Process Reliability Manager

Process Reliability Manager • Strategic Materials Inc • Durham, NC, US Job Description

The Reliability Engineer will work closely with Sibelco plant maintenance, production and leadership teams to develop and utilize effective tools and systems for measuring reliability of our production process. This position is responsible for providing engineering support for maintenance planning/supervision, operation and maintenance of Sibelco North America Processing plants, developing and implementing programmatic methods to ensure safe operation and high equipment reliability/availability, cost effective maintenance, and continuous improvement culture. This role includes applying lean maintenance strategies and predictive technologies while optimizing a system’s operational performance, life cycle cost, and payback. This role will act as primary liaison for capital projects with the Capital implementation team for all cluster plants. Responsibilities

Safety

— Maintain and promote a safe working environment for all employees. Project Management/Improvement

— Lead and be responsible for the execution of reliability excellence/maintenance program. Write and maintain reliability maintenance strategy documents. Work with Maintenance Planners/Supervisors to implement Lean manufacturing tools to empower employees and facilitate growth to improve financial performance. Responsible for ranking the criticality of the assets under their care, typically using Reliability Centered Maintenance approaches, and for defining the proactive maintenance approaches that are cost-beneficial to the business. Identifies and implements predictive maintenance technologies. Manages predictive maintenance equipment. Performs/supports operational event and equipment failure investigations to ensure that the root cause/causal factors have been identified, corrective actions prescribed, and follow-up monitoring conducted as applicable, to determine effectiveness. Conducts program and system/equipment audits on a periodic and as needed basis. Audits will generally be focused on safety, risk analysis, regulatory compliance, maintenance effectiveness, cost savings, and energy conservation. Participates in the planning, design review, value management and construction document development of new facilities and renovations. Supports utility distribution, master planning, and business continuity planning. Supports commissioning activities for all upgrade, renovation, and construction projects which may include, but is not limited to, PM job plans, reviews for maintainability, critical spares, documentation, etc. Analysis and KPI Reporting

— Develop and maintain new “Key Performance Indicators" of equipment reliability. Lead in maintenance improvement tools (PM Optimization, RCM, RCA, RCFA, FMEA, etc.) and knowledgeable in predictive maintenance tools. Maintain a high level of technical competency in advanced maintenance technology. Maintain equipment repair history and evaluate repair costs & trends. Analyze equipment failure data patterns and interpret ERP PM maintenance data to generate priorities and action lists for improving reliability of site. Track the performance of reliability improvements to determine their effectiveness and make additional modifications if required. By working closely with the local Maintenance Teams, use intervals for potential failures to appropriately prioritize, plan, and schedule to minimize downtime. Develop solutions to repetitive, chronic, or costly failures and other maintenance problems, and apply value analysis to repair/replace, repair/redesign, and make/buy decisions. Assist in troubleshooting techniques for major/repetitive equipment. Advise the Maintenance Supervisors/Managers of any problems or potential problems which affect the ability of the operation to produce in a safe and efficient manner. Monitor and report on all relevant maintenance activity KPI’s including wrench time analysis. Perform other duties as assigned. Competencies

(Reference : Sibelco (Leadership) Competency Model) Decision Making

— Defines and frames situations clearly, identifies potential root causes and makes timely recommendations and decisions based on accurate and reliable analysis. Planning & Prioritizing

— Accurately determines the complexity of tasks and projects and required resources; breaks down projects or assignments into steps; sets priorities and time parameters; coordinates efforts to implement plan. Optimizes Work Processes

— Actively uses practices, processes, and procedures within the operating model; organizes people and activities for simple and complex processes; looks for opportunities to improve the way of working. Collaborates

— Consistently fosters collaboration across the organization; builds inclusive relationships across Business/Functions and levels; inspires individuals and maximizes team dynamics to achieve common goals. Drives Engagement

— Enables and empowers people to give their best; links what drives people to organizational goals; makes each employee feel their contributions are important. Managing Change & Ambiguity

— Stays composed and navigates through change effectively; leads others in absence of clear structure; comfortable making decisions with incomplete information; handles risk and uncertainty. (Technical) Capabilities Industry knowledge Comprehensive understanding of glass processing equipment and processes Engineering skills Practical knowledge of engineering principles applied to design, operation and maintenance of building structures and mechanical and electrical equipment for buildings; knowledge of facilities maintenance subject area and progressive industry developments. Technical Skills Experience w/ predictive maintenance technologies including vibration analysis, oil analysis, infrared Thermography, ultrasound and motor current analysis. Experience w/ Root Cause Failure Analysis, Equipment Criticality Ranking, Preventive Maintenance (PM) and Condition Based Maintenance (CBM). Behavioral skills Open minded Team player Pro-active Able to work independently Diplomatic Self-motivated Educational Background and prior professional experience Language requirements Minimum 10-15 years engineering/industrial maintenance experience, including experience with mechanical design/testing, international quality standards. Minimum 5 years utility systems/management and/or facilities/plant management and maintenance. Experience in the Glass industry is preferred. Certified Plant Engineer or Certified Maintenance Reliability Professional is preferred. English – proficient verbal & writing

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