Torchora
Back to Home

Key Responsibilities and Required Skills for Industrial Maintenance Electrician

💰 $ - $

MaintenanceElectricalEngineeringSkilled TradesIndustrial

🎯 Role Definition

An Industrial Maintenance Electrician is responsible for maintaining, troubleshooting, repairing, and upgrading electrical and electromechanical systems in manufacturing and industrial facilities. This role combines hands-on electrical work—such as wiring, motor and control repairs, VFD and PLC troubleshooting—with safety compliance, documentation, and collaboration with operations and engineering teams to ensure maximum equipment uptime and continuous improvement of maintenance processes.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Electrical Apprentice or Journeyman Electrician who has industrial exposure.
  • Maintenance Technician or Millwright transitioning to electrical focus.
  • Technical school graduate in industrial maintenance or electromechanical technology.

Advancement To:

  • Lead Maintenance Electrician or Senior Maintenance Technician.
  • Maintenance Supervisor / Shift Maintenance Manager.
  • Reliability Engineer or Controls Engineer.
  • Maintenance Manager or Facilities Manager.

Lateral Moves:

  • Instrumentation & Controls Technician.
  • Automation / PLC Programmer.
  • Field Service Electrician for equipment vendors.

Core Responsibilities

Primary Functions

  • Perform complex electrical troubleshooting on production equipment, identifying root causes and implementing corrective actions to restore systems to full operational status with minimal production downtime.
  • Execute scheduled and unscheduled preventive maintenance on motors, starters, variable frequency drives (VFDs), motor control centers (MCCs), transformers, and distribution panels to reduce failures and extend asset life.
  • Diagnose, program, and troubleshoot PLCs and HMIs (Allen‑Bradley, Siemens, Schneider, etc.), including ladder logic review, I/O checks, and communication network verification to ensure reliable control system operation.
  • Install, wire, and commission new electrical equipment and control panels, following electrical schematics, manufacturer instructions, and company standards while coordinating with engineering and production teams.
  • Perform conduit bending, cable pulling, terminations, splicing, and panel wiring in compliance with the National Electrical Code (NEC) and company electrical standards to maintain safe and code-compliant installations.
  • Conduct lockout/tagout (LOTO) procedures, arc flash hazard assessments, and work within established electrical safety policies and PPE requirements to protect personnel and equipment.
  • Carry out predictive maintenance techniques such as vibration analysis, infrared thermography, ultrasonics, and motor current analysis to detect anomalies early and schedule proactive interventions.
  • Repair and maintain pneumatic and hydraulic systems associated with electrical controls, including solenoid valves, sensors, actuators, pumps, and filtration components to ensure integrated system reliability.
  • Troubleshoot control circuits, timing issues, sensors, proximity switches, and feedback devices, using multimeters, oscilloscopes, and process analyzers to verify signal integrity and system performance.
  • Replace, align, and balance rotating equipment such as motors, gearboxes, conveyors, and pumps, coordinating downtime windows to minimize impact on production operations.
  • Manage spare parts inventory for critical electrical components, recommend stocking levels, and place part orders to support rapid turnaround during repairs and planned outages.
  • Maintain accurate maintenance records and job documentation in the facility CMMS (e.g., Maximo, SAP, Infor) including work orders, failure codes, root cause analysis, and parts used to improve asset history and reporting.
  • Support mechanical repair activities that interface with electrical systems, including coupling replacements, bearing changes, and basic welding or fabrication to resolve complex failures quickly.
  • Participate in plant shutdowns, turnarounds, and capital project installations by performing pre-shutdown preparation, prioritizing tasks, and executing high-complexity electrical work under tight schedules.
  • Perform electrical system upgrades and retrofits—such as VFD installations, PLC migrations, and energy efficiency improvements—by collaborating with engineering teams and validating post-installation performance.
  • Respond to emergency breakdowns and after-hours troubleshooting calls, providing technical mentorship to junior technicians and coordinating external contractors when specialist skills are required.
  • Test and calibrate industrial instrumentation and sensors—pressure, temperature, flow, and level—to ensure accurate process control and product quality as part of routine maintenance or troubleshooting events.
  • Ensure compliance with environmental, health, and safety (EHS) regulations, participate in safety audits, and contribute to the development of safe work procedures and continuous safety improvements.
  • Train production operators and maintenance apprentices on basic electrical safety, lockout/tagout procedures, and equipment troubleshooting techniques to reduce recurring issues and promote first-line problem solving.
  • Analyze recurring failures and implement reliability-centered maintenance solutions—such as root cause corrective actions, component redesigns, or lubrication changes—to improve mean time between failures (MTBF).
  • Coordinate with vendors and OEMs for warranty repairs, equipment overhauls, and technical support, negotiating service agreements and ensuring timely resolution of complex equipment problems.
  • Review electrical drawings, schematics, and P&IDs to plan work activities, identify interlocks, and understand system interdependencies before performing any invasive maintenance.
  • Maintain a clean, organized maintenance area and ensure tools, test equipment, and safety gear are calibrated, stored, and managed in accordance with company policies.
  • Participate in continuous improvement initiatives (5S, Kaizen, TPM) and provide input on maintenance best practices, spare parts rationalization, and cost-saving opportunities to improve overall facility performance.

Secondary Functions

  • Assist in developing and updating standard operating procedures (SOPs), maintenance checklists, and electrical troubleshooting guides for consistent team execution.
  • Support reliability and continuous improvement teams by providing hands-on data for failure analysis, recommending corrective actions, and participating in root cause workshops.
  • Help coordinate contractor activities on site, review contractor work scopes for electrical safety, and verify contractor work complies with company and regulatory standards.
  • Contribute to training programs by creating practical exercises, shadowing plans, and competency matrices for maintenance apprentices and cross-trained electricians.
  • Participate in spare parts lifecycle reviews and help implement inventory optimization strategies to balance availability and carrying costs.
  • Provide input during capital projects on constructability and maintainability issues, ensuring new equipment design supports safe and efficient future maintenance.
  • Support environmental and quality teams during investigations related to equipment-driven process deviations, supplying technical evidence and repair histories as needed.

Required Skills & Competencies

Hard Skills (Technical)

  • Advanced electrical troubleshooting and diagnostics for industrial production equipment, including motor control circuits, starters, relays, and distribution systems.
  • PLC/HMI programming and troubleshooting experience (Allen‑Bradley/Rockwell, Siemens S7, Mitsubishi, or similar), including ladder logic analysis and communication network diagnostics.
  • Installation, commissioning, and troubleshooting of Variable Frequency Drives (VFDs) and adjustable speed drives, including parameter tuning and motor protection settings.
  • Strong understanding of AC/DC theory, three-phase power systems, transformers, grounding, and electrical distribution systems in an industrial environment.
  • Proficiency reading and interpreting electrical schematics, wiring diagrams, P&IDs, and control logic diagrams to plan and execute work safely and effectively.
  • Hands-on experience with pneumatic and hydraulic systems troubleshooting and repair as they relate to automated equipment.
  • Experience using CMMS systems (e.g., IBM Maximo, SAP PM, Infor EAM) to create, track, and close work orders and to log maintenance history.
  • Predictive maintenance skills: infrared thermography, vibration analysis, motor testing, and condition monitoring equipment to prioritize interventions.
  • Familiarity with electrical code and regulatory compliance (NEC, NFPA 70E) and practical application of lockout/tagout, arc flash, and confined space procedures.
  • Skilled use of industrial test equipment: multimeter, clamp meter, oscilloscope, insulation tester (Megger), motor testers, and thermal cameras.
  • Basic welding, mechanical alignment, and fabrication skills to support integrated electrical-mechanical repairs during downtime.
  • Experience with instrumentation calibration and control devices (PID loops, sensors, transmitters) to maintain process control integrity.
  • Ability to program or interpret basic ladder logic changes for routine control modifications and small-scale automation updates.

Soft Skills

  • Strong analytical problem-solving and root cause analysis abilities, with a methodical approach to diagnosing intermittent or complex failures.
  • Clear verbal and written communication skills to interact effectively with operations, engineering, contractors, and management.
  • Teamwork and collaboration mindset, able to work cross-functionally and mentor junior technicians while prioritizing plant safety and production needs.
  • Excellent time management and organizational skills to balance reactive repairs, preventive tasks, and project work under competing deadlines.
  • Attention to detail and documentation discipline to ensure accurate CMMS entries, safety records, and compliance documentation.
  • Adaptability and continuous learning attitude to stay current with evolving electrical and automation technologies.
  • Safety-first mindset with strong commitment to following EHS policies and promoting a culture of workplace safety.

Education & Experience

Educational Background

Minimum Education:

  • High School Diploma or GED with completion of an electrical apprenticeship or equivalent hands-on industrial electrical experience.

Preferred Education:

  • Associate degree or technical diploma in Electrical Technology, Industrial Maintenance, Electromechanical Technology, or related field.
  • Journeyman Electrician license or equivalent trade certification preferred.

Relevant Fields of Study:

  • Electrical Technology
  • Industrial Maintenance / Mechatronics
  • Electromechanical Technology
  • Instrumentation & Control

Experience Requirements

Typical Experience Range:

  • 3 to 7 years of progressively responsible industrial electrical maintenance experience in manufacturing, food & beverage, chemical, pharmaceutical, or heavy industry settings.

Preferred:

  • 5+ years of industrial maintenance electrician experience with strong PLC, VFD, and motor control exposure, plus documented experience using a CMMS and performing predictive maintenance techniques.
Explore More Careers