PLC Tech II

Worklane GmbH; Truesdale (MO); On-site; USD 65,000 - 90,000; Full time

Job summary

Refresco is seeking a PLC Technician II to design, program, repair, and maintain PLC systems across our facilities. You will inspect equipment, perform preventative maintenance, and support installations for advanced production equipment.

The role requires diagnosing malfunctions and implementing complex repairs to ensure safe, efficient operations. You will work with production teams to troubleshoot issues, upgrade PLC systems, and train colleagues on basic PLC functions.

Qualifications

• Five+ years of experience in industrial manufacturing maintenance.
• Rockwell Logix Programmer or equivalent certificate is required.
• Experience with Allen Bradley PLCs is required.
• Willingness to undergo a Maintenance Skills Assessment.

Responsibilities

• Troubleshoot equipment failures with production team and resolve issues.
• Maintain, test and upgrade production equipment and interfaces.
• Diagnose and repair PLC and automation faults, including wiring.
• Calibrate and test equipment to ensure performance per specs.
• Lead or assist in PLC system upgrades and safety improvements.

Skills

RSLogix 5000/500/5

HMI programming

Electrical schematics

Allen Bradley PLCs

VFDs & motor control

Education

Rockwell Logix Programmer Certificate

Tools

AutoCAD

AutoCAD Electrical

AutoCAD Plant 3D

Panelbuilder 32

RS View Studio Machine Edition

Job description

Summary Description:

Reporting to the Maintenance Manager, the PLC Technician II is responsible for designing, programming, repairing, and maintaining programmable logic controller (PLC) systems used within Refresco facilities. The PLC Tech II inspects equipment for proper functioning and performs preventative maintenance duties per manufacturer's specifications. May support repairs and installations for other advanced production/manufacturing equipment. The PLC Tech II diagnoses equipment malfunctions and makes more complicated repairs or adjustments as needed.

Essential Job Functions:

• Adhere to all health and safety policies/procedures, Good Manufacturing Practices (GMPs) and wear the required personal protective equipment (PPE) while working.
• Responsible to adhere to food quality and food safety as per quality standards and/or Safe Quality Food requirements.
• Lead and participate in troubleshooting activities during equipment failures, collaborating with the production team to analyze, resolve, and prevent issues through investigation, testing, and follow-up.
• Maintenance, testing and upgrading of all production equipment. Installation and testing of new food manufacturing, packaging and processing equipment. Interface with machine tools and special equipment or test modules, troubleshoot existing equipment for electrical or electronics failures and change or modify machines to improve or update.
• Diagnose and troubleshoot PLC and automation issues, including faulty components and wiring.
• Calibrate and test equipment to ensure accurate performance and compliance with specifications.
• Assist with PLC system upgrades and improvements to optimize production efficiency and safety.
• Modify existing programs for system optimization, new process requirements, or enhanced safety protocols.
• Maintain accurate records of maintenance, repairs, programming changes, and upgrades.
• Train other team members on basic PLC functions and troubleshooting as needed.
• Preventative maintenance and repair when required in addition to planned mechanical maintenance duties.
• Participate in a continuous improvement culture while following safe workplace practices.
• Develop positive and respectful interactions with managers, supervisors, maintenance technicians, and machine operators.
• Identify and suggest process improvements to enhance system reliability and reduce costs.

Required Skills:

• Proficient in using RS Logix 5000, RS Logix 500, and RS Logix 5 software for machine troubleshooting, with the ability to go online with Control Logix, Compact Logix, SLC500, or PLC5 systems via Ethernet I/P, DH+, or RS232, and download PLC programs as needed.
• Must be able to read and understand electrical schematics.
• Must be able to use a multimeter and work in control panels with up to 480VAC.
• Understands symbols on P&ID’s and tag references online layout drawing.
• Able to follow information between controllers and components (MSG, AOP’s…etc.)
• Understands advanced programming concepts such as AOI’s, UDT’s, Arrays…etc.
• Should be able to replace and configure AB Powerflex 40, 400, and 525 VFDs (Variable Frequency Drives) and Yaskawa V1000 and P1000 VFDs.
• Knowledgeable of different PLC tag types/tag references on online layout drawing.
• Able to decipher more complex PLC logic (possibly without descriptive tag names, motor speed control/analog value manipulation, indirect addressing).
• Use RSLogix information to help understand/troubleshoot devices connected to the PLC.
• Understands how to setup different PLC tasks and different ways to write PLC code (FB diagram, STL… etc.
• Understand how an HMI interacts with a controller to update screen information.
• Comfortable uploading and restoring HMI projects from active displays.
• Understand and use of HMI animation tools (visibility, object movement, color change…etc.) and HMI behavior (global variables…etc.).
• Able to create and implement basic HMI programs (project and communication setup).
• Understands object importing, alarm banner setup.
• Comfortable with HMI scripting and indirect addressing.
• Able to open DWG and make simple edits.
• Able to create component blocks with attributes for future use.
• Understand and use different “layers” within an AutoCAD drawing.
• Understanding of other AutoCAD programs (AutoCAD Electrical, AutoCAD Plant 3D…etc)
• Should be able to replace Panelview and download application using Panelbuilder 32.
• Should be able to replace Panelview Plus and download application using RS View Studio Machine Edition.
• Aptitude for further development of technical skills.

Competencies:

• Decisive, pro-active, self-motivated and assertive.
• Strong interpersonal and developed communication skills.
• Data analysis and identification of trends.
• Internal customer focus with the ability to adapt to the variable demands of the business.
• Ability to demonstrate working under initiative and think things through to solution.
• Ability to work under own supervision.
• Ability to influence, persuade and lead at all levels of the business.

Education and Experience:

• Five (5) plus years’ experience in industrial manufacturing maintenance required.
• Rockwell Logix Programmer or equivalent Certificate required.
• Experience with Allen Bradley PLCs required.
• Electrical/electronic troubleshooting and repair skills required.
• Candidates will be required to take a Maintenance Skills Assessment in order to be considered.

Working Conditions:

• Work Schedule: Weekdays, weekends, afternoon, evenings, overnight and holidays may be required. Overtime scheduled as needed.
• Work Environment: Operating in a fast-paced production plant with numerous moving parts. Noise levels require hearing protection and temperatures can get very hot and/or relatively cold. The environment is structured and supervised, with clear production targets and schedules to meet.

Travel Requirements:

• Travel anticipated: Rarely

Physical Requirements:

R = Rarely (0-15%) O = Occasionally (16-45%) F = Frequently (46-100%)

Physical Demand:

• Stand or Sit - X
• Stoop, kneel, crouch, or crawl - X
• Lifting 50 lbs. (minimum lbs. lifted 5 lbs.) - X
• Carry weight, lift - X
• Walking - X
• Driving - X
• Climb (stairs/ladders) or balance - X

Visual/Sensory - Have vision abilities to include proximate vision, color vision and the ability to adjust focus as well as be able to effectively see and process computer generated images on a screen or hand-held device. Will require attention with one or two senses at a time.

Coordination and Dexterity: Excellent hand-eye coordination and manual dexterity for precise control of equipment.

Mental Stress- There is pronounced pressure from deadlines, production quotas, accuracy or similar demands.

Other Duties:

This job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee. Duties, responsibilities, and activities may change, or new ones may be assigned at any time with or without notice.