Industrial maintenance mechanics repair and maintain machines, mechanical equipment and buildings, and work on plumbing, electrical and air-conditioning and heating systems. They build partitions, make plaster or drywall repairs, and fix or paint roofs, windows, doors, floors, woodwork and other parts of building structures. They also maintain and repair specialized equipment and machinery found in cafeterias, laundries, hospitals, stores, offices and factories. Typical duties include troubleshooting and fixing faulty electrical switches, repairing air-conditioning motors and unclogging drains. New buildings sometimes have computer-controlled systems, requiring mechanics to acquire basic computer skills. For example, new air conditioning systems can often be controlled from a central computer terminal or light sensors can be electronically controlled to automatically turn lights on and off. (See also Electrical Trades and Heating, Air Conditioning and Refrigeration Technology).

General maintenance mechanics inspect and diagnose problems and determine the best way to correct them, often checking blueprints, repair manuals, and parts catalogs. They obtain supplies and repair parts from distributors or storerooms. They use common hand and power tools such as screwdrivers, saws, drills, wrenches, and hammers, as well as specialized equipment and electronic test devices. They replace or fix worn or broken parts, where necessary, or make adjustments. These mechanics also do routine preventive maintenance and ensure that machines continue to run smoothly, building systems operate efficiently, and the physical condition of buildings does not deteriorate. Following a checklist, they may inspect drives, motors, and belts, check fluid levels, replace filters, and perform other maintenance actions. Maintenance mechanics keep records of maintenance and repair work.

Industrial maintenance mechanics in small establishments are often the only maintenance worker. They do all repairs except for very large or difficult jobs. In larger establishments, maintenance mechanics are more specialized.

Stationary or operating engineers start up, regulate and shut down equipment. They ensure that it operates safely, economically and within established limits by monitoring meters, gauges, and other instruments and computerized controls. They manually control equipment, and if necessary, make adjustments. They use hand and power tools to perform repairs and maintenance ranging from a complete overhaul to replacing defective valves, gaskets or bearings. They also record relevant events and facts concerning operation and maintenance in an equipment log. On steam boilers, for example, they observe, control and record steam pressure, temperature, water level and chemistry, power output, fuel consumption and emissions. They watch and listen to machinery and routinely check safety devices, identifying and correcting any trouble that develops.

Industrial machinery mechanics or maintenance machinists, maintain and repair machinery found in a plant or factory. Their work is not only important because an idle machine will delay production, but also because a machine that is not properly repaired and maintained may damage the final product or injure the operator (see also Metal Trades).

Commercial and industrial electronic equipment repairers, also called industrial electronics technicians, install and repair industrial controls, radar and missile control systems, medical diagnostic equipment and communications equipment (see Electronics/Microcomputer Technology).

Equipment cleaners clean machinery, storage tanks, pipelines, and similar equipment using water and other cleaning agents, vacuums, hoses, brushes, cloths and other cleaning equipment.

Mechanical engineers plan and design tools, engines, machines and other mechanical equipment. They design and develop power-producing machines such as internal combustion engines, steam and gas turbines, and jet and rocket engines. They also design and develop power-using machines such as refrigeration and air-conditioning equipment, robots, machine tools, materials handling systems and industrial production equipment.

Mechanical engineering technicians help engineers design, develop, test and manufacture industrial machinery, mechanical parts and other equipment. They may assist in the testing of a guided missile, or in the planning and design of an electric power generation plant. They make sketches and rough layouts, record data, make computations, analyze results and write reports. When planning production, mechanical engineering technicians prepare layouts and drawings of the assembly process and of parts to be manufactured. They estimate labor costs, equipment life and plant space. Some test and inspect machines and equipment in manufacturing departments or work with engineers to eliminate production problems.

 

Industrial maintenance mechanics often do a variety of tasks in a single day, generally at a number of different locations in a building or in several buildings. They may have to stand for long periods, lift heavy objects, and work in uncomfortably hot or cold environments, in awkward and cramped positions, or on ladders. They are subject to electrical shock, burns, falls, cuts and bruises. Most industrial maintenance workers work a 40-hour week. Some work evening, night or weekend shifts, or are on call for emergency repairs.

Those employed in small establishments, where they may be the only maintenance worker, often operate with only limited supervision. Those working in larger establishments often work under the direct supervision of an experienced worker.

 

Mechanical aptitude, ability to use shop math and manual dexterity are important. Good health is necessary because the job involves much walking, standing, reaching and heavy lifting. Difficult jobs require problem-solving ability, and many positions require the ability to work without direct supervision.

 

Graduation from high school is preferred for entry into this occupation. High school courses in mechanical drawing, electricity, woodworking, blueprint reading, science and mathematics are useful. Most general maintenance mechanics learn their skills informally on the job. They start as helpers, watching and learning from skilled maintenance workers. Helpers begin by doing simple jobs such as fixing leaky faucets and replacing light bulbs, and progress to more difficult tasks such as overhauling machinery or building walls.

Others learn their skills by working as helpers to other repair or construction workers such as carpenters, electricians or machinery repairers. Necessary skills can also be learned in high school shop classes and postsecondary trade or vocational schools. It generally takes from 1 to 4 years of on-the-job training or school, or a combination of both, to become fully qualified, depending on the skill level required. Because a growing proportion of new buildings rely on computers to control building systems, industrial maintenance mechanics may need basic computer skills such as logging on to a central system and navigating through a series of menus. Usually companies that install computer-controlled equipment provide on-site training for industrial maintenance mechanics.

 

Many industrial maintenance mechanics in large organizations advance to maintenance supervisor or to one of the crafts such as electrician, heating/air conditioning mechanic, or plumber. In small organizations, promotion opportunities are limited.

 

Earnings vary widely by industry, geographic area and skill level. According to a survey of workplaces in 160 metropolitan areas, general maintenance mechanics had median earnings of about $9.88 an hour in 1995, with the middle half earning between $8.36 and $11.86 an hour. Median earnings were about $9.41 an hour in service businesses, and about $9.90 an hour in manufacturing businesses. On average, workers in the Midwest and Northeast earned more than those in the West and South. Mechanics earn overtime pay for work in excess of 40 hours per week.

Some industrial maintenance mechanics are members of unions, including the American Federation of State, County and Municipal Employees and the United Automobile Workers.

 

General maintenance mechanics held about 1,362,000 jobs in 1996. They were employed in almost every industry in the economy. More than one-third worked in service industries; most of these worked for elementary and secondary schools, colleges and universities, hotels, and hospitals and nursing homes. About 17 percent worked in manufacturing industries. Others worked for real estate firms that operate office and apartment buildings, wholesale and retail firms, or government agencies.

Job openings should be plentiful for general maintenance mechanics. Employment is related to the number of buildings—for example, office and apartment buildings, stores, schools, hospitals, hotels, and factories—and amount of equipment needing maintenance and repair. Although the pace of construction of these facilities is expected to be slower than in the past, employment growth is still expected to be about as fast as the national average for all occupations through the year 2006. In addition to growth openings, this is a large occupation with a significant turnover rate, and many replacements are needed for those who transfer to other occupations or stop working for other reasons.