Process Coordinator - Electrical Maintenance (Rolling)

We are focused on operational excellence through safe, reliable, and efficient steelmaking and rolling operations. The Process Coordinator – Electrical Maintenance (Rolling) provides advanced technical leadership for electrical and automation systems supporting cold rolling, and finishing lines. This role focuses on maximizing uptime and product quality in high-speed, continuous processing environments by optimizing drive systems, automation platforms, and power distribution. The position also leads the technical development and qualification of electrical maintenance personnel to ensure a highly skilled and capable workforce.

Key Responsibilities

• Technical Leadership & Maintenance Execution
• Lead and enforce electrical safety programs, including LOTO, arc flash compliance per NFPA 70E, and safe work practices for high-energy systems
• Supervise union electrical maintenance crews and coordinate with OEMs, system integrators, and contractors for mill outages, upgrades, and commissioning
• Provide technical leadership for troubleshooting and maintenance of:
• High-horsepower, coordinated multi-axis drive systems (roughing/finishing stands)
• VFDs, DC drives, and cycloconverters used in rolling mill applications
• Tension control, looper systems, and strip speed synchronization
• Shears, tension reels, payoff reels and mill stands
• Maintain and optimize automation platforms, including PLCs, HMIs, and Level 1 control systems
• Diagnose complex faults using drive diagnostics, high-speed trending, and event logs to minimize downtime

Training & Workforce Development

• Develop, implement, and continuously improve structured training programs for electricians, including:
• Electrical safety (LOTO, arc flash, energized work boundaries)
• Rolling mill-specific systems (drives, inner stand tension control, AGC/AFC, automated strip handling equipment)
• PLC troubleshooting, basic programming, and control system diagnostics
• Reading and interpreting electrical schematics, one-lines, and control logic diagrams
• Lead hands-on training, mentoring, and job shadowing to build troubleshooting competency in high-speed process environments
• Establish and manage skills progression matrices and qualification standards for electrical maintenance personnel
• Evaluate workforce competency and identify skill gaps; develop targeted training plans to close gaps
• Support cross-training initiatives to improve crew flexibility and response capability during outages and production events
• Ensure compliance with company and regulatory training requirements; maintain training documentation and certifications

Reliability & Continuous Improvement

• Develop and improve preventive and predictive maintenance strategies:
• Thermal imaging of power components
• Motor testing (insulation resistance, surge comparison)
• Drive health monitoring and condition-based maintenance
• Lead root cause failure analysis (RCFA) on critical failures (e.g., drive trips, motor failures, control faults)
• Manage spare parts strategy for critical electrical and automation components
• Analyze production and maintenance data (downtime, cobbles, drive faults, MTBF/MTTR) to improve reliability and throughput

Planning, Projects, and Documentation

• Plan and coordinate maintenance outages, including job scoping, manpower allocation, and scheduling
• Support capital projects involving modernization of drive systems and automation upgrades
• Maintain technical documentation, including electrical schematics, PLC backups, drive parameters, and change management records

Qualifications & Requirements

• Bachelor’s degree in electrical engineering, engineering technology, or related field
• OR 6+ years of progressive experience in electrical maintenance within rolling mill or heavy industrial environments
• 3–5+ years of direct experience with rolling mill systems or high-speed continuous processing lines
• Strong technical expertise in:
• Medium- and low-voltage power distribution (480V–13.8kV)
• High-power motor control systems and coordinated drive systems
• PLC platforms (e.g., GE, Rockwell Automation, Allen-Bradley, Siemens S7)
• Industrial communications and real-time control systems
• Demonstrated ability to train, mentor, and develop skilled trades personnel in a technical environment
• Strong analytical and troubleshooting skills in complex manufacturing systems
• Experience with CMMS systems (Oracle)
• Preferred / Advanced Skills
• Experience with rolling mill control systems (AGC, AFC, tension/loop control)
• Familiarity with Level 2 systems and process optimization tools
• Knowledge of encoder systems, load cells, and high-speed feedback instrumentation
• Project management experience supporting major outages or system upgrades