What You'll Be DoingJob Scope: This role will work hand in hand with the operations, engineering, maintenance and asset management personnel to improve plant reliability. Through assessment of plant performance and maintenance data, the Maintenance & Reliability Engineer will develop and update preventative and predictive maintenance strategies to improve asset availability and minimize overall maintenance costs. Tools such as root cause failure analysis (RCFA), failure mode and effects analysis (FMEA), "Bad Actor" evaluations, risk-based inspection (RBI), reliability centered maintenance (RCM), lifespan/ probability of failure tools, predictive modeling tools and asset effectiveness data will be used to provide the information driving a long-term reliability plan. This role works closely with Operations, Engineering, Maintenance, and Asset Management to improve plant reliability. Reliability tools such as RCFA, FMEA, Bad Actor analysis, RBI, RCM, and predictive reliability modeling are used to develop and execute long term reliability strategies. The role works closely with site subject matter experts (pressure vessels, metallurgy, rotating equipment, IEC) and technology teams. The role is a shared resource across three chemical plants, including high hazard processes and a Tier 1 automotive supplier.
Primary responsibilities will include but are not limited to:- Actively reviewing predictive and preventative maintenance data and making recommendations regarding equipment inspection plans, frequency, corrective maintenance or capital improvements.
- Leading monthly reliability review meetings with the operations, maintenance and asset management teams and supporting the asset management team in proper selection and storage of spare parts for critical equipment.
- Working with site pressure vessel, rotating equipment and IEC engineers to review and revise Risk Based Inspection assessments, and making recommendations on inspection scope, intervals, repairs or capital investment as needed.
- Leading reliability-based root cause analysis investigations for the area and maintaining the unit's action item database.
- Revising the "Bad Actor" list, considering production loss, maintenance costs and related production/process cost in the assessment, and prioritizing and leading the most impactful Bad Actor reliably improvement projects.
- Developing a new Autonomous Maintenance (AM) plan to establish new AM activities such as Clean, Inspect & Lubricate (CILs) and When-Down-Do lists. This will include working closely with Operations resources to review and create lubrication routes and setup of a new lubrication bay.
- Leading and driving Preventative Maintenance Plan Optimization efforts within the assigned unit and driving improvements to equipment preventative and predictive maintenance plans by utilizing PM effectiveness data.
- Leading and/or participating in FMEAs for critical equipment as necessary and applying changes to equipment strategy documentation as a result of FMEA reviews as needed.
- Participating in capital project scope development and designing reviews related to reliability, modifications or improvements as necessary, advising project managers on appropriate changes on preventative maintenance and sparing strategies as needed and acting as a project manufacturing representative as appropriate.
- Supporting scope development and execution of turnaround work as needed.
- Communicating with the unit's asset owner to make updates to the long-term capital and major maintenance strategies and associated cost plans as needed.
- Supporting the maintenance teams in troubleshooting followed by scope development for reliability related equipment modifications. Participation in management of change process from resulting modifications.
- Working with Maintenance personnel to optimize planned maintenance activities, including further digitalization of PMs, that will simultaneously improve both records retention and "wrench time".
Ideal BackgroundEducation: Bachelor or Master of Science degree in Mechanical Engineering from an accredited university is required.
Certification: Professional Engineering registration is highly preferred.
Experience: This position requires 5 or more years of relevant industrial experience in reliability engineering.
Knowledge, Skills and Abilities Required: - Extensive experience in rotating machinery reliability (pumps, fans, compressors, conveyors, agitators, gearboxes, bearings, mechanical seals, couplings).
- Demonstrated success in the application of advanced reliability tools such RCM, RCA, RBI, FMEA, apportionment methods, etc.
- Extensive knowledge in the use and application of Predictive and Preventive Technologies (vibration, lubricant and fluid analysis, infrared, alignment, balancing, and other NDT technologies as it applies to rotating machinery and fixed equipment).
- Extensive experience with Computerized Maintenance Management Systems (CMMS) such as Maximo and SAP Maintenance Module.
- Knowledge and understanding of human factors in reliability.
- Ability to plan and schedule routine and shutdown maintenance activities.
- General understanding of corrosion mechanisms, prevention, and materials selection.
- Ability to maintain reliability program management over the entire equipment life cycle.
- Ability to accurately estimate completion of assigned tasks.
- Ability to develop design criteria and scope of work.
- Provide outage QA/QC support to ensure precision maintenance execution is adhered to.
- Proficient in the use of Microsoft Word, Excel and Outlook.
- Working knowledge of CAD software, either AutoCAD, Microstation or both.
- Excellent communication skills, both verbal and written.
- Virtual team skills and relationships are developed, and able to provide interoffice execution leadership and support.
Physical Requirements: - Ability to sit or stand for long periods of time.
- Ability to walk reasonable distances, potentially on uneven ground or catwalks, and ascend stairs.
- Ability to climb ladders and otherwise navigate through industrial/manufacturing settings and around equipment/installations.
- Ability to stoop, bend, crouch, kneel, and crawl.
- Ability to maneuver in confined spaces.
- Ability to reach with both arms.
- Ability to walk reasonable distances, potentially on uneven ground, and ascend stairs.
#LI-MR1
