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Key Responsibilities and Required Skills for Manufacturing Support Technician

💰 $40,000 - $70,000

ManufacturingMaintenanceEngineeringOperations

🎯 Role Definition

The Manufacturing Support Technician provides hands-on mechanical, electrical, and process support to production teams to maximize uptime, product quality, and safety. This role is responsible for diagnosing and repairing production equipment, performing preventive maintenance, supporting installations and changeovers, and driving continuous improvement initiatives. The ideal candidate combines technical troubleshooting skills (mechanical, electrical, PLC), solid use of CMMS, adherence to safety and quality standards (ISO/GMP/OSHA), and strong collaboration with engineering and operations to reduce downtime and improve throughput.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Production Operator promoted to Technician (1–2 years on the line)
  • Maintenance Helper or Facilities Technician
  • Technical school graduate with an Associate's in Industrial Maintenance or Mechatronics

Advancement To:

  • Senior Maintenance Technician or Lead Manufacturing Technician
  • Maintenance Supervisor / Shift Maintenance Lead
  • Reliability Technician / Maintenance Engineer
  • Automation or Controls Technician

Lateral Moves:

  • Process Technician
  • Manufacturing Engineer (after upskilling)
  • Quality Technician

Core Responsibilities

Primary Functions

  • Diagnose, troubleshoot, and repair mechanical, electrical, pneumatic, and hydraulic systems on production lines to minimize production downtime and restore equipment to full operating condition.
  • Perform scheduled preventive and predictive maintenance tasks, including lubrication, alignment, belt and chain replacement, bearing changes, and vibration checks, according to the preventive maintenance plan.
  • Troubleshoot and debug PLC-controlled equipment (Allen‑Bradley, Siemens, etc.), including I/O checks, ladder logic validation, firmware checks, and communication network troubleshooting to resolve automation issues.
  • Respond to production downtime events rapidly, lead root cause analysis with cross-functional teams, implement corrective actions, and document findings to prevent recurrence.
  • Execute machine changeovers and setups, including tool changes, recipe loading, calibration, and verification of process parameters to ensure fast, repeatable line changeovers that meet quality standards.
  • Read and interpret electrical and mechanical schematics, P&IDs, wiring diagrams, and equipment manuals to perform repairs and modifications safely and accurately.
  • Perform instrument calibration and testing of sensors, transducers, temperature controllers, pressure switches, and flow meters to maintain process accuracy and product quality.
  • Maintain and update the Computerized Maintenance Management System (CMMS) — create and close work orders, log downtime, update spare part usage, and record maintenance history for asset reliability tracking.
  • Replace and install mechanical components (motors, gearboxes, couplings, bearings), electrical components (contactors, relays, fuses), and pneumatic/hydraulic components (valves, cylinders, regulators) during repairs and upgrades.
  • Conduct preventive inspections and audits of production equipment and infrastructure, identifying potential failure modes and recommending mitigation measures to Engineering and Operations.
  • Support installation, qualification and commissioning of new equipment and pilot lines, coordinating with vendors, contractors, and quality engineering to ensure on-time ramp-up.
  • Maintain spare parts inventory levels, perform parts identification, procure replacements, and organize parts storage to reduce lead time for critical repairs.
  • Implement and support continuous improvement and lean manufacturing initiatives (5S, Kaizen, SMED) to increase equipment availability, reduce waste, and streamline maintenance processes.
  • Ensure compliance with environmental, health, and safety (EHS) policies — perform lockout/tagout (LOTO), energy isolation, and use PPE; participate in safety investigations and corrective actions.
  • Perform electrical troubleshooting using multimeters, clamp meters, megohmmeters, and oscilloscopes to diagnose short circuits, ground faults, and intermittent electrical issues.
  • Assist in quality investigations by performing in-line checks, supporting non-conformance containment, and implementing corrective and preventive actions related to equipment and process issues.
  • Provide hands-on support during production start-ups and rush orders, prioritizing tasks to ensure customer commitments and minimizing line losses.
  • Execute basic welding, fabrication, and mechanical modifications to fixtures, guards, and machine mounts under Engineering direction to maintain equipment fit and function.
  • Train operators and junior technicians on basic troubleshooting, preventive maintenance tasks, and safe work practices to build site-level capability and reduce reliance on external support.
  • Compile and maintain accurate maintenance documentation, SOPs, repair guides, and maintenance checklists to preserve institutional knowledge and support continuous training.
  • Coordinate with external service providers and OEM vendors for specialized repairs, spare parts ordering, and warranty work; manage vendor schedules to minimize production impact.
  • Support energy and utilities troubleshooting (pumps, compressors, HVAC) that affect production systems and coordinate corrective actions with building maintenance teams.
  • Participate in shift handovers and communication of outstanding maintenance issues, completed repairs, and planned work to ensure continuity of coverage and adherence to production schedules.
  • Apply failure mode and effects analysis (FMEA) and reliability-centered maintenance (RCM) principles to recommend equipment upgrades, critical spare holdings, and redesigns to improve asset reliability.
  • Maintain high standards of housekeeping and 5S in maintenance areas and production support zones to create a safe, efficient work environment.

Secondary Functions

  • Support continuous improvement projects by collecting field data, performing time studies, and participating in cross-functional problem-solving workshops.
  • Assist in site-level audits and regulatory inspections by preparing maintenance records, calibration certificates, and equipment documentation.
  • Create and update preventive maintenance procedures and calibration schedules in collaboration with Reliability or Engineering teams.
  • Provide ad-hoc production support during process trials, product changeovers, or pilot programs to validate equipment performance.
  • Aggregate and deliver maintenance performance metrics (MTTR, MTBF, overall equipment effectiveness) to reliability teams and production leadership.
  • Participate in scheduled training and certification programs (PLCs, hydraulics, electrical safety) to maintain technical currency and site competency.
  • Assist with capital improvement projects including layout changes, machine relocations, and asset tagging to support expansion and capacity increases.
  • Support the implementation of condition monitoring tools (vibration sensors, thermal imaging, oil analysis) and interpret preliminary results to prioritize repairs.
  • Facilitate knowledge transfer and update training materials for succession planning and cross-training initiatives across shifts.
  • Help create cost estimates for repair jobs, spare parts needs, and specialized vendor services as part of annual maintenance budgeting.

Required Skills & Competencies

Hard Skills (Technical)

  • Mechanical troubleshooting and repair of rotating equipment, gearboxes, couplings, bearings, and mechanical drives.
  • Electrical troubleshooting up to 480V, including motor starters, contactors, relays, fuses, and circuit protection.
  • PLC troubleshooting and basic programming/logic interpretation (Allen‑Bradley, Siemens, Mitsubishi).
  • Pneumatics and hydraulics maintenance: valve replacement, cylinder service, pressure and flow tuning.
  • Use and administration of CMMS platforms (IBM Maximo, SAP PM, Fiix, UpKeep) for work order lifecycle management.
  • Instrumentation and process control fundamentals: sensors, transmitters, PID control loops, and calibration techniques.
  • Basic welding, fabrication, mechanical assembly, and use of hand and power tools.
  • Electrical test equipment proficiency: multimeter, clamp meter, insulation tester, oscilloscope, and thermal imaging camera.
  • Safety systems knowledge: lockout/tagout (LOTO), machine guarding, NFPA 79, OSHA regulations, and PPE best practices.
  • Conveyor and material handling systems maintenance, including belt tracking, motor alignment, and roller replacement.
  • Familiarity with robotics and pick-and-place systems (basic troubleshooting and coordination with robot technicians or integrators).
  • Reading and interpreting electrical/mechanical schematics, P&IDs, bills of materials, and technical manuals.
  • Basic PLC-to-HMI troubleshooting, Ethernet/IP, Profibus, Modbus communication awareness, and serial diagnostics.
  • Preventive and predictive maintenance techniques including vibration analysis, thermography, and oil analysis fundamentals.
  • Basic computer skills: Microsoft Office (Excel for logging and simple analysis), email, and the ability to use mobile tablets for CMMS input.

Soft Skills

  • Strong analytical problem-solving and root-cause analysis capability with a methodical, evidence-based approach.
  • Clear verbal and written communication; able to write concise maintenance reports and communicate issues to operators, engineers, and vendors.
  • Collaborative team player who builds productive relationships with production, quality, engineering, and supply chain.
  • Ability to prioritize tasks and manage time during high-pressure downtime events while maintaining safety and quality.
  • Attention to detail when performing calibrations, documenting maintenance actions, and following SOPs.
  • Adaptability and flexibility to support multiple shifts, respond to emergent production needs, and work varied schedules.
  • Continuous improvement mindset—proactive about identifying process improvements and cost-saving opportunities.
  • Customer-service orientation, supporting internal customers (production teams) with timely and respectful service.
  • Ability to train and mentor less-experienced technicians and operators in basic troubleshooting and preventive maintenance.
  • Initiative and ownership—takes responsibility for follow-through on repairs and improvement projects.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED with technical coursework or certification in electrical, mechanical, or industrial trades.

Preferred Education:

  • Associate degree or technical diploma in Industrial Maintenance, Mechatronics, Electrical Technology, or Manufacturing Technology.
  • Certificates in PLCs, electrical safety, hydraulics/pneumatics, or HVAC.

Relevant Fields of Study:

  • Industrial Maintenance
  • Mechatronics / Electro-Mechanical Technology
  • Electrical Technology / Industrial Electronics
  • Mechanical Engineering Technology
  • Automation & Controls

Experience Requirements

Typical Experience Range:

  • 1–5 years of hands-on maintenance or production support experience in a manufacturing environment (preferred minimum 2 years).

Preferred:

  • 3–7+ years of progressive experience supporting production equipment, including demonstrable PLC and electrical troubleshooting experience.
  • Experience with CMMS platforms, preventive maintenance program development, and root cause analysis methodologies.
  • Prior exposure to Lean, 5S, Kaizen, or continuous improvement frameworks is a plus.
  • Certifications such as OSHA-10/30, NFPA 70E electrical safety, forklift operator, or specific PLC training are highly desirable.
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