Maintenance Technician

Location: Chennai

Job Purpose

The Electrical Maintenance Technician is responsible for maintaining, troubleshooting, repairing, and improving electrical systems, production machinery, and plant utilities to ensure safe operation, high equipment availability, and minimum production downtime.

Key Responsibilities

1. Electrical Maintenance

• Perform preventive, predictive, and breakdown maintenance of industrial electrical equipment.
• Troubleshoot electrical faults in production machinery and utility equipment.
• Maintain motors, control panels, MCCs, PCCs, DBs, contactors, relays, breakers, and electrical protection systems.
• Inspect electrical wiring, cables, terminals, earthing, and electrical connections.
• Replace defective electrical components and restore equipment safely.
• Perform routine electrical inspections and identify abnormalities before failures occur.

2. Machine Troubleshooting

• Attend production machine breakdowns and minimize MTTR.
• Troubleshoot motor control circuits, sensors, limit switches, proximity sensors, photoelectric sensors, solenoid valves, and safety interlocks.
• Diagnose electrical problems using multimeters, clamp meters, insulation testers and other electrical testing instruments.
• Identify root causes of repetitive failures and support permanent corrective actions.

3. PLC, VFD & Automation

• Perform basic troubleshooting of PLC-controlled machinery.
• Check PLC inputs/outputs and identify field-device faults.
• Troubleshoot VFDs, soft starters and motor control systems.
• Check machine alarms, electrical signals and interlocks.
• Support automation engineers or machine suppliers during PLC/HMI troubleshooting and modifications.
• Maintain sensors, encoders, temperature controllers, timers and process-control devices.

4. Motors & Electrical Equipment

• Maintain AC motors, brake motors, gear motors, pumps, blowers, fans and related electrical equipment.
• Check motor current, voltage, insulation resistance, terminals and operating condition.
• Perform motor replacement, connection and direction-of-rotation checks.
• Identify overload, phase failure, overheating and abnormal current conditions.

5. Plant Utilities

Support electrical maintenance of:

• Air compressors
• Chillers and cooling systems
• Boilers and associated electrical controls
• Pumps and water systems
• HVAC equipment
• Exhaust and ventilation systems
• DG sets
• UPS systems
• Electrical distribution systems
• Lighting and emergency lighting

6. Preventive Maintenance

• Execute daily, weekly, monthly and annual preventive maintenance schedules.
• Follow machine PM checklists and record findings.
• Check panel condition, terminal tightness, electrical heating, insulation, earthing and component condition.
• Report abnormalities and complete corrective actions.
• Support predictive maintenance activities such as thermography and electrical condition monitoring.

7. Electrical Safety

• Follow electrical safety procedures and company EHS requirements.
• Follow LOTO (Lockout/Tagout) before maintenance activities.
• Verify isolation and absence of voltage before starting electrical work.
• Use appropriate PPE and insulated tools.
• Maintain machine electrical guards, safety switches, emergency stops and interlocks.
• Report unsafe electrical conditions immediately.
• Support electrical safety inspections and corrective actions.

Education: ITI Electrician / Diploma in Electrical or Electrical & Electronics Engineering.

Experience: Typically 2–5 years of industrial electrical maintenance experience in a manufacturing environment.

Technical Skills Required

Candidate should have practical knowledge of:

• Industrial electrical maintenance
• Electrical control circuits
• MCC/PCC/control panels
• AC motors and motor starters
• Star-delta and DOL circuits
• VFD and soft starters
• PLC I/O troubleshooting
• Sensors and limit switches
• Relays, contactors and protection devices
• Electrical drawings and control schematics
• Multimeter and clamp-meter testing
• Insulation resistance testing
• Earthing systems
• Machine safety circuits
• LOTO and electrical safety
• Preventive and breakdown maintenance