{"id":3262196,"url":"https://alion.io/job/thorne-maintenance-controls-technician","title":"Maintenance Controls Technician","company":{"id":1769319,"name":"Thorne","domain":"thorne.com","url":"https://alion.io/company/thorne-com","size_band":"501-1000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Pinpoint","truth_index":{"grade":"A","score":100,"open_postings":3,"ghost_share":0,"stale_share":0,"repost_share":0,"time_to_fill_p50_days":12,"computed_at":"2026-10-29T05:49:05Z"}},"role":"Field & Service","role_family":"Field & Service","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Summerville, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":54000,"max_usd":105000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":3574},"experience_years_min":7,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"FMEA","optional":false},{"name":"GMP","optional":false}],"status":"live","first_seen_at":"2026-10-25T06:18:26Z","employer_posted_date":"2026-10-25","last_verified_at":"2026-10-30T01:18:16Z","board_verified":true,"closed_at":null,"days_open":4,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":4},"description":"At Thorne, we work to deliver high-quality, science-backed solutions to empower individuals to take a proactive approach to their well-being. Each day begins with a mission to help others discover and achieve their best health. We count on our team members to challenge and push the boundaries to make that happen. At Thorne, you’ll be joining a team of more than 750 passionate individuals committed to our cause of providing superior health solutions at every age and life stage.\n\nThe Maintenance Controls Technician serves as a senior technical resource within Thorne’s Maintenance Department, specializing in industrial controls, automation, electrical systems, and advanced equipment troubleshooting. This role provides hands-on technical expertise to resolve complex equipment issues, improve system reliability, reduce manufacturing downtime, and support the continued development of Thorne’s automated manufacturing operations.\n\nWorking closely with Maintenance Technicians, Maintenance Tech Leads, Maintenance Supervisors, Engineering, and other cross-functional partners, the Maintenance Controls Technician leads advanced troubleshooting efforts, supports controls-related projects, and provides technical guidance to strengthen the maintenance team's capabilities.\nThis position plays a key role in maintaining and improving programmable logic controllers (PLCs), human-machine interfaces (HMIs), variable-frequency drives (VFDs), servo systems, industrial networks, instrumentation, machine safety systems, and other automated manufacturing technologies.\nThe ideal candidate is a highly experienced industrial controls and automation professional with exceptional electrical troubleshooting skills, strong technical judgment, and the ability to independently diagnose complex equipment failures. This individual combines hands-on technical expertise with a proactive approach to equipment reliability, continuous improvement, and developing the technical capabilities of others.\nThis is a senior technical individual contributor position. While the Maintenance Controls Technician provides technical direction and mentorship, responsibility for daily work assignments, shift management, attendance, performance management, and disciplinary matters remains with the Maintenance Supervisor.\nWork Schedule\nThis position follows a rotating 2-2-3 overnight schedule, working 12-hour shifts from 5:00 p.m. to 5:30 a.m. The schedule alternates between two days on, two days off, and three days on, followed by two days off, two days on, and three days off. This rotation provides every other weekend off.\nEmployees must be available to work their assigned schedule and provide additional support for critical equipment failures, planned shutdowns, startups, and projects as business needs require.\nRESPONSIBILITIES\nControls & Automation\nServe as the primary Maintenance Department technical resource for PLCs, HMIs, VFDs, servo systems, motion controls, industrial networks, sensors, instrumentation, machine safety systems, and automated manufacturing equipment.\nProvide advanced technical support to Maintenance Technicians, Maintenance Tech Leads, and Maintenance Supervisors.\nReview PLC and HMI programs, machine sequences, alarms, interlocks, inputs, outputs, and safety circuits to identify equipment failure root causes.\nConnect to, monitor, and troubleshoot PLC, HMI, VFD, servo, and other control systems using approved software and procedures.\nPerform approved programming and parameter changes in accordance with Thorne's change control, Quality, Validation, IT, and documentation requirements.\nMaintain current and secure backups of PLC, HMI, VFD, servo, robotics, vision system, and other critical equipment programs and parameters.\nSupport the configuration, installation, replacement, and commissioning of controls components, including PLC processors, I/O modules, HMIs, VFDs, sensors, encoders, servomotors, power supplies, safety relays, and communication devices.\nTroubleshoot industrial communication networks and protocols used throughout Thorne's manufacturing operations.\nDevelop and maintain controls standards for hardware, software, programming, naming conventions, backups, system access, spare parts, and technical documentation.\nIdentify obsolete controls hardware and software and recommend appropriate upgrades or migration strategies.\nAdvanced Troubleshooting & Equipment Reliability\nLead advanced troubleshooting efforts during significant, complex, or recurring equipment downtime.\nApply systematic troubleshooting methodologies using equipment symptoms, alarms, machine sequences, electrical drawings, program logic, historical work orders, and previous corrective actions.\nIdentify technical root causes rather than relying on repeated component replacement or temporary corrective measures.\nPartner with Maintenance leadership to determine when Engineering, IT, equipment manufacturers, system integrators, or other external resources should be engaged.\nProvide assigned after-hours or on-call technical support for critical equipment failures, shutdowns, startups, and projects.\nEnsure equipment is returned to service safely and in accordance with applicable Quality, Validation, Production, and cGMP requirements.\nCommunicate significant equipment failures, controls risks, safety concerns, and extended downtime promptly to Maintenance leadership.\nMaintain accurate troubleshooting, repair, modification, and preventive maintenance records within eMaint.\nSupport effective shift transitions by documenting equipment conditions, troubleshooting completed, corrective actions, and outstanding follow-up requirements.\nTechnical Leadership & Team Development\nServe as a technical mentor and resource for Maintenance Technicians, Maintenance Tech Leads, and Maintenance Supervisors.\nProvide technical direction during controls-related troubleshooting and repair activities.\nHelp develop the team's capabilities in electrical troubleshooting, controls systems, equipment operation, root cause analysis, and safe diagnostic practices.\nSupport Maintenance Supervisors in evaluating repair complexity, technical requirements, safety risks, resources, and estimated repair durations.\nAssist Maintenance leadership in assessing technician controls and electrical troubleshooting capabilities and recommending development opportunities.\nPromote consistent troubleshooting, repair, and documentation standards across maintenance shifts.\nShare technical lessons learned and best practices to improve team effectiveness.\nProvide recommendations to the Maintenance Manager regarding equipment risks, controls obsolescence, critical spare parts, and improvement priorities.\nReliability & Continuous Improvement\nLead or support root cause analysis for major and recurring equipment failures.\nDevelop lessons learned and apply structured problem-solving methodologies, including 5 Whys, to identify and address recurring equipment issues.\nAnalyze downtime data, CMMS history, PLC information, alarms, equipment trends, and technician observations to identify improvement opportunities.\nSupport reliability initiatives, equipment criticality assessments, failure mode analysis, and preventive maintenance optimization.\nPartner with Production, Engineering, Quality, Validation, IT, EHS, and other stakeholders on equipment reliability and continuous improvement initiatives.\nImprove controls-related preventive and predictive maintenance activities to strengthen equipment safety, reliability, maintainability, availability, and operational performance.\nSupport improvements in preventive maintenance completion, mean time between failures (MTBF), mean time to repair (MTTR), equipment availability, and planned and unplanned downtime.\nPreventive Maintenance & Technical Documentation\nReview and verify preventive maintenance procedures for electrical, instrumentation, and controls systems.\nCreate and maintain troubleshooting guides, technical work instructions, inspection checklists, standard equipment settings, and controls documentation.\nMaintain accurate electrical drawings, control panel drawings, I/O lists, network diagrams, manuals, program backups, and related technical records.\nDocument work performed, time spent, materials used, failure symptoms, troubleshooting steps, root causes, corrective actions, equipment settings, and follow-up recommendations.\nPartner with Maintenance Supervisors and storeroom personnel to maintain appropriate controls-related spare parts inventory.\nEvaluate spare parts requirements based on equipment criticality, failure history, obsolescence, cost, and lead time.\nEquipment Projects & Commissioning\nSupport new equipment installations, controls upgrades, system integrations, equipment relocations, and capital projects.\nParticipate in project design reviews and provide technical recommendations regarding controls standards, component selection, maintainability, equipment access, safety, documentation, and spare parts.\nParticipate in Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), commissioning, startup, qualification, and performance verification as required.\nReview vendor controls designs and verify receipt of required programs, backups, passwords, software licenses, electrical drawings, manuals, parameter lists, and technical documentation.\nMaintain required programming software, communication cables, test equipment, licenses, and controls troubleshooting tools.\nVerify that controls modifications are appropriately reviewed, risk-assessed, tested, approved, backed up, and documented before implementation.\nProvide technical support during planned shutdowns and equipment improvement projects.\nSafety, Quality & Compliance\nPerform all work in accordance with Thorne's safety policies, Lockout/Tagout procedures, electrical safety requirements, and applicable OSHA and NFPA 70E standards.\nEnsure machine safety circuits, guards, emergency stops, safety interlocks, and protective devices remain operational and are not bypassed without an approved, documented process.\nIdentify and promptly report safety incidents, near misses, unsafe conditions, and equipment hazards.\nFollow applicable SOPs, cGMP requirements, change control procedures, and documentation standards when working in production and controlled environments.\nEnsure contractors performing controls or electrical work comply with applicable safety, Quality, documentation, and technical requirements.\nMaintain controls work areas, maintenance tools, programming equipment, and control panels in accordance with cleanliness and 5S standards.\nSupport continuous improvement in workplace safety, environmental practices, equipment reliability, operational processes, and waste reduction.\nWHAT YOU NEED\nEducation & Experience\nAssociate degree or technical diploma in Industrial Automation, Electrical Technology, Mechatronics, Instrumentation, or a related discipline, or an equivalent combination of education and relevant experience.\n7+ years of industrial maintenance experience, including at least 5 years of advanced controls and automation troubleshooting within a manufacturing environment\nDemonstrated experience troubleshooting PLCs, HMIs, VFDs, control power, instrumentation, industrial networks, and machine electrical systems to root cause.\nExperience reading and interpreting electrical schematics, ladder logic, P&IDs, sequence-of-operations documentation, and technical manuals.\nExperience using a Computerized Maintenance Management System (CMMS) and maintaining accurate electronic technical records.\nPrevious experience within cGMP nutraceutical, pharmaceutical, biotechnology, or food manufacturing preferred.\nExperience with reliability methodologies, Failure Mode and Effects Analysis (FMEA), Root Cause Analysis (RCA), and Total Productive Maintenance (TPM) preferred.\nExperience with high-speed encapsulation equipment is a plus.\nTechnical Knowledge\nAdvanced knowledge of industrial automation, electrical...","description_format":"text","description_chars":17033,"description_truncated":true,"requirements":{"experience_years_min":7,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"associate","optional":false},"security_clearance":false,"languages":[]},"benefits":["401k plan","Growth opportunities","Gym membership","Insurance coverage","Life insurance","Professional development","Vision 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