SCOPE:The Reliability Engineer is responsible for driving continuous improvements to equipment reliability by providing and coordinating technical support and implementing the reliability improvement processes for the facility. The primary role of the Reliability Engineer is to identify and manage asset reliability risks that could adversely affect plant or business operations. This candidate will have the goal of reducing the downtime and equipment failure risk levels to the business and will directly report to the Cold Mill - Engineering & Reliability Leader in the Cold Rolling - Business Unit.
The Reliability Engineer will provide expertise and leadership for key equipment assets ensuring reliability is maintained at the highest levels; and will drive for increased reliability of work processes, procedures and operating practices.
KEY RESPONSIBILITIES AND JOB DUTIES:- Assist in the development and implementation of a comprehensive Reliability Centered Maintenance strategy for the plant, based upon business needs.
- Provide support and leadership around Plant wide Business Continuity efforts to allow for the continued delivery of products and services at acceptable predefined levels following a disruptive event.
- Provide support and follow up with Business Unit resources to effectively track critical spares items (with zero on hand quantity) that make the plant wide Level 1 - Priority Spares list, and assist with developing mitigation plans to reduce exposures and risks around current assets in service.
- Identify and assist in the implementation of best practices related to reliability improvements across the site that continuously strive to achieve World Class levels.
- Guide efforts to ensure reliability and maintainability of equipment, processes, utilities, facilities and plant assets.
- Apply appropriate reliability tools to drive improvements, optimize costs, and improve asset effectiveness (i.e., Pareto Analysis, FMEA, Criticality Analysis, RCM, Reliability Roadmap, etc.).
- Monitor and compile Key Performance Indicators (KPIs) and Reliability metrics for proactive identification and resolution of reliability issues.
- Tracks production losses and abnormally high maintenance cost assets to find ways to reduce those losses or high costs through root cause analysis, data trending, and facilitates implementation.
- Lead Root Cause Failure Analysis (RCFAs) and corrective actions for complex and/or repetitive problems that lead to unplanned downtime events. Participate in reliability related incident investigations; prioritize action items, establish single point accountability (SPA) and follow-up on their implementation as part of maintaining the Plant wide RCA list.
- Identify, develop and help implement engineered improvements and solutions for chronic or repetitive issues.
- Improve overall plant reliability through PM effectiveness tracking, corrective work orders and PM process improvements through PM optimization efforts.
- Development of critical equipment list and critical spare parts inventory that fits into the LRPP (Logan Risk Prioritization Process) model as new assets and equipment are commissioned into the facility.
- Provides input to a risk management plan that will anticipate reliability-related and non-reliability related risks that could adversely impact plant operations.
- Support capital projects by supplying historical data, cost analysis, or other information related to reliability during scope development.
- Works with an Engineering / Cross-Functional Team to ensure the reliability and maintainability of owned assets.
- Participates in the development of design and installation specifications along with commissioning plans for new assets to ensure that reliability considerations are being included.
- Participates in the final check-out of new installations to assure adherence to functional specifications.
QUALIFICATIONS:- The candidate must possess the ability to effectively communicate with all levels of the organization in both written and oral form. Practices active listening. Communicates openly and shares information with others, as appropriate.
- He or she should also possess strong and advanced computer skills utilizing Microsoft Office products (Word, Excel, PowerPoint, Project, etc.) with demonstrated experience and good working knowledge with a Computerized Maintenance Management System (CMMS), preferably using TabWare or Octave Attune EAM. Experience using Microsoft Outlook software for email, calendar and work execution is also preferred. Drafting and CAD / 3D Modeling experience a plus.
- The passion to exist in a dynamic environment that has a continuous improvement focus.
- Having any of the following certifications is considered a plus: CMRP (Certified Maintenance Reliability Professional), CRL (Certified Reliability Leader), CRE (Certified Reliability Engineer), Six Sigma / Lean Manufacturing (i.e. White Belt, Yellow Belt, Green Belt, Brown Belt, Black Belt, etc.)
- Experience and demonstrated knowledge with predictive / preventative maintenance (PdM) technologies with the capability to effectively interpret results from data obtained using Vibration Analysis, Balancing, Infrared / Thermography, Ultrasound, Condition Monitoring, Oil Analysis, Lubrication Best Practices, Nondestructive Testing (NDT), Precision Alignment / Precision Maintenance, Motor Circuit Analysis, Failure Analysis and Motion Amplification Camera technology.
- Troubleshooting, root cause analysis, inspection and final acceptance testing experience desired.
- Ability to understand and clearly explain complicated concepts and processes.
- Proven ability to be an effective teacher and comfortable leading group discussion and presenting material in front of peers, teams and co-workers in a group or classroom setting.
- Be flexible and available to interact and connect with people at all levels in the organization.
- Be self-directed and highly motivated.
- Demonstrate proven organizational skills and ability to prioritize, while being detail oriented and able to meet deadlines.
- Display the ability to multi-task and be effective in a fast paced, dynamic environment.
- Proven ability to collaborate and work closely with cross-functional teams.
- Ability to effectively read and interpret drawings and blueprints.
- Bachelor's Degree in an Engineering discipline (preferably Mechanical or Electrical Engineering), with a preferred 5 years of relevant experience
- An understanding of best practices for maintenance processes; including, but not limited to Risk Based assessment, Total Productive Maintenance, Design for Reliability, Design for Operability, Design for Maintainability and Reliability Based Inspections is also an important asset for this position.
