Senior Maintenance Technician

PURPOSE

The Senior Maintenance Technician is responsible for the daily activities required to ensure the safe and efficient operation of production equipment at the Mahwah manufacturing plant by diagnosing complex equipment faults, carrying out advanced repairs, and documenting work performed, all while maintaining compliance with SOP, FDA, and ISO standards. The Senior Maintenance Technician serves as a technical resource for the maintenance team and plays a key role in minimizing downtime, improving equipment reliability, and supporting manufacturing continuity.

ACCOUNTABILITIES

• Perform precise geometry adjustments and calibration activities on 5-axis CNC machines to maintain production accuracy and equipment performance.
• Diagnose and resolve complex mechanical, hydraulic, pneumatic, electrical, and controls-related equipment malfunctions.
• Serve as the primary technical resource for difficult troubleshooting activities and recurring equipment failures.
• Conduct repairs of machinery components, control systems, and hydraulic or pneumatic equipment to restore equipment functionality and minimize downtime.
• Respond to emergency maintenance needs during manufacturing operations and lead technical problem resolution efforts.
• Lead equipment validation, testing, commissioning, and startup activities in compliance with SOP, FDA, and ISO requirements.
• Evaluate equipment performance trends and implement preventive maintenance and reliability improvement strategies to reduce downtime and improve asset performance.
• Identify root causes of recurring equipment issues and recommend long-term corrective actions.
• Accurately document maintenance activities, equipment failures, investigations, and performance variances within maintenance management systems.
• Support equipment modifications, upgrades, and continuous improvement initiatives to enhance manufacturing efficiency and reliability.
• Serve as an informal technical resource for maintenance technicians, providing guidance, troubleshooting assistance, and sharing best practices.
• Effectively communicate critical equipment, maintenance, and operational information across shifts and functional teams.
• Work flexible hours including 2nd and 3rd shifts, weekends, and extended periods as required.
• Other duties as assigned to support departmental and organizational goals.

KNOWLEDGE, SKILLS & EXPERIENCE

Critical Knowledge and Qualifications:

• High School diploma, GED, or equivalent experience in lieu of education required
• College or trade school degree in engineering mechanics or electronics, preferred
• Advanced knowledge of mechanical, electrical, hydraulic, pneumatic, and automated manufacturing systems.
• Working knowledge of CNC equipment, including FANUC, Heidenhain, and Siemens controls preferred.
• Knowledge of equipment reliability principles, preventive maintenance strategies, and root cause analysis methodologies.
• Working knowledge of maintenance management systems (eMaint or equivalent).
• Knowledge of SOP, FDA, ISO, and applicable regulatory requirements within a manufacturing environment.
• Demonstrated commitment to safety, quality, and continuous improvement.

Critical Skills/technical know-how:

• Ability to perform advanced troubleshooting and repair of mechanical, electrical, hydraulic, pneumatic, and controls-related equipment issues.
• Ability to perform geometry adjustments, calibration activities, and precision alignments on 5-axis CNC machines.
• Ability to read and interpret electrical schematics, mechanical drawings, hydraulic diagrams, pneumatic diagrams, and technical documentation.
• Ability to diagnose and replace faulty sensors, relays, motor starters, drives, breakers, and other control components.
• Ability to perform root cause analysis and develop effective corrective actions for recurring equipment failures.
• Ability to independently prioritize work, develop action plans, and make sound technical decisions with minimal supervision.
• Ability to lead equipment validation, commissioning, and startup activities.
• Ability to support equipment upgrades, process improvements, and reliability initiatives.
• Ability to guide and provide technical assistance to less experienced technicians.
• Advanced computer skills, including Microsoft Office and maintenance management systems.
• Strong verbal and written communication skills.
• Proficient in English (reading, writing, and speaking).
• Flexibility to work overtime in response to business needs.
• Ability to stand, walk, bend, and perform physical work for extended periods (up to 8 hours per shift).

Critical Experience:

• More than 5 years of maintenance experience in a manufacturing, industrial, or similarly technical environment.
• Demonstrated experience troubleshooting and repairing complex mechanical, electrical, hydraulic, and pneumatic equipment.
• Experience supporting CNC equipment and automated manufacturing systems preferred.
• Demonstrated experience performing advanced diagnostics, root cause analysis, and reliability improvement activities.
• Experience leading or supporting equipment validation, commissioning, installation, or startup activities.
• Demonstrated experience working with analog and digital instrumentation.
• Experience serving as a technical resource or mentor to less experienced technicians preferred.
• Experience with Lean Manufacturing, Six Sigma, SPC, TPM, or continuous improvement methodologies preferred.
• Experience working in a highly regulated manufacturing environment preferred.

COMPETENCIES – Essential for the role: Collaborates, Drives Results, Communicates Effectively, Action Oriented, Optimizes Work Processes