Senior Maintenance Reliability Engineer

Summary

The Sr. Reliability Engineer will lead the implementation, continuous improvement, and sustainability of reliability systems and processes within the manufacturing site. This position is responsible for developing, managing and coordinating the reliability programs and activities of the location key assets, utilities and support equipment through the use of personal knowledge, engineering resources, OEM and maintenance employees, to ensure maximum availability of these key assets, utilities and support equipment, while supporting the policies, goals and objectives of the company.  

Principal and Essential Duties & Responsibilities

• Responsible for the implementation of reliability concepts including development of Root Cause Analysis, Reliability Centered Maintenance, Predictive Maintenance technologies and Preventive Maintenance development/optimization to achieve high levels of availability of plants assets
• Driving increased production and uptime using reliability tools and processes, including Root Cause Failure Analysis (RCFA), and Failure Mode Effects Analysis (FMEA)
• Provide technical and engineering support and troubleshooting advice to maintenance and various operational areas
• Subject Matter Expert in the design and operation of rotating equipment, development of equipment strategies (including lubrications, conditions monitoring, and preventive maintenance), and management of mechanical integrity (including tanks, pressure vessels, and piping)
• Develop and implement plans for continuous improvement of production equipment, processes, and process controls
• Work closely with both operations and maintenance in the development of long-term equipment maintenance strategies and operator basic care (OBC) as well as support troubleshooting efforts through formal Root Cause Analysis (RCA)
• Provide technical expertise to the site with field application of precision maintenance techniques. Provide training, field coaching and mentoring of maintenance supervisors and craftsmen.
• Deliver a strategic reliability-centered maintenance approach to optimizing asset life and productivity through documented asset strategies.
• Identify and manage asset reliability risks that could adversely affect plant or business operations. He/she selects engineering techniques to solve problems and makes recommendations including the coordination of projects for process improvements.
• Work closely with maintenance planner, superintendents, and technicians to coordinate a variety of installation, repair, and maintenance tasks performed so that the production departments can function properly and reliably, and achieve their quality and quantity goals.
• Establish and maintain reliable equipment using predictive and preventative maintenance tools, preserve plant assets, and continuously seeks methods for reducing maintenance cost while insuring high equipment availability and reliability in a safe working environment.
•  Provide technical and project management support for the operation, maintenance, betterment, development, design, construction and testing of manufacturing assets and ancillary components.
• Support Area Teams in achieving production/cost goals through reliability leadership. Develop and implement best practices for assets to improve the mean time between failures (MTBF).

Additional Responsibilities

• Develop and implement best practices for assets to improve the mean time between failures (MTBF).
• Utilize Root Cause Analysis processes to review significant failures, identify corrective action to prevent re-occurrence and refine asset strategy to sustain improvement.
• Mine data to identify reliability improvement opportunities and develop corrective actions focused on delivering Net Hours improvement and cost reduction.
• Develop engineering solutions to repetitive failures and all other problems that adversely affect plant operations. These problems include capacity, quality, cost or regulatory compliance issues.
• Identifies deficiencies in maintenance processes and develop sustainable improvements.
• Provide reliability technical support to Production, Maintenance, Engineering and Procurement activities.
• Provides input to a Risk Management Plan that will anticipate reliability-related, and non-reliability-related risks that could adversely impact plant operation.
• Generate statistical reviews of equipment maintenance history and production loss. Continually improve the preventive maintenance program using Reliability Centered Maintenance.

Requirements

• Bachelor’s Degree in Reliability, Mechanical or Electrical in Engineering; Advanced degree in this or related field is highly desirable.
• Five (5) or more years of reliability experience within an industrial manufacturing environment preferably in mid-sized manufacturing companies in a similar industry.
• Experience developing asset strategies (time-based inspection/replace, and condition-based tasks)
• Experience with Reliability Centered Maintenance (RCM) and facilitating Root Cause Analysis (RCA)
• Strong technical expertise in applying Precision Maintenance techniques in industrial manufacturing processes. Strong knowledge of Precision Maintenance procedures.
• Knowledge of equipment design and failure modes. Experience with interpreting forensic evidence to identify failure modes.
• Experience developing asset strategies (time-based inspection/replace, and condition-based tasks)
• Experience with Reliability Centered Maintenance (RCM) and facilitating Root Cause Analysis (RCA). Exposure to operations, process control, project engineering, plant maintenance, construction and new installations

What Will Put You Ahead

• Experience working in the food industry
• Supervisory experience
• Experience with/Certifications in Predictive maintenance technologies (Vib, IR, UL, MCA/MCSA, Oil Analysis, NDT)
• CMRP or CRL Certifications
• Certification in Lean Six Sigma ideal
• Experience with computer maintenance management systems (CMMS) preferably IBM Maxim. Advanced skills in basic personal computer software (Microsoft applications); Experience using Microsoft Word, Excel and Outlook
• Strong communication (written, oral, and interpersonal) skills. Ability to lead and be part of cross-functional teams.
• Ability to support risk-based inspection of fixed assets. 
• Provide technical support for Operational and Maintenance Teams. 

Environmental Factors and Physical Requirements

• Must be able to move throughout assigned areas of responsibility carrying required equipment and tools to perform trouble shooting procedures, repairs and preventative maintenance.
• Must be able to reach vertical heights up to 150' to perform repairs, preventative maintenance and monitor equipment both open and in confined spaces.
• Must be able to work outside in all seasonal weather, stand for 8 to 14 hours. Exposure to air born dust, chemicals, such as hexane, caustic sode, butanone, ethanol and aluminum chloride.
• When in a plant environment: Exposure primarily consists of wet and moist floors which include metal and plastic grating surfaces.
• May be exposed to temperatures of 28 degrees to 100 degrees Fahrenheit with both ambient and 100% humidity. May handle product 25 degrees to 50 degrees Fahrenheit.
• May be exposed to noise ranges of 50 db. to 110 db.May be exposed to all chemicals used in poultry, food, processing facility.
• Must wear and use protective and safety equipment required for the job as directed by the Company. May need to climb ladders.