Job Description

The Lead Drive Shop Technician is responsible for providing technical leadership, maintenance support, troubleshooting, optimization, and reliability improvement for Variable Speed Drives, also known as VSDs or Variable Frequency Drives, across the site or business unit.

The role ensures that VSD systems operate safely, efficiently, and reliably while supporting production, maintenance, engineering, commissioning, and continuous improvement activities. The Lead Drive Shop Technician acts as the site subject matter expert for drive systems, motor control, associated protection systems, and integration with PLC, SCADA, and control networks.

Key Responsibilities Technical Leadership

• Act as the primary technical lead for Variable Speed Drives across assigned assets, production lines, or facilities.
• Provide expert support for VSD fault diagnosis, parameter configuration, tuning, commissioning, and performance optimization.
• Support engineering, maintenance, and operations teams with drive-related technical issues.
• Develop and maintain site standards for VSD installation, configuration, backup, maintenance, and replacement.
• Review proposed VSD applications to ensure correct sizing, specification, cooling, protection, harmonics management, and control integration.

Maintenance and Reliability

• Lead planned and reactive maintenance activities involving VSDs, motors, control panels, power circuits, and associated instrumentation.
• Investigate recurring VSD failures and implement corrective and preventive actions.
• Maintain accurate records of VSD parameters, firmware versions, fault history, spare parts, and lifecycle status.
• Support reliability improvement initiatives to reduce downtime, nuisance trips, and equipment failures.
• Ensure critical VSD spares are identified, stocked, and managed effectively.

Troubleshooting and Support

• Diagnose faults involving drives, motors, encoders, braking systems, control signals, communication networks, and electrical supply quality.
• Support root cause analysis for production losses, process interruptions, and equipment failures involving drive systems.
• Provide technical support during breakdowns, shutdowns, startups, and commissioning activities.
• Escalate complex technical issues to OEMs, vendors, or engineering specialists when required.

Projects and Commissioning

• Support capital projects, equipment upgrades, and process improvement projects involving VSD systems.
• Review electrical drawings, control philosophies, cable schedules, drive specifications, and commissioning documentation.
• Assist with factory acceptance testing, site acceptance testing, loop checks, drive setup, and startup activities.
• Ensure new or modified VSD installations comply with company standards, safety requirements, and applicable electrical regulations.

Safety and Compliance

• Ensure all work involving VSDs and electrical systems is performed in accordance with company safety procedures, lockout/tagout requirements, electrical safety rules, and permit-to-work systems.
• Support risk assessments, method statements, and safe systems of work for VSD-related activities.
• Promote safe working practices when dealing with high-voltage equipment, stored energy, rotating machinery, and control systems.
• Ensure compliance with applicable electrical codes, standards, and site engineering requirements.

Documentation and Knowledge Management

• Maintain up-to-date VSD configuration files, parameter backups, drawings, manuals, and commissioning records.
• Develop troubleshooting guides, maintenance procedures, and standard work instructions for drive systems.
• Train technicians, engineers, and operators on VSD operation, basic fault finding, reset procedures, and escalation requirements.
• Share lessons learned from major faults, failures, and improvement activities.

Required Knowledge and Experience

• Strong working knowledge of Variable Speed Drives, Variable Frequency Drives, AC motors, motor control centers, and electrical distribution systems.
• Experience with drive configuration, parameterization, fault diagnosis, and commissioning.
• Understanding of PLC, SCADA, HMI, and industrial communication networks such as Profibus, Profinet, Ethernet/IP, Modbus, or similar.
• Knowledge of electrical protection, grounding, harmonics, EMC, braking resistors, regenerative drives, and motor cable requirements.
• Experience working in an industrial, manufacturing, utilities, process, energy, mining, marine, or heavy engineering environment.
• Ability to read and interpret electrical schematics, single-line diagrams, control diagrams, and technical manuals.
• Experience working with major drive manufacturers such as ABB, Siemens, Rockwell/Allen-Bradley, Schneider, Danfoss, Yaskawa, WEG, or similar.

Qualifications

Essential:

• Electrical, Electronic, Mechatronic, Controls, or Automation Engineering qualification; or equivalent trade/technical qualification with relevant experience.
• Demonstrated experience working with industrial VSD/VFD systems.
• Strong fault-finding and problem-solving capability.
• Knowledge of electrical safety practices and isolation procedures.

Desirable:

• OEM training or certification on major VSD platforms.
• PLC or automation system experience.
• High-voltage or medium-voltage drive experience.
• Experience with reliability tools such as RCA, FMEA, 5 Whys, or condition-based maintenance.
• Knowledge of functional safety, machine safety, or process safety standards.

Key Competencies

• Strong technical judgment and analytical thinking.
• Ability to lead technical investigations and drive issues to resolution.
• Clear communication with maintenance, operations, engineering, vendors, and management.
• Strong ownership of equipment reliability and asset performance.
• Ability to work under pressure during breakdowns or production-critical events.
• Good planning, documentation, and organizational skills.
• Commitment to safety, compliance, and continuous improvement.

Key Performance Indicators

• Reduction in VSD-related downtime.
• Improvement in VSD reliability and mean time between failures.
• Completion of planned maintenance and inspection activities.
• Accuracy and availability of VSD parameter backups and technical documentation.
• Timely resolution of recurring drive faults.
• Reduction in repeat failures and nuisance trips.
• Successful support of project commissioning and startup activities.
• Compliance with electrical safety and company engineering standards.