Nature of the Work
Imagine an automobile assembly line: a large conveyor system moves unfinished automobiles down the line, giant robotic welding arms bond the different body panels together, hydraulic lifts move the motor into the body of the car, and giant presses stamp body parts from flat sheets of steel. All of these machines—the hydraulic lifts, the robotic welders, the conveyor system, and the giant presses—sometimes break down. When the assembly line stops because a machine breaks down, it costs the company money. Industrial machinery mechanics and machinery maintenance workers maintain and repair these very different, and often very expensive, machines.
The most basic tasks are performed by
machinery maintenance workers. These employees are responsible for cleaning and lubricating machinery, performing basic diagnostic tests, checking performance, and testing damaged machine parts to determine whether major repairs are necessary. In carrying out these tasks, maintenance workers must follow machine specifications and adhere to maintenance schedules. Maintenance workers may perform minor repairs, but major repairs are generally left to machinery mechanics.
Industrial machinery mechanics, also called industrial machinery repairers or maintenance machinists, are highly skilled workers who maintain and repair machinery in a plant or factory. To do this effectively, they must be able to detect minor problems and correct them before they become major. Machinery mechanics use technical manuals, their understanding of the equipment, and careful observation to discover the cause of the problem. For example, after hearing a vibration from a machine, the mechanic must decide whether it is due to worn belts, weak motor bearings, or some other problem. Mechanics need years of training and experience to diagnose problems, but computerized diagnostic systems and vibration analysis techniques provide aid in determining the nature of the problem.
After diagnosing the problem, the industrial machinery mechanic disassembles the equipment to repair or replace the necessary parts. When repairing electronically controlled machinery, mechanics may work closely with electronic repairers or electricians who maintain the machine's electronic parts. (
Electrical and electronics installers and repairers, as well as
electricians, appear elsewhere in the
Handbook.) Increasingly, mechanics are expected to have the electrical, electronics, and computer programming skills to repair sophisticated equipment on their own. Once a repair is made, mechanics perform tests to ensure that the machine is running smoothly.
Primary responsibilities of industrial machinery mechanics also often include preventive maintenance and the installation of new machinery. For example, they adjust and calibrate automated manufacturing equipment, such as industrial robots. Part of setting up equipment is programming the programmable logic control (PLC), a frequently used type of computer used as the control system for automated industrial machines. Situating and installing machinery has traditionally been the job of millwrights, but as plants retool and invest in new equipment, companies increasingly rely on mechanics to do this task for some machinery. (A section on
millwrights appears elsewhere in the
Handbook.)
Industrial machinery mechanics and machinery maintenance workers use a variety of tools to perform repairs and preventive maintenance. They may use handtools to adjust a motor or a chain hoist to lift a heavy printing press off the ground. When replacements for broken or defective parts are not readily available, or when a machine must be quickly returned to production, mechanics may create a new part using lathes, grinders, or drill presses. Mechanics use catalogs to order replacement parts and often follow blueprints, technical manuals, and engineering specifications to maintain and fix equipment. By keeping complete and up-to-date records, mechanics try to anticipate trouble and service equipment before factory production is interrupted.
Work environment. In production facilities, these workers are subject to common shop injuries such as cuts, bruises, and strains. They also may work in awkward positions, including on top of ladders or in cramped conditions under large machinery, which exposes them to additional hazards. They often use protective equipment such as hardhats, safety glasses, steel-tipped shoes, hearing protectors, and belts.
Because factories and other facilities cannot afford to have industrial machinery out of service for long periods, mechanics may be on call or assigned to work nights or on weekends. Overtime is common among full-time industrial machinery mechanics; about 30 percent work over 40 hours a week.
