance teams.
Assist with small capital projects and equipment upgrades, including scoping, risk assessment, and technical execution under direction of engineering.
Perform periodic housekeeping and 5S activities in mechanical and electrical workshops to maintain a safe, organized and efficient work environment.
Support cross-functional teams during audits, safety inspections and regulatory compliance checks by providing technical records and demonstrating corrective actions.
Participate in competency assessment and skills development programs to maintain certifications and trade competencies relevant to electro‑mechanical systems.
Gather and provide data for continuous improvement metrics—such as MTTR, MTBF, and OEE—to help prioritize maintenance and reliability initiatives.
Provide input into risk assessments and failure mode effects analysis (FMEA) for new equipment or process changes from a maintenance and reliability perspective.

Required Skills & Competencies

Hard Skills (Technical)

Strong troubleshooting of electrical systems including wiring, relays, contactors, and control circuits with the ability to read and interpret single-line diagrams and electrical schematics.
PLC and HMI programming, debugging, and ladder logic experience (e.g., Allen‑Bradley/Rockwell, Siemens TIA Portal, Omron) with ability to modify logic and test I/O.
Experience with VFDs, servo drives, motion control systems, and the ability to configure and tune drive parameters for motors and axis control.
Proficiency in mechanical diagnostics: bearings, couplings, belts, gears, conveyors, precision alignment, and torque specifications.
Pneumatics and hydraulics troubleshooting, including valve replacement, cylinder repair, air/gas line leak detection and pressure regulation.
Use of diagnostic and test equipment: multimeters, clamp meters, insulation testers, oscilloscopes, thermal cameras, vibration analyzers, and loop calibrators.
Experience using Computerized Maintenance Management Systems (CMMS) such as SAP PM, Maximo, UpKeep, or Fiix for work orders, preventive maintenance scheduling, and asset history.
Familiarity with industrial networking and communication protocols: Ethernet/IP, Modbus TCP, Profibus, Profinet, and network diagnostics.
Ability to perform electrical panel wiring, control cabinet assembly, terminal strip wiring, crimping, and soldering to industry standards.
Knowledge of safety standards and compliance: lockout/tagout (LOTO), NFPA 70E, OSHA, machine guarding, and safe electrical work practices.
Calibration and metrology skills for sensors, instruments, and process control devices.
Fabrication and light machining skills: cutting, drilling, tapping, welding (MIG/TIG/basic), and fitting mechanical parts as required.
Experience supporting robotics and automation systems, including safety interlocks, end‑of‑arm tooling, and collaborative/industrial robot interfaces.
Ability to read and modify P&IDs, mechanical drawings, BOMs and technical manuals; strong documentation skills for change control.
Knowledge of lean manufacturing and continuous improvement tools (Kaizen, 5S, root cause analysis, PDCA) to improve equipment reliability.

Soft Skills

Strong problem-solving mindset with attention to detail and ability to prioritize multiple reactive and planned tasks under tight production schedules.
Clear verbal and written communication skills to interact with operations, engineering, vendors, and management, and to document technical work effectively.
Team player with collaborative attitude, able to mentor junior technicians and work cross-functionally to achieve uptime targets.
Time management and organizational skills to manage preventive maintenance schedules, spare parts, and project deadlines.
Adaptability and resilience working in fast-paced manufacturing or field environments with varying shifts and emergency call-outs.
Safety-first attitude and professional accountability for following procedures, reporting hazards, and driving a culture of continuous improvement.
Customer-focused service orientation for field service or production support roles with strong interpersonal skills.
Analytical and data-driven approach to interpreting maintenance metrics and initiating targeted reliability actions.

Education & Experience

Educational Background

Minimum Education:

High school diploma or equivalent with completion of accredited trade school, technical certificate, or apprenticeship in electro‑mechanical, mechatronics, or industrial maintenance.

Preferred Education:

Associate degree or diploma in Electro‑Mechanical Technology, Mechatronics, Industrial Maintenance, Electrical Engineering Technology, or related technical field.
Additional certifications (preferred): PLC certification, VFD/drive training, robotics certification, IPC soldering, OSHA 10/30, NFPA 70E training.

Relevant Fields of Study:

Electro‑Mechanical Technology
Mechatronics
Electrical or Mechanical Engineering Technology
Industrial Maintenance and Automation
Electronics Technology

Experience Requirements

Typical Experience Range: 2–6 years of hands-on electro‑mechanical maintenance and troubleshooting in manufacturing, automation, or field service environments.

Preferred:

4+ years of progressive experience supporting automated production equipment with documented troubleshooting and reliability improvements.
Experience with PLCs and industrial networks, VFDs and motor controls, pneumatics/hydraulics, and CMMS systems.
Previous work in regulated industries (medical device, food & beverage, pharmaceutical, automotive) or with OEM equipment is a plus.
Demonstrated track record of reducing downtime, performing root cause analysis, and implementing corrective actions.