Technician,Electronics,Panther

1.1 Non‑negotiable behaviors

• Own the process, not the opinion: bring data, facts, root cause, options.

• Bias to action: raise issues early, propose containment + permanent fix, follow through.

• Standardize then improve: build/maintain standard work and then optimize it.

• Digital-first mindset: eliminate repeat manual work; automate, template, or systemize.

• Professional discipline: on-time delivery of commitments; clear escalation when blocked.

1.2 Self-development ownership (explicit expectation)

• Each engineer/lead is accountable for maintaining role competence and must:

• Maintain an annual Individual Development Plan (IDP) with manager sign-off.

• Complete minimum agreed learning (minimum: 40 hours/year).

• Demonstrate skills through applied deliverables (dashboards, macros, standards, project results), not certificates only.

• Maintain a personal “automation backlog”: top recurring tasks to digitize/automate.

1.3 Minimum digital competence baseline (plant standard)

• Each role is expected to be competent in:

• Excel at working professional level: tables, pivot tables, XLOOKUP, SUMIFS, charts

• Data shaping: Power Query (or equivalent)

• Basic automation: macros/VBA or scripted automation (where permitted)

• Structured problem solving: A3 / 8D, Pareto, 5-Why, fishbone

• Presenting in 1-page formats (A3, scorecards) for decision-making

Key accountabilities

2.1 Automation and OT systems (core scope)

• PLCs (plant standard platforms), remote I/O, safety PLCs (where installed)
• HMIs, CBM, cybersecurity dashboard, historian interfaces, Andon/FIS systems (where applicable)
• Industrial networks: Ethernet/IP, Profinet/Profibus, DeviceNet, AS-i, IO-Link (as applicable), switches and managed network components in OT scope
• Variable speed drives (VSDs), servo drives, motion controllers (where applicable)
• Industrial PCs, panel PCs, thin clients used for control systems
• Instrumentation interfaces: sensors, transducers, flow/pressure/temperature measurement (interface integrity, scaling, diagnostics)
• Machine communication and data interfaces: OPC, database/logging links, barcode/RFID/traceability devices (where present)
• Manage all software and hardware installed on different types of continuous process equipment while ensuring minimal down times, proper documentation, and software version control.
• Improve Assembly and Machining equipment uptime using data analysis and preventative maintenance planning.

2.2 Controls governance and standards (plantwide)

• Controls change management and program version control
• Backup and disaster recovery readiness for control systems
• Alarm management / rationalization standards (where applicable)
• Controls documentation: electrical drawings interfaces, I/O lists, network diagrams, program documentation, standard templates
• OT cyber hygiene (in alignment with plant IT/OT governance): access control, password/credential management, remote access controls, patching coordination, asset register
• Execute machine upgrades, new installations, obsolescence replacements, and capacity/quality projects
• Commissioning, acceptance testing, and handover packs for controls-related works support
• Technicians training for “universal soldier”/ able to work on all lines/, development & performance management (evidence: versatility matrices, IDP, 1:1, disciplinary records, process verification & confirmation sheets)
• Leadership of the next level-up artisans programs & screening the pipeline of the training centre artisans.
• Benchmark & Active networking with the sister plants on the Maintenance best practices, cost saving projects, research improvement opportunities in the field.

• Drive the i4.0, ML, AI & innovation projects related to production equipment.

2.3 Projects and commissioning support (in partnership with FTPM/Engineering)

• Execute machine upgrades, new installations, obsolescence replacements, and capacity/quality projects
• Commissioning, acceptance testing, and handover packs for controls-related works support
• Technicians training for “universal soldier”/ able to work on all lines/, development & performance management (evidence: versatility matrices, IDP, 1:1, disciplinary records, process verification & confirmation sheets)
• Leadership of the next level-up artisans programs & screening the pipeline of the training centre artisans.
• Benchmark & Active networking with the sister plants on the Maintenance best practices, cost saving projects, research improvement opportunities in the field.

• Drive the i4.0, ML, AI & innovation projects related to production equipment.

3.1 Safety, compliance & functional integrity (non-negotiable)

• Ensure all work supports safe systems of work (ECPL, permits, safe commissioning).
• Ensure safety-related control functions are maintained and changes are governed (safety circuits, safety PLC logic, interlocks), aligned to plant functional safety requirements.
• Prevent bypass culture: identify, record, and drive closure of bypasses/overrides and unsafe workarounds through Maintenance governance.

3.2 Uptime & breakdown response (controls reliability)

• Provide rapid, structured troubleshooting for controls-related breakdowns and chronic faults.
• Own controls-related downtime reduction through:
• Pareto of recurring faults
• RCAs (A3/8D discipline)
• permanent corrective actions with verification
• Implement early warning and diagnostics where feasible (fault logging, health checks, alarm improvements).

3.3 Preventative controls maintenance & obsolescence management

• Define and maintain a controls PM strategy (in partnership with Maintenance planning), including:
• panel inspections, cooling/ventilation checks, backup verification, battery replacement cycles
• network health checks, drive diagnostics, critical parameter baselining
• Own controls obsolescence risks:
• risk-ranked list of end-of-life PLCs/HMIs/drives/PCs
• upgrade plans with parts strategy and downtime windows

3.4 Change control, backups, and documentation discipline

• Operate a strict controls change governance system:
  • pre-change risk assessment (impact to safety/quality/delivery)
  • authorization and documented change records
  • version control and rollback readiness
• Maintain complete and tested backups:
  • PLC programs, HMI/SCADA projects, drive parameters, robot backups (if applicable), PC images where required
  • defined backup frequency and verification (restore test discipline)
• Maintain controls documentation accuracy:
  • I/O lists, network topology, IP plans, panel documentation, as-built updates and handover packs.

3.5 Quality and process capability support (automation-enabled)

• Improve detection, error-proofing, and traceability systems (where applicable) to prevent defects and recurrence.
• Support process engineers with robust data capture and automation improvements that reduce human error.

3.6 i4.0 enablement & elimination of manual work

• Identify and deliver controls/digital improvements that reduce manual repetitive tasks:
• automated data capture, automated reporting triggers, digitized checks
• simple operator guidance systems (HMI prompts, interlocks, standard sequences)
• Maintain an “automation backlog” (ranked by risk, downtime, and ROI) and execute through a disciplined cadence.

3.7 Contractor and vendor governance (controls works)

• Participate in verification/verify quality of work (standards, documentation, backups, safety function verification).
• Drive corrective actions for poor workmanship and repeat failures; escalate via Maintenance Manager and Purchasing as required.

3.8 Capability building and standards

• Coach technicians and maintenance teams in basic controls fault-finding and correct escalation and cyber security.
• Build and enforce plant controls standards (naming conventions, code templates, network standards, documentation packs).

4. Key deliverables

• Weekly maintenance plan and schedule with adherence report, 0 overdue, MTTR, PVS, PJO, LPR for maintenance tasks.
• Maximo accuracy for the area of responsibility
• Top 10 breakdown Pareto with RCA and permanent actions. 0 leak after containment & PCA
• PM optimization plan and execution
• Backup compliance pack: backup schedule, latest backup evidence, restore test evidence, access control list. Cyber security compliance actions.
• Change control register: change requests, approvals, implementation records, validation evidence, rollback plan.
• Network and other documentation pack upkeep: network diagram, IP list, I/O lists, panel standards, as-builts/handover packs.

Interfaces

• Internal: Production, Engineering/Process, Stores, Safety, Controls/Automation, Contractors, Quality, Purchasing, Suppliers, Finance.

External: PTOME, MP&L, Maintenance from central functions & sister plants. Active networking & benchmark from the sister plants. GDIA teams.

KPIs (key KPI, full list of KPIs reviewed on the annual basis)

• Reliability / delivery support
  • Controls-related downtime minutes (monthly) and repeat failure rate
  • Mean time to respond / restore for controls incidents (where tracked)
  • % RCAs closed on time and verified effective
• Governance / compliance

  • Backup compliance % (on-time backups + restore test completion)

  • Change control compliance % (no unauthorized changes; complete records)

• Documentation accuracy score (audit sample pass rate)
• Digitalization / improvement
  • Number of implemented automations/digital improvements per quarter (plant-defined)
  • Reduction in manual reporting/logging hours enabled by automation changes 
• 7% annual maintenance operational budget improvement

Self-development expectations

• Reliability methods (RCA, FMEA, PM optimization)
• Digital adoption: be able to run and improve FIS, MFM, CBM data quality
• Maintain an annual IDP covering platform competence (PLC/HMI/CBM/Enterprisegateway/CIAB/GTSV), networking, change governance, and at least one i4.0/digital initiative.
• Deliver at least one controls reliability improvement and one automation/digitalization improvement per quarter (or plant-defined cadence), each with evidence of downtime reduction, risk reduction, or hours saved.
• Coaching capability: develop artisans/technicians, not just dispatch work 
• Part/Product damage incidents and cost due to maintenance
• Maintenance employee productivity
• ML, Python & AI knowledge and practical projects on the improvement/ optimization of the entrusted area of responsibility.
• Master A3/8D, PFMEA facilitation, basic capability analysis
• Become proficient in i4.0, robotics, co-bots, 3D printing, CBM, data automation analysis and visualization (stop manual “copy/paste quality” reporting)
• Build/maintain a maintenance knowledge base (lessons learned, standard fixes)

I4.0, automation, AGV.

Knowledge

• MOS 3x3 model & standards
• MFM, corporate EJP, OSHAC, GNR & SANS pertaining to the following: Driven Machinery, General Safety; Construction, Environmental, Hazardous chemical substances, Noise induced Hearing loss Regulations, Incorporation of health and safety standard in terms of section 44 (1)of the act: Driven Machinery Regulations, General Machinery, Pressure Equipment, Electrical Installation Regulations; Ford global & local procedures pertaining to the area of responsibility.
• Preventive maintenance systems and PM optimization (not just PM compliance)
• Breakdown elimination and reliability methods (RCA, Pareto, defect elimination)
• Basic asset health metrics (MTBF/MTTR, ERC/ERR/GRR vs actual JPH concepts where tracked)
• PFMEA, Control Plan, Process Flow, Reaction Plans; change control discipline
• Root cause methods (5-Why, fishbone, A3/8D)
• PLC/HMI/SCADA fundamentals and structured troubleshooting methods
• Industrial networking principles and common failure modes (noise, addressing, topology, switch configuration basics)
• Drives/servo fundamentals (parameter integrity, fault interpretation, basic tuning concepts where applicable)
• Instrumentation signal basics (4–20 mA, 0–10 V, digital inputs, scaling, noise/earthing fundamentals)
• Controls change governance, version control, and backup/restore discipline
• Functional safety principles relevant to automation (interlocks, safety circuits, safety PLC governance) aligned to plant standards
• OT cyber hygiene basics (asset awareness, access control, secure remote access discipline)
• Assembly & machining processes & equipment.

Skills

• Fault-find logically under time pressure and communicate clearly (symptom → cause → fix → prevention)
• Read and interpret electrical drawings, I/O lists, and network diagrams
• Build/maintain backups and perform controlled restores when required
• Implement controlled code changes with testing/validation evidence
• Lead RCAs and convert repeat faults into permanent improvements
• Build practical dashboards/action trackers (Excel competence; automation of reporting where feasible) 
• Coach artisans/technicians; build a skill matrix and training actions
• Lean Manufacturing, VSM

Abilities

• Ability to read blueprints, AutoCAD, E-Plan, interpret and modify electrical schematics. 
• Ability to reduce reactive work over time and stabilize uptime
• High discipline and integrity around safety and change control (no “quick hacks”)
• Ability to challenge poor standards and stop bypass/override culture
• Ability to prioritize actions by risk to safety, quality, and uptime
• Ability to standardize and simplify (templates, libraries, reusable diagnostics)
• Ability to build capability in others (technicians, operators) without doing all work personally 
• Ability to manage priorities across breakdown response, planned work, and improvement work
• Ability to challenge poor workmanship/recurrence and close loops with evidence
• Ability to prevent recurrence (system fix vs symptom fix)
• Ability to work with incomplete data initially and quickly improve data quality
• Ability to drive discipline without damaging relationships (firm, fair, factual)

Ability to manage multiple issue streams and prioritize by risk and impact

Qualifications & experience

Minimum

• National Diploma or Bachelor’s degree in Electrical / Electronic / Mechatronic Engineering,  
• Working competence in Excel for reporting and analysis
• 3–8 years experience in manufacturing/industrial automation with hands-on accountability for:
  • PLC troubleshooting and modifications
  • HMI/SCADA/FIS support. Knowledge of Rexroth, Siemens
  • industrial networks and drives exposure
  • commissioning support. 

Preferred

• OEM/platform training in the plant’s PLC/HMI standards (e.g., Siemens, Bosch-Rexroth, Allen-Bradley, Schneider)
• Functional safety training aligned to plant expectations (safety PLC/safety circuits governance)
• OT/cyber hygiene training (industrial networking security basics)
• Lean/Six Sigma problem-solving exposure (A3/8D)

• Knowledge of: 1.Laser Marking software package. 2. ABB and Festo Robot systems. 3. QLSCM and Quality-Works system. 4. Troubleshoot and program Bosch and Atlas Copco tightening systems. 5. Bosch software packages such as: Indraworks Engineering, BS 350, DS drive and Drive Top 6. Dataman, Cognex, EtherInspect Vision Systems. 7. Jager TPS fault finding and teaching. 8. Siemens software packages such as: WinCC, Step 7, TIA, Starter and Sinumerik. 9. Cognex and Zebra scanner setup and interface with PLC. 10. Different bus communication protocols and networking. 11. GPTS and Siemens RFID and PLC interface. 12. Sciemetric testing systems and interfaces to PLC. 13. Promess Drives and Software packages.

• Siemens TIA Portal, Step 7, IndraWorks Engineering, Schneider, Festo

• ABB Robot systems, Festo Robot System.

• CNC machines fit with Siemens and Bosch controls.

• Experience:
  • Automotive or high-volume machining/assembly environment
  • Traceability systems, vision systems, barcode/RFID integration experience (where present)
  • Experience with historian/data integration for i4.0 monitoring and automated reporting
• ML, AI knowledge & projects portfolio.
• Reliability training (RCM basics, PM optimization)
• Experience leading shutdown planning/execution

• Familiarity with digital maintenance systems (e-permits, mobile work orders, condition monitoring)

• Six Sigma Green Belt (or equivalent evidence of leading multiple A3/8D closures)
• ML, Python & AI knowledge