The Senior Electrician supports both foundry and machining operations by performing advanced maintenance and repair of electrical, PLC, robotic, CNC, and automation systems. This role emphasizes safe practices, expert troubleshooting, and independent execution of complex technical tasks. The Senior Electrician is expected to apply strong technical knowledge, mentor junior staff, and contribute to efficient and reliable plant operations.
Key Responsibilities
· Work safely with 24VDC, 120VAC, 480VAC, and 13.8kVA systems.
· Use multimeters and other diagnostic equipment.
· Rack the breakers for the plant’s main substation as required.
· Troubleshoot, repair, and maintain electrical components of foundry and machining equipment, including furnaces, conveyors, sand systems, mold-making machines, casting equipment, lathes, drills, mills, CNCs, and robotics.
Installation & Wiring
· Lead installation, wiring, and repairs of motors, drives, sensors, relays, and control systems.
· Install, configure, and maintain Variable Frequency Drives (VFDs).
· Install and troubleshoot soft starts for motor applications.
· Work with 4–20mA analog devices for process control.
· Bend and install rigid conduit for new or modified systems.
· Build and modify electrical panels and control systems as needed.
Troubleshooting & Diagnostics
· Independently troubleshoot and repair electrical, PLC, CNC, and robotic systems to minimize downtime.
· Connect to and navigate PLC programs at the PLC or over the network.
· Perform minor PLC program changes such as toggling bits, forcing inputs/outputs, or adding jumper logic.
· Jog robots and move CNC equipment safely without assistance.
· Review robot programs and follow program movements step-by-step in single-step mode.
· Read, interpret, and update electrical schematics and technical documents.
Maintenance & Safety
· Conduct advanced inspections, identify root causes of issues, and implement corrective actions.
· Perform preventive maintenance tasks and ensure documentation in the Computerized Maintenance Management System (CMMS).
· Ensure compliance with OSHA, NFPA, NEC, and company safety standards, including proper PPE usage.
· Support emergency electrical and automation system repairs to minimize production disruptions.
· Provide guidance and mentoring to Junior Electricians and maintenance staff.
Qualifications & Skills
· High school diploma or equivalent; technical or trade school training in electrical systems required, associate degree preferred.
· Strong knowledge of electrical systems, troubleshooting techniques, and industrial wiring.
· Proficiency with electrical testing equipment, including multimeters and circuit testers.
· Ability to connect to PLCs and make minor program changes.
· Familiarity with CNC and robotic systems, including the ability to jog, move, and review programs.
· Ability to read and understand electrical diagrams, schematics, and technical manuals.
· Strong computer skills for maintenance recordkeeping, PLC connections, and reporting.
· Strong attention to detail and ability to follow safety protocols.
· Team-oriented with strong communication and leadership skills.
· Ability to work in a physically demanding environment, including lifting up to 50 lbs, standing for long periods, and working in hot, dusty, and noisy conditions.
· Flexibility to work different shifts, weekends, and overtime as needed.
Preferred Qualifications
· Extensive experience in industrial electrical maintenance, especially in foundry or machining environments.
· Experience working with electrical systems up to and including 480V three-phase and supervised work with 13.8kVA.
· Knowledge of NFPA 70E electrical safety procedures.
· Proficiency with robotics, CNC, and PLC systems.
· Forklift or aerial lift certification is a plus.
Work Environment
This position requires working in both foundry and machine shop environments with exposure to high temperatures, molten metal, electrical systems, coolant, dust, noise, and heavy machinery. Proper PPE must be worn at all times, including:
· Hard Hat
· Eye Protection
· Ear Protection
· Steel-Toe Boots
· Arc Flash PPE as required
· Insulated Gloves (when working with live electrical components)
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