MMM42 Reliability Engineer at FPC of Decatur

Position: Reliability Engineer

Reports: To: Maintenance Manager

Salary Range: $85K-$105K DOE

Position Overview:
The primary function of the role is to provide accurate and prioritized reliability engineering support to work in a safe and productive manner, while minimizing production losses and maintenance cost per shingle. 

Key Responsibilities: 

Root Cause Analysis and FMECA/RCM Support: 

• Lead training to utilize the Maximo-integrated, 5-Why RCA’s and Troubleshooting as a part of keeping the Mechanical, Electrical and Process FMECA/RCM alive to drive down highest Pareto valued production losses.

• Actively participate in the Corporate Weekly Reliability GoTo Meetings, training, webinars, SMRP, and Reliability Magazine subscriptions in order to keep up to date with reliability knowledge, techniques and methodologies and provide support for continued reliability improvements and development.
• Lead initiatives for corporate surveys, questionnaires and benchmarking as part of the Reliability Assessments.
• Utilize Prodac/Maximo interface, production loss and Maintenance cost data to lead Problem Solving / troubleshooting teams prioritized to generate the greatest value return.
• Develop and utilize a strong work relationship with the Maintenance and Operations employees to build the necessary disciplines for efficient and effective Running PdM and Shutdown PM plans that meet or exceed critical leading indicators.
• Prepare, organize and facilitate a shingle line FMECA/RCM, after detailed Pareto analysis of production losses associated with critical assets, for use in PM Optimization and corresponding Spare Parts strategy.
• Troubleshooting equipment, Design for Reliability, select and managing qualified contractors to precision-install and commission new equipment, monitor modifications, upgrades and critical parts required.
• Act as back up for the Inventory Coordinator and Planner/Scheduler during emergencies and for vacation, staying updated with the standardized format and disciplines required.
• Supporting, promoting and demonstrating the core values and leadership behaviors.
• Other highest valued reliability related responsibilities as may be assigned from time to time by the Manager.

Maximo Support: 

• Follow Corporate Reliability Engineering Roles Responsibilities and Expectations (RR&E’s)
• Provide necessary service support and training to Plant Maximo users, utilizing the Maximo Best Practices.
• Update Plant Numerical Criticality Ranking in accordance with standardized FMECA templates.
• Standardize the PM and PdM task format to align with failure modes of FMECA, transitioning to mostly condition-based inspections while aligning weekly Maximo resource requirements to plant resource availability.
• Develop and network PM’s and PdM’s from other plants to continuously improve safety, health, environment, quality, production efficiency, labor/material effectiveness, etc. to optimize critical asset Total Life Cycle Costs.
• “Pare down” on low critical ranked asset PMs to build thorough PM’s for “highly critical” assets, aligning PM’s and PdM inspections with asset Failure Modes developed from FMECA’s.
• Lead Co-Op Engineering Students as required to update drawings with standardized asset names and numbers linked into Maximo as part of the Plant Document Navigation Accelerator (DNA).
• Apply Best Practices and Lessons Learned from Plant Maximo experiences to contribute to continuously improve the Maximo preparation of new green field sites and other existing company plants.

Qualifications: 

• Completion of University degree in Engineering (preferably in Mechanical Engineering)
• 3 or more years of reliability experience in continuous process manufacturing environments.
• Familiar with condition monitoring tools such as: vibration analysis, Ultrasonic, lubrication, thermography, etc.
• Experience facilitating dozens of successful RCFA’s.
• Experience with: FMECA’s, PM recommendations associated with preventing most probable Failure Modes, Production loss analysis, failure mitigation strategies, Spare Parts optimization supporting the PM tasks, etc.
• Verbal and written fluency in English, effective presentation skills and ability to communicate well at all levels.
• Proficiency with building standardized PM’s & PdM’s within Maximo or similar CMMS, MS Office, AutoCAD, etc.
• Willing to travel on occasion to learn and share knowledge with other plant sites.
• Analytical skills with high level of accuracy and strong work ethic.
• Operational and supervisory experience is a plus.