Reliability Engineering Lead

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The Reliability Engineering Lead is responsible for improving asset reliability, maintenance effectiveness, and operational performance through data analysis, reliability engineering methodologies, maintenance strategy optimization, and continuous improvement initiatives. This role partners closely with Operations, Maintenance, Planning, Scheduling, Engineering, and Plant Leadership to reduce equipment failures, improve uptime, optimize maintenance costs, and support achievement of safety, quality, production, and financial objectives.

The Reliability Engineering Lead serves as the technical expert for asset reliability and drives sustainable improvements through Root Cause Analysis (RCA), Preventive Maintenance (PM) optimization, predictive maintenance technologies, failure elimination, and reliability work process implementation.

Reports to:

Maintenance & Reliability Leader

Location & Travel:
Role sits in the Kansas City Facility – ability to travel up to 40%.

• Develop and execute reliability improvement plans for critical assets.
• Identify and eliminate chronic equipment failures.
• Analyze reliability data to improve Mean Time Between Failure (MTBF).
• Recommend corrective actions to improve asset performance and lifecycle costs.
• Lead equipment criticality assessments and risk-based maintenance initiatives.
• Establish reliability standards and best practices across the plant.
• Develop and monitor reliability KPIs including, Asset Reliability (MTBF, MTTR etc.), Maintenance Effectiveness (PM Compliance, Planned & Reactive Maintenance etc.), Cost Metrics (Inventory Optimization, Emergency work cost etc.)

• Facilitate Root Cause Failure Analysis (RCFA) investigations.
• Lead problem-solving using structured methodologies (RCA,5-Why, Fishbone Analysis, Fault Tree Analysis, Weibull Analysis)
• Ensure corrective and preventive actions are implemented and verified for effectiveness.
• Track recurring failures and develop elimination strategies.

• Evaluate and optimize PM programs based on failure history and asset criticality.
• Drive conversion of time-based maintenance to condition-based maintenance where appropriate.
• Support usage of Predictive Maintenance technologies including:
• Vibration Analysis
• Infrared Thermography
• Ultrasound Monitoring
• Oil Analysis
• Monitor PM compliance and PM effectiveness metrics.

• Partner with Maintenance Planners to improve asset master data quality.
• Support development and optimization of:
• Maintenance Plans
• Task Lists
• Equipment Records
• Functional Locations
• Failure Coding
• Bill of Materials
• Analyze maintenance work order history and cost trends.
• Utilize SAP PM reporting and KPIs to identify improvement opportunities.

• Support implementation and sustainment of Reliability Work Processes (RWP).
• Ensure work management processes are followed consistently.
• Coach planners, supervisors, and operations personnel on reliability best practices.
• Conduct audits and assessments of maintenance process compliance.
• Drive PM Pillar and TPM initiatives.
• Develop maintenance strategies using:
• Reliability Centered Maintenance (RCM)
• Failure Modes and Effects Analysis (FMEA)
• Risk-Based Maintenance (RBM)
• Review new equipment designs and provide reliability input.
• Support commissioning and startup activities to ensure maintainability and reliability requirements are met

• Bachelor's Degree in an Engineering or related discipline.

• 5-10 years of maintenance, engineering, manufacturing, or reliability experience preferred.
• Experience in continuous-process manufacturing environments.
• Experience with SAP PM or similar CMMS systems.
• Experience leading reliability improvement initiatives.

• Certified Maintenance & Reliability Professional (CMRP)
• Certified Reliability Engineer (CRE)
• Lean Six Sigma Green Belt or Black Belt
• Vibration Analysis Certification
• Infrared Thermography Certification

• SAP PM / S4 Asset Management
• Power BI
• Excel Advanced Analytics
• Reliability Software Platforms
• Predictive Maintenance Technologies
• Strong facilitation and influencing skills.
• Ability to drive cross-functional alignment.
• Excellent presentation and communication skills.
• Strong organizational and project management capabilities.
• Ability to translate technical findings into business value.

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