Senior Reliability Engineer: Asset Optimization & PM

Sr. Reliability Engineer

Position Summary:

As Sr. Reliability Engineer (RE) supporting our manufacturing client in Savannah, GA, you will identify and mitigate risks that could adversely affect plant or business operations. You will provide leadership and technical expertise in support of the asset management plan implementation and associated practices, to ensure maximum equipment reliability at minimum life cycle cost. You will assist in training and mentoring of mechanics in electrical, mechanical, hydraulic, and pneumatic maintenance and repair of assets.

You will evaluate asset/equipment conditions using invasive and non-invasive practices/technologies to monitor equipment for early signs of deteriorating condition; allowing for early prediction and failure analysis. You will document and oversee mitigation and intervention of identified issues to ensure that the temporary/permanent resolution is planned, scheduled, and implemented.

Essential Functions and Responsibilities:

• Guides efforts to ensure reliability and maintainability of equipment, processes, utilities, facilities, mechanical, electrical, control, and safety/security systems.
• Defines, develops, administers, and refines the asset management plan, maintenance plan, and preventive/predictive maintenance programs.
• Reduces and improves maintenance work wherever feasible; assuring efficient and productive operation of processes and equipment. Protect and prolong the economic life of assets at the lowest practical cost.
• Be proactive in addressing strategic long term problems/issues affecting the organization.
• Supports the capital project process to ensure the reliability and maintainability of new and modified installations.
  • Participates in the qualification and validation of capital installations to ensure adherence to functional specifications.
  • Guides designs to ensure reliability and maintainability of equipment and processes.
  • Participates in the design review of capital additions and changes to ensure full life cycle maintainability of equipment, utilities, and facilities.
  • Participates in approval of all new installations, including those done by contractors, to ensure their maintainability and reliability follows life cycle costing methods.
• Supports the Asset Operating Plan that provides standardized processes and procedures for proper operation and operator care of production, utility, and auxiliary assets.
• Develops engineered solutions to mitigate repetitive failures and problems that adversely affect plant availability, performance, capacity, quality, cost, or regulatory compliance.
• Facilitate root-cause and root-cause failure analysis (RCA, RCFA).
• Support failure reporting; analysis and corrective actions systems.
• Maintains the Asset Maintenance Plans that define the maintenance practices for production, utility, and auxiliary assets. Including the development and optimization of the predictive and preventive maintenance programs for assets.
  • Works with all levels of maintenance and operations obtaining owner approval prior to implementation and changes.
  • Analyzes planned idleness of operating equipment to develop and improve PM/PdM schedules.
  • Periodically compares PM/PdM frequencies to downtime reports and equipment histories to identify where frequencies require adjustment. Refining the frequencies on an "economic" basis to avoid "over maintenance".
• Regularly review equipment failures. Determine what PM action might have been taken to prevent failure in order to protect against reoccurrence.
• Participates in the optimization of maintenance to maximize production capacity based upon analysis of preventive maintenance time needs, repair histories, inspection reports, etc.
• Develop standardization programs, which influences new equipment purchases including construction, materials, equipment, and spare parts.

• Bachelor's degree in Engineering
• Minimum of 5 years' experience in reliability engineering related processes.
• Expertise in multiple areas of maintenance and reliability, material management, planning and scheduling, and CMMS / EAM / ERP optimization.
• Industry experience in food manufacturing
• Competent with data analysis techniques that can include:
  • Statistical Process Control
  • OEE Overall Equipment Effectiveness
  • Reliability modeling and prediction
  • RCFA fault analysis techniques
  • Six Sigma (6) methodology
• Competent in the implementation of Predictive/Maintenance Methods/Technologies that include:
  • Vibration Sampling and Analysis
  • Lubrication Sampling and Analysis
  • Thermography:
    Mechanical, Electrical
  • Ultrasonic Thickness, Ultrasonic Sound:
    Electrical, Mechanical, Air
  • Machine Alignment and Balancing
• Demonstrated effective communication skills and practices; experience with office and reliability productivity tools.
• Understanding of the RCM process, failure mode identification, defect analysis, cause and effect analysis, loss elimination, determination of probability, and consequence of failures; along with the use of FMEA, RCFA decision…