Process Reliability Manager

Job Description

Job Description Summary

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

Achieve safety and health objectives.

Leads and is responsible for the execution of reliability excellence/maintenance program. Writes and maintains 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 different steps (group of activities)

Sets priorities and time parameters to accomplish tasks and projects

Coordinates efforts to implement plan

Optimizes Work Processes

Actively uses the practices, processes, and procedures within the operating model to get things done

Organizes people and activities for simple and complex processes in an effective way

Looks for opportunities to improve the way of working

Collaborates

Consistently fosters collaboration across the organization

Builds strong inclusive relationships across Business/Functions and levels

Inspires individuals and maximize team dynamics to achieve common goals.

Drives Engagement

Enables and empowers people to give their best

Makes the link between what drives people and the organizational goals

Makes each Sibelco employee feel that their contributions are important

Managing Change & Ambiguity

Stays composed and navigates through change effectively

Leads others to operate effectively in absence of clear structure and processes

Comfortable in making decisions and taking actions, even with incomplete information

Handles risk and uncertainty comfortably

(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.

Has an excellent working knowledge of the facilities maintenance subject area, knowledge of the workforce and supplier capabilities as well as an awareness of progressive developments within the industry.

Technical Skills

Experience w/ predictive maintenance technologies including, but not limited to, vibration analysis, oil analysis, infrared Thermography, ultra sound 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

Full-time