Sr Reliability Engineer

CSL•Kankakee, IL

1d•$108,000 - $128,000

About The Position

This position is responsible for the equipment reliability and maintenance strategy of utility and manufacturing equipment through continuous monitoring of equipment operational performance and implementing actions needed for improvement (Reliability-Centered Maintenance). Develops engineering solutions to repetitive failures and all other problems that adversely affect plant operations by applying data analysis techniques (statistical process control, reliability modeling and prediction, fault tree analysis, Six Sigma (6σ) methodology, etc.), root cause analysis (RCA), root cause failure analysis (RCFA), and failure reporting, analysis, and corrective action system (FRACAS).

Requirements

Bachelor’s degree in Engineering (Mechanical, Electrical, Chemical, or related discipline)
7+ years of maintenance and engineering experience within biopharmaceutical, pharmaceutical, or regulated manufacturing environments.
Strong background supporting GMP manufacturing operations (aseptic, fill/finish, bulk, fractionation, or utilities preferred).
Experience with reliability engineering, maintenance strategies, and CMMS systems
Experience with CMMS platforms (e.g., Maximo, SAP, TrackWise Digital).
Strong understanding of reliability engineering principles and asset management best practices.
Strong shop-floor leadership presence with the ability to make timely operational decisions.
Strong analytical and problem-solving skills.
Excellent communication abilities.
Technical Expertise in Asset Management
Data-Driven Decision Making
Change Leadership & Transformation
Cross-Cultural Collaboration
Commitment to CSL values, ethical behavior, inclusive teamwork, and modeling a positive, respectful culture.

Nice To Haves

Knowledge of Six Sigma/Lean principles is a plus.
Certified in Data Analysis (Preferred but not required).
Certified Maintenance & Reliability Professional (CMRP) (Preferred but not required).
Certified Reliability Engineer (CRE) (Preferred but not required).
Certified in Mechanical Integrity (API 510, 570, or 653 certification preferred).

Responsibilities

Serve as the reliability leader within the organization, mentoring and coaching junior engineers and technicians on best practices in equipment reliability and mechanical integrity.
Lead reliability improvement teams and collaborate with other departments (e.g., Operations, Maintenance, Engineering) to address equipment issues and improve overall plant reliability.
Use reliability engineering tools like Failure Modes and Effects Analysis (FMEA) and Root Cause Analysis (RCA) to analyze maintenance and integrity data trends
Promote a culture of reliability and continuous improvement through proactive leadership, problem-solving, and cross-departmental collaboration.
Develop, implement, and maintain comprehensive maintenance strategies and mechanical integrity (MI) plans for plant equipment, including pressure vessels, piping, and rotating equipment.
Continuously improve maintenance programs (PMs), Bill of Materials (BOMs), and spare parts inventories to ensure regulatory compliance.
Collaborate with engineering teams on equipment classification, SAP location hierarchy, asset information population, and acquisition of equipment manuals
Utilize advanced data analysis, statistical modeling, and machine learning algorithms to analyze equipment performance data and predict potential failures.
Develop predictive maintenance models to forecast equipment failures and implement proactive maintenance actions, minimizing unplanned downtime and extending equipment lifespan.
Identify and implement opportunities for reliability and mechanical integrity improvement to enhance equipment uptime and performance.
Develop Power BI dashboards to visualize reliability data and performance metrics, enabling better decision-making and communication of reliability improvements to stakeholders.
Oversee mechanical integrity programs to ensure the safe and reliable operation of pressure vessels, piping systems, and rotating equipment.
Implement and manage risk-based inspection (RBI) programs to ensure compliance with industry standards and regulatory requirements (API, ASME, OSHA).
Recommend and implement improvements to ensure the effectiveness of maintenance and mechanical integrity programs.
Ensure that all equipment meets mechanical integrity standards through regular inspections and the application of non-destructive testing (NDT) methods.
Ensure CMMS data integrity to support preventive, predictive, and condition-based maintenance processes, including mechanical integrity requirements.
Oversee maintenance planning processes and the evaluation of new predictive technologies.
Lead the application of predictive maintenance (PdM) technologies and non-destructive testing (NDT) methods to minimize downtime and ensure the structural integrity of critical assets.
Lead the application of predictive maintenance technologies to monitor and improve equipment reliability.
Oversee the use of the following technologies for condition monitoring: Vibration Analysis, Ultrasound Scanning, Infrared Scanning, Oil Analysis, Eddy Current, Liquid Penetrating Testing, Dynamic/Static Motor Current Testing
Use these tools to detect early signs of equipment degradation and take proactive maintenance actions to prevent unplanned downtime
Implement and manage condition-based monitoring programs using IoT and sensor-based technologies to monitor the health and mechanical integrity of critical assets.
Utilize real-time sensor data to detect early signs of equipment degradation and initiate proactive actions.
Lead the application of predictive maintenance technologies to monitor and improve equipment reliability and take proactive maintenance actions to prevent unplanned downtime.
Measure and report reliability and mechanical integrity performance metrics such as Mean Time Between Failures (MTBF), Mean Time to Repair (MTTR), equipment downtime, and maintenance costs.
Develop performance reports and Power BI dashboards to showcase improvements in maintenance and mechanical integrity practices.
Act as the Subject Matter Expert (SME) for internal and regulatory audits concerning equipment reliability, mechanical integrity, and maintenance.
Ensure compliance with mechanical integrity standards such as API 510, 570, 653, ASME, and OSHA.
Continuously enhance knowledge in biopharmaceutical industry best practices, mechanical integrity, and problem-solving techniques.
Promote CSL values: Customer Focus, Innovation, Integrity, Collaboration, and Superior Performance.
Ensure adherence to CSL Behring’s Safety Program, complying with OSHA and health and safety mandates, particularly in areas related to mechanical integrity.