Reliability Engineer

The primary role of the Reliability Engineer is to identify and manage asset reliability risks that could adversely affect plant or business operations. This broad primary role can be divided into three smaller, more manageable roles: Loss Elimination, Risk Management and Life Cycle Asset Management (LCAM)., * Works with Project Engineering to ensure the reliability and maintainability of new and modified installations. The Reliability Engineer is responsible for adhering to the Life Cycle Asset Management (LCAM) process throughout the entire life cycle of new assets.

• Participates in the development of design and installation specifications along with commissioning plans. Participates in the development of criteria for and evaluation of equipment and technical MRO (Maintenance, Repair and Operations) suppliers and technical maintenance service providers. Develops acceptance tests and inspection criteria.
• Participates in the final check out of new installations. This includes factory and site acceptance testing that will assure adherence to functional specifications.
• Guides efforts to ensure reliability and maintainability of equipment, processes, utilities, facilities, controls, and safety/security systems.

• Professionally and systematically defines, designs, develops, monitors, and refines an Asset Maintenance Plan that includes:

• Value-added preventive maintenance tasks

• Effective utilization of predictive and other non-destructive testing methodologies designed to identify and isolate inherent reliability problems

• Provides input to a Risk Management Plan that will anticipate reliability-related, and non-reliability-related risks that could adversely impact plant operation.

• Develops engineering solutions to repetitive failures and all other problems that adversely affect plant operations. These problems include capacity, quality, cost, or regulatory compliance issues. To fulfill this responsibility the Reliability Engineer applies:

• Data analysis techniques that can include:

• Lean Tools and Procedures
• Statistical Process Control
• Reliability modeling and prediction
• Fault Tree Analysis
• Weibull Tree Analysis

• Six Sigma (6σ) Methodology

• Root-cause and Root-Cause Failure Analysis (RCA, RCFA)

• Failure Reporting, Analysis and Corrective Action System (FRACAS)

• Works with Production to perform analyses of assets including:

• Asset Utilization
• Overall Equipment Effectiveness
• Remaining useful life

• Other parameters that define operating condition, reliability, and costs of assets

• Provides technical support to production, maintenance management and technical personnel.
• Applies value analysis to repair/replace, repair/redesign, and make/buy decisions.
• Develops Standard Operating Procedures (SOP) for methods and processes.
• Ensure any process changes meet ISO process requirements and are documented accurately.
• Champions asset upgrades and provides input in the calculations of the ROI for production equipment investments and capital expenditure requests.
• Other tasks as assigned.

• BSME, BSCHE, BSEE, BSIE or equivalent experience.
• 5+ years hands-on experience in heavy manufacturing industry, mechanical systems troubleshooting, design, fabrication, manufacturing, installation and operations.
• AutoCAD/Inventor experience.
• Solid knowledge base of manufacturing processes in an industrial manufacturing environment.
• Ability to effectively implement a change in a department through personal leadership with the support of department managers and plant leadership, without direct reporting responsibility.
• Strong project management skillset.
• Can conceptualize an ideal state and communicate it through the organization.
• Proactive, ability to think in an overall business and financial manner.
• Motivated self-starter who is able.
• Be able to work under pressure and as business needs change.
• High level of proficiency in Microsoft Office applications, AutoCAD, and statistical software.
• Proficient in technical writing.
• Self-disciplined and able to manage multiple tasks and priorities with minimal direct supervision.
• Additional experience desired: Metals recovery, smelting and converting; ferrous and non-ferrous metals selection and application; high temperature refractory and metals selection and application; large capacity air/gas/02 fired furnaces; CMMS and MP2 application, implementation, and utilization; SCAQMD, OSHA, NIOSH, Industrial Ventilation requirements, permitting, standards and regulations; ISO 9001, ISO 14001 & OHSAS 18000 awareness., * Safety & environmental training
• Operations familiarization training
• Quality system familiarization
• EMS ISO 14001 awareness, including plant EMS objectives and targets
• Significant environmental air aspects and impacts
• Plant JTE (lean manufacturing) initiative