Reliability Engineer - HROC - Lehigh Hanson

THE ROLE AND THE COMPANY

Heidelberg Materials provides the materials to build our future. Our future is sustainable. Our future is digital. And it goes way beyond cement, aggregates and ready-mixed concrete. Heidelberg Materials North America, previously known as Lehigh Hanson, operates more than 450 locations with approximately 9,000 employees in the U.S. and Canada.  

Heidelberg Materials seeks to future proof its cement operations with increased digitization and operational capability. The overarching goal is to centralize operations, and to achieve operational excellence. For this purpose, it is establishing the Heidelberg Materials Remote Optimization Center (HROC) in its headquarters in Irving, Texas.

As an HROC Reliability Engineer, you will be responsible for providing technical support and expertise in reliability engineering to multiple cement plants within a designated region. Based in a central location, you will collaborate closely with plant teams to improve equipment reliability, optimize maintenance strategies, and drive continuous improvement initiatives across the region. Occasional travel to the plant sites supported will be required.

What You’ll Get to Do

• Reliability Engineering: Develop and implement reliability engineering strategies and programs across multiple cement plants to improve equipment performance, increase uptime, and reduce maintenance costs. Apply reliability tools and methodologies to analyze data, identify failure modes, and implement preventive and predictive maintenance techniques.
• Equipment Performance Monitoring: Monitor equipment performance and health using all available condition monitoring systems in place (including vibration analysis, thermography, oil analysis, and other predictive maintenance technologies). Identify potential issues (with equipment or monitoring techniques), develop maintenance plans, and collaborate with plant teams to ensure equipment reliability and availability.
• Root Cause Analysis: Lead and facilitate root cause analysis investigations for equipment failures, reliability incidents, recurring issues, and facilitation of process/quality/production RCFAs. Identify underlying causes, develop corrective actions, and collaborate with cross-functional teams to implement sustainable solutions to improve equipment reliability and performance. Follow up and monitor the implementation of agreed to changes and improvements.
• Maintenance Optimization: Collaborate with plant maintenance teams to optimize maintenance strategies and practices, including preventive and predictive maintenance programs. Analyze maintenance data, evaluate equipment performance trends, and recommend improvements to increase efficiency and reduce downtime. Participate in the outage planning process by developing work packages and specific work schedules for projects or major repair work as required by the maintenance planner.
• Spare Parts Management: Develop and implement effective spare parts management strategies across the plants supported, ensuring identification and availability of critical spare parts, optimizing inventory levels, and minimizing costs.
• Reliability Reporting and Analysis: Prepare regular reports on equipment reliability, maintenance performance, and KPIs for regional and plant management review. Conduct data analysis to identify areas for improvement, track reliability trends, and provide recommendations for reliability enhancement initiatives. Develop and maintain an expert level of competence in using the CMMS and reporting systems.
• Training and Knowledge Sharing: Provide training and guidance to plant maintenance personnel on reliability engineering principles, techniques, and best practices. Share knowledge and lessons learned with plant teams to enhance their understanding and competency in reliability engineering.
• Continuous Improvement: Drive a culture of continuous improvement by actively seeking opportunities to enhance equipment reliability, maintenance practices, and overall plant performance. Initiate and lead improvement projects, collaborate with cross-functional teams, and implement best practices regionally.
• Support facilities in the implementation of Heidelberg Materials maintenance and reliability programs.

Essential Experience and Skills

• Bachelor's degree in Mechanical Engineering, Electrical Engineering, or a related field.
• Previous experience in reliability engineering within a heavy industrial or continuous manufacturing environment, preferably in cement production.
• Strong knowledge of reliability engineering principles, tools, and methodologies, including root cause analysis and condition-based maintenance.
• Proficiency in using condition monitoring techniques and predictive maintenance technologies.
• Familiarity with computerized maintenance management systems (CMMS) preferably SAP. Excellent analytical and problem-solving skills, with the ability to analyze complex equipment issues and implement effective solutions.
• Strong project management skills, with the ability to plan, prioritize, and execute multiple tasks concurrently in a remote support role.
• Excellent communication and interpersonal skills to collaborate effectively with plant teams and stakeholders remotely.
• Willingness to travel occasionally to the plant and corporate sites supported for inspections, meetings, and project implementation.

Proficiency in data analysis software and MS Office applications.

What We Have to Offer:

• Competitive base salary and participation in our annual incentive plan
• Competitive benefits program
• 401k retirement savings plan with an automatic company contribution as well as matching contributions

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