Supports cement plant Maintenance and Production departments with problem solving and project execution in order to reduce down time, improve process and lower operating costs by effectively applying Reliability Engineering methods and predictive/preventive maintenance programs. Reports to the Maintenance Manager.
 
ESSENTIAL FUNCTIONS 
 

• Oversee the Plant Reliability including all Plant Utilities (Dust Collectors, Water, Plant Air), Implementation of Preventative Maintenance Activities (PMO), and all reliability task on both kiln lines (Vibration, Inspections, Tribology, Ultrasound, etc.)
• Lead and develop new Reliability Engineers including overseeing activities, supplying guidance, setting up training, and implementing new reliability techniques.
• Works closely with Planner and Procurement to ensure that all necessary inventories are established for spare parts and most common repair parts for critical equipment.
• Inspects and evaluates equipment and develops reliability centered maintenance programs.
• Works closely with Planner and Procurement to establish and maintain effective Bill of Materials (BOM) process in conjunction with maintenance program.
• Troubleshoots problems in the plant by studying and determining root causes of failures.

Implements corrective / preventive maintenance actions ensuring optimal reliability.

• Identifies, collects, analyzes, and manages various types of data to minimize failures and improve performance, and will use failure analysis and other types of root cause analysis in support of reliability.
• Develop a catalog database of prior RCA’s and develop SOP’s when needed. Develop database that is searchable and sharable with other plants to improve reliability.
• Implement a continuous improvement program in the Reliability Department to improve process/condition of plant utilizing 5-S strategy
• Establishes and manages the lubrication and oil analysis programs for all systems.
• Establishes and maintains preventative maintenance measures and documentation for all equipment.
• Maintains and modifies, as needed, the plant engineering systems and library.
• Manages projects including but not limited to project safety, scope development, budget, tracking/controlling, coordinating with internal resources as well as outside vendors.
• Assists with departmental budget development, maintenance reporting, and capital expenditure requests.
• Motivates and engages all levels of employees to assist in generating creative ways to drive continuous improvement and increased reliability.
• Must stay up to date with current industry equipment to advise on improvements that could be implemented within the facility.
• Fosters a culture of reliability. Develops and provides training to personnel so that they can support safety, equipment reliability, and process efficiency.
• Develop Annual Budget for Reliability including Dust Collector re-bag cycle, lubrication costs, and liner changeout plan.
• Oversee department with total of 4 salary positions, 2 inspectors, 6 lubrication techs, and 6 Dust Collector Attendants.
• Assist in other plant facilities when needed with Reliability tasks or training opportunities including the implementation of new technologies within the industry.
     

MINIMUM EDUCATION AND EXPERIENCE

• Bachelor of Science degree in Mechanical Engineering, Reliability Engineering or other related engineering field. 
• Related Master’s Degree preferred.
• Maintenance or Reliability Engineering internship or work experience preferred. 
• Previous experience working in manufacturing or industrial setting preferred.
• Experience in cement, lime or similar process strongly preferred

KNOWLEDGE, SKILLS AND ABILITIES

• Understands strategic management aspects of reliability engineering, its relationship to safety and quality, its impact on warranty programs, the consequences of failure, and the potential for liability.
• Understands reliability programs and how various engineering and operational systems must be integrated to achieve overall program goals and alignment with organizational goals. Will use risk analysis tools and techniques to evaluate equipment and system safety and efficiency issues.
• Ability to develop product and process reliability requirements using reliability and design techniques such as FMEA, fault tolerance, optimization, etc. 
• Ability to develop models to analyze and predict reliability performance using block diagrams, physics of failure, apportionment, dynamic reliability, and simulations.
• Ability to use probability and statistical tools to analyze equipment lifecycle, conduct testing, understand, and interpret appropriate statistical models.
• Ability to apply the principles of maintainability and availability over the lifecycle of the equipment, process, or system and will identify and support appropriate testing methods and maintenance activities.
• Knowledge of cement production process, instrumentation, process controls (PLC’s), motors, starters, and VFD’s preferred
• Knowledge of fluid systems (compressible and non-compressible), Vibration, Rotating
  equipment
• Extensive computer software knowledge required including proficiency in Microsoft Office (Excel, Word, PowerPoint, Access) and Autocad.  Experience with or ability to quickly learn Oracle and Project software.
• Project management skills
• Ability to work under tight deadlines and to research to resolve ambiguous information effectively
• Ability to direct, motivate and coach activities of others
• Ability to exercise sound judgment in problem solving
• Excellent work ethic – high standard of performance and production
• Ability to exercise independent decision-making, prioritize conflicting demands
• Ability to read, write and verbally communicate in the English language, communicate positively with employees, customers, and vendors at all levels
• Must understand and comply with Lockout/Tagout procedure and safety requirements

Cement Recruiter operated by Harpe & Associates, Inc., is a high performing Recruiter with over thirty years recruiting experience for the heavy industrial manufacturing sectors of cement, lime, aggregates, minerals, metals and commercial construction.  How can I help you today?

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