Reliability Engineer

About the Role

The Mechanical Reliability Engineer will act in both a supervisory and staff capacity to promote and advance the Reliability program across the entire mill. The role involves using equipment failure analyses to overcome repetitive maintenance and repair problems to reduce maintenance costs, and using proactive, preventative, and predictive maintenance techniques to avoid and to detect equipment failures. The Mechanical Reliability Engineer reports to the Reliability Superintendent and supervises the Reliability Technicians and Lubrication Technicians.

Key Responsibilities

• Lead the reliability program to continuously improve equipment availability and reduce maintenance costs
• Serve as a tireless and enthusiastic champion of reliability and as an equipment reliability Subject Matter Expert (SME) for the site
• Assure predictive and preventive maintenance activities support the strategy and core values of the Maintenance Department and the corporation
• Manage the Pressure Vessel and Tank integrity program for the site, including inspection and repairs, working with the Engineering & Manufacturing Services (EMS) and local and State regulations
• Lead the lubrication program for the site, including vendor interface, oil sampling and analysis, thermography, inspections, route development, updates and reporting functions using the lubrication software
• Assure that an appropriate response is promptly enacted based on results from predictive failure analysis and condition monitoring processes
• Request measuring and testing equipment to keep the reliability programs current with the latest technological advances where those advances provide cost-effective upgrades
• Assure the Preventive Maintenance (PM) and Predictive Maintenance (PdM) routes and programs are implemented, audited, and improved on existing equipment and as equipment is added, removed, and improved
• Research and request formal training for maintenance and reliability personnel to increase their technical skill and knowledge
• Provide input for Key Process Indicators (KPIs) detailing all the results of the reliability programs activities on a weekly basis
• Ensure Design for Maintainability and Design for Reliability are implemented with purchasing, stores, and engineering throughout all project phases including procurement, vendor selection, spare part selection and stocking
• Develop and adopt standards that improve equipment reliability in areas such as Essential Care, OBC, ODR, PM, PdM, CM, RCFA, MRO, precision rebuilds, precision installations and work execution
• Continuously work with Maintenance and Operations to educate, promote, and support program buy-in throughout the mill
• Review modification drawings and specifications and direct the implementation of appropriate preventive maintenance actions
• Recommend innovative solutions to increase equipment and facility life and reduce maintenance costs through the analysis of repetitive equipment failures/breakdowns and predictive maintenance analysis reports
• Provide guidance and participation in the Reliability related Root Cause Failure Analysis (RCFA) process, ensuring follow-through, completion, and documentation of the RCFA Action Items
• Review and refine the PM process based on breakdown repair costs, down-time requirements, and production losses from individual pieces of equipment
• Submit recommendations and justification for capital expenditures that support and improve the Reliability Program
• Submit regular reports covering the overall program costs and benefits, the "finds" and improvements made, as well as the strategic way forward for the Reliability Program
• Direct the accumulation and maintenance of reliability records so that they are available to mill personnel digitally on-line
• Maintain awareness of advances at other sites that would be of benefit to adopt
• Serve as a leader and example for behavior and performance to all employees

Performance Metrics

• Mechanical PM/PdM route compliance
• Tank and Vessel inspections and repairs kept current and costs reduced
• Quality of failure analyses, root cause determination, and corrective/preventive actions
• Implementation of current best practice lubrication and inspection methods
• The impact of all reliability activities on the maintenance program as indicated by standardized KPIs (overall site vibration level, route compliance, equipment availability, lubrication cleanliness from sampling, etc.)
• The implementation of effective reliability and maintenance improvements associated with practice changes, equipment redesign, upgrades, and replacements

Collaboration & Advisory Responsibilities

Maintenance Department: Consult and advise on predictive maintenance techniques that could replace PM work tasks and enhance maintenance work. Provide training and leadership in the application and benefits of reliability techniques.

Maintenance Leadership: Advise on the generation, execution, and completion of work orders as indicated by preventive maintenance findings in terms of priority and impact. Advise on the continued education and skills development of the maintenance department and on the content of work indicated by preventive maintenance findings.

Maintenance Planner/Schedulers: Advise and consult regarding the specifics and priority of PdM generated work orders. Assist in formulating repair plans and Management of Change.

Engineering: Advise on the application of predictive maintenance techniques for the acquisition and improvement of equipment. Design out maintenance whenever possible.

Operations: Consult on the use of reliability techniques as they apply to the daily operations of the equipment (Essential Care, Condition Monitoring, etc.).

Mill Leadership: Report on the results attainable by the various preventive maintenance techniques and programs. Advise on the applicability of reliability-based programs on all aspects of mill operations.

Qualifications

• Preferred BS in Mechanical Engineering
• 2-5 years' experience in a manufacturing environment, preferably pulp & paper

Pay & Benefits

• Salary range: $87,000.00 - $145,000.00, depending on role, level, and location
• Short-term bonus incentive
• Health, dental, and vision insurance
• Flexible spending accounts or health savings accounts
• Retirement savings plans
• Life and disability insurance programs
• Paid sick leave as required by applicable state/local law
• 15 days of paid vacation
• 11 days of paid holidays, subject to annual change