Industrial machinery repairers maintain and repair machinery found in a plant or factory. This must be done accurately and quickly because an idle machine will delay production. In addition, a machine that is not properly repaired and maintained may damage the final product. All these factors cost companies money.
Industrial machinery repairers often called maintenance mechanics spend much of their time doing preventive maintenance. This includes keeping machines and their parts well oiled, greased, and cleaned. Repairers regularly inspect machinery and check performance. For example, they adjust and calibrate automated manufacturing equipment such as industrial robots and rebuild components of other industrial machinery. By keeping complete and up-to-date records, mechanics try to anticipate trouble and service equipment before factory production is interrupted.
Maintenance mechanics must be able to spot minor problems and correct them before they become major ones. 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. Computerized maintenance-management and self-diagnostic systems are making this task easier. Self-diagnostic features on new industrial machinery can determine the cause of a malfunction and, in some cases, can alert the mechanic to potential trouble spots before symptoms develop.
After diagnosing the problem, the mechanic disassembles the equipment and repairs or replaces the necessary parts. The final step is to test the machine to ensure that it is running smoothly. When repairing electronically controlled machinery, these mechanics may work closely with electronic repairers or electricians who maintain the machine's electronic parts. However, industrial machinery repairers increasingly need electronic skills to repair sophisticated equipment on their own. (Additional information about commercial and industrial electronic equipment repairers and electricians appears elsewhere in the Handbook.)
A wide range of tools may be used when doing preventive maintenance or making repairs. For example, repairers may use a screwdriver and wrench to adjust an engine, or a hoist to lift a 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, repairers may sketch a part that can be fabricated by the plant's machine shop. Repairers use catalogs to order replacement parts and often follow blueprints and engineering specifications to maintain and fix equipment.
Some of the industrial machinery repairer's duties may be performed by millwrights. (See the statement on millwrights elsewhere in the Handbook.)
Industrial machinery repairers may be called to the plant at night or on weekends to make emergency repairs.
Working conditions for repairers who work in manufacturing are similar to those of production workers. However, they often work underneath or above large machinery in cramped conditions or on the top of a ladder. These workers are subject to common shop injuries such as cuts and bruises and often use protective equipment such as hard hats, protective glasses, and safety belts.
Because factories and other organizations cannot afford breakdowns in industrial machinery, industrial machinery repairers may be called to the plant at night or on weekends for emergency repairs. Although most mechanics usually work a standard 40 hour week, overtime is often necessary.
Industrial machinery repairers held about 477,000 jobs in 1992. Seven of every 10 worked in manufacturing industries, primarily food processing, textile mill products, chemicals, fabricated metal products, and primary metals. Others worked for government agencies, public utilities, mining companies, and any other business that relies on machinery. About 20,000 of these mechanics are contractors.
Because industrial machinery repairers work in a wide variety of plants, they are employed in every part of the country. Employment is concentrated, however, in heavily industrialized areas.
Many workers learn their trade through a 4-year apprenticeship program that combines 144 hours of related classroom instruction each year with on-the-job-training. These programs are usually sponsored by a local trade union. Others start as helpers and pick up the skills of the trade informally and by taking courses offered by machinery manufacturers.
Repairers learn from experienced repairers how to operate, disassemble, repair, and assemble machinery. Classroom instruction focuses on subjects such as shop mathematics, blueprint reading, and welding. In addition, electronics and computer training are an increasingly important part of the apprenticeship program.
Most employers prefer to hire those who have completed high school. However, opportunities do exist for those without a high school diploma. High school courses in mechanical drawing, mathematics, blueprint reading, physics, and electronics are useful.
Mechanical aptitude and manual dexterity are important qualifications for workers in this trade. Good physical condition and agility are also necessary because repairers sometimes have to lift heavy objects or climb to reach equipment located high above the floor.
Opportunities for advancement are limited. Industrial machinery repairers advance either by working with more complicated equipment or by becoming a supervisor. Some of the most highly skilled repairers can be promoted to master mechanic or can become a machinist or a tool and die maker.
Employment of industrial machinery repairers is expected to decline through the year 2005 as more firms introduce automated production equipment. All job openings will result from the need to replace repairers who transfer to other occupations or leave the labor force.
More companies are choosing to schedule the orderly replacement of machinery before it wears out completely because the total costs associated with repairs increasingly are higher than the costs of new equipment. New equipment has lower operating costs per volume of output, requires less maintenance than many existing machines, and often has diagnostic devices that isolate potential mechanical problems before they lead to costly breakdowns. If this trend continues, it could further reduce demand for mechanics.
Unlike many other manufacturing occupations, industrial machinery repairers are not usually affected by seasonal changes in production. During slack periods, when some plant workers are laid off, repairers often are retained to do major overhaul jobs. Although these workers may face layoff or a reduced workweek when economic conditions are particularly severe, they generally are less affected than other workers because machines have to be maintained regardless of the level of production.
Median weekly earnings of full time industrial machinery repairers were $498 in 1992; the middle 50 percent earned between $384 and $626 weekly. The lowest 10 percent earned less than $296, and the top 10 percent earned more than $773. However, earnings often vary by industry and the area of the country.
Labor unions to which some industrial machinery repairers belong include the United Steelworkers of America; the United Automobile, Aerospace and Agricultural Implement Workers of America; the International Association of Machinists and Aerospace Workers; and the International Union of Electronic, Electrical, Salaried, Machine, and Furniture Workers.
Other occupations that involve repairing machinery include aircraft mechanics and engine specialists, automotive and motorcycle mechanics, diesel mechanics, elevator installers and repairers, farm equipment mechanics, machinists, general maintenance mechanics, heating, air-conditioning, and refrigeration mechanics, millwrights, and mobile heavy equipment mechanics.
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Reprinted with Permission of U. S. Department of Labor