Job Summary/General Accountability
Reporting to the Maintenance Manager, the Reliability Engineer identifies and manages asset reliability risks that could adversely affect operation's ability to meet corporate and site objectives. This includes: leading the improvement of asset health/reliability performance, failure elimination initiatives, risk management and life cycle asset management in alignment with corporate Asset Reliability programs, site 3-year maintenance and reliability roadmap, and all other corporate policies and local SOP’s.
The Reliability Engineer is an experienced Reliability Specialist with at least 5 years of experience in a reliability, operational excellence and/or continuous improvement role applying proven best practices in an industrial environment. An Engineering degree is required. The Reliability Engineer is familiar with using a CMM system and MS Office tools and with applying Standard Operating Procedures in his/her work. The Reliability Engineer follows company policies, standards and guidelines as they apply to all activities.
The Reliability Engineer has good leadership, communication, analytical skills, works well in a team environment, is responsible and is open to change. The person is results oriented and quality driven.
The Reliability Engineer promotes and maintains a safe working environment through compliance with MLF’s Health and Safety Program. This includes Food Safety and Environmental compliance.
Dimensions and Responsibilities
- Develop solutions to repetitive failures and all other problems that adversely affect plant operations.
- Involved in the design and installation stages of projects for new assets and modification of existing assets.
- Review and resolve production losses and abnormally high Maintenance cost assets.
- Manage risk to the achievement of MLF’s strategic objectives in the areas of environmental health and safety, asset capability, food quality and production.
- Lead efforts to ensure reliability and maintainability of equipment, processes, utilities, facilities, controls and safety/security systems.
- Define, design, develop, monitor and refine maintenance strategies based on asset performance.
- Provide technical assistance to review equipment rebuilds and Supplier performance.
- Responsible for ranking the major physical assets in terms of criticality and risk to the organization.
- Provide input in the creation of corrective action plans.
- Review mean time to repair (MTTR) and mean time between failures (MTBF) results to identify and lead maintenance program/department improvements.
- Review plant history and other technical files to identify/resolve opportunities for improvement.
- Validate inputs into condition-based monitoring routes, load levels, and seed dates.
- Monitor the potential maintenance impact and/or opportunity of the production plan.
- Conduct lifecycle costing (LCC) analyses on new, problematic and aging assets.
- Work with stores to identify the best part/material solution for the application.
- Incorporate continuous improvement feedback into the planning strategy.
- Provide technical assistance as required for maintenance personnel in executing the work.
- Use work history when identifying asset reliability shortfalls.
- Apply the Bad Actor Report process to track significant issues.
- Apply value analysis to repair/replace, repair/redesign and make/buy decisions.
- Develop and manage the site's asset management strategy.
- Track, report an develop action plans to attain the asset management strategy's goals and objectives.
- Utilize the site’s 3 Year Plan in setting reliability improvement priorities.
- Identify knowledge gaps and future skill requirements.
- Research external references for current best practices and use to influence maintenance and reliability strategy.
- Work with Engineering to integrate Capital project changes into the PMs.
- Develop and maintain a formal preventive and predictive (PM/PdM) program for all key asset.
- Review 5% of the PM/PdM programs every quarter.
- Provide technical support, guidance and validation for all new PM/PdM tasks.
- Ensure that appropriate documents are updated when modifications occur.
- Following a modification apply a formal management of change (MOC) process, which includes a review of existing maintenance strategies.
- Asset risk and criticality rankings are reviewed every 5 years and whenever there is a significant change to the process or equipment performance requirements.
- Risk ranking is used to identify candidate assets for improvements and when designing, commissioning a new asset.
- Conduct failure mode and affect analysis (FMEA) and root cause failure analysis (RCFA).
- Condition monitoring and predictive technologies are used to collect and analyze patterns in equipment behavior in order to determine the onset of failure and end of life.
- Involved in the selection of new assets and responsible for developing a life cycle management strategy throughout its useful life.
- Develop asset hierarchies, maintenance plans and critical components defined before the commissioning of assets.
- Use Reliability-Availability-Maintainability (RAM) modeling to estimate the expected Reliability, Availability and Maintainability of assets.
- Use LCC algorithm for deciding between maintain, overhaul or replacing assets.
- Include Sanitation, RAM Analysis, Maintenance Plans, Spare parts and Salvage Value in the maintenance cost components considered within the LLC Model.
- Manage the Failure reporting, analysis and corrective action system (FRACAS).
- Develop strategies to improve asset performance and reliability.
- Use the Value Driver Tree methodology to identify value drivers.
- Generate Bad Actor Report/Analysis.
- Manage non-conformance reporting and post-mortem with follow-up action logs.
- Use SAP to understand spares related asset health issues.
- Participate in the Maintenance department’s continuous improvement and knowledge collection efforts.
- Support the Maintenance department's participation in the formal and standardized intra-company knowledge sharing process.
- Collect and track work identification KPIs related to the proactive maintenance program.