Reliability Engineer

Ferrara•DeKalb, IL

30d

About The Position

The Reliability Engineer is responsible for supporting the factory to enable and deliver asset Maintenance according to the Ferrara Strategy (using TPM as the multi-disciplined approach to maintain/improve fixed assets, and AMM to manage their life cycle) with a goal of sustainable and long term low cost of production and high reliability, and not the immediate correction of daily losses. The Reliability Engineer is also responsible for partnering with the factory to establish a “Continuous Improvement and Zero Loss” culture in Maintenance, consistent with the principles of Lean and Reliability Centered Maintenance. The Reliability Engineer must actively champion the RCM program and initiatives. The position provides support and coaching within the factory in loss elimination, risk management and life cycle asset management (LCAM). Assist in Master plan & Skill development to transition to and sustain a proactive - planned maintenance program.

Requirements

Recognized skills in Engineering and Maintenance.
Knowledge, understanding, and passion for continuous improvement methodologies.
Knowledge and understanding of the cost drivers of Maintenance in manufacturing operations.
Good working knowledge of CMMS systems (SAP preferred) with the ability to mine and analyze data for trends/reports.
Analytical and problem solving skills
Excellent verbal and written communication skills to assure support of the multi-disciplined approach to maintain/improve fixed assets at all levels of Factory management, also to lead the transformation of the factory culture from reactive/breakdown to proactive/planned maintenance
The ability to interact professionally with a diverse group, including managers, technicians, operators and subject matter experts
Able to organize, coordinate, and direct users and teams
Able to interpret blue prints and machine manuals
Able to write maintenance related SOPs, PM schedules, Job plans, etc.
Good understanding of preventive and predictive maintenance tasks and their implementation
Excellent presentation skills
Project Engineering/Management
Associate or Bachelor’s Degree in Engineering (Maintenance & Reliability, Mechanical, Electrical, Process, Chemical or equivalent) preferred or equivalent work experience and relevant certifications (i.e., SMRP, CMRP).
Minimum 5 years experience in Engineering and/or Maintenance field with direct experience in leading and engaging technicians with equipment modifications and improvements. TPM experience, Maintenance Planning and/or supervision a plus.
This position also requires working knowledge of TPM-PM, Downtime Recording Systems and CMMS, and broad experience in multiple Engineering and/or Maintenance positions.
Willingness to embrace new technologies, analysis techniques, and lead improvements is also required.

Responsibilities

Define, propose, and monitor the Maintenance and Reliability plans and objectives in accordance with plant goals, objectives, KPIs, Maintenance initiatives, et
Validate results achieved in the program.
Monitor plant/equipment trends to ensure best possible operation and reduction of planned/unplanned downtime.
Propose and monitor key performance indicators in accordance with the Best Maintenance Practices.
Lead the factory to reduce technical stoppages in equipment or areas of common occurrence (priority given to areas of highest incidence or impact).
Ensure the systematic review of all line, processes, and utilities that are critical to the business and those where failure can have an unacceptable impact on safety, personnel safety, food safety, environment, or compliance with the law.
Encourage close teamwork between all functions (Maintenance, Operations, Quality Management, etc.)
Develop capability in and be able to coach and guide the use on the floor of Maintenance Continuous Improvement Tools such as BDA, X-Matrix, AMM, SAM, Tags, etc, as well as Reliability Centered Maintenance and Root Cause Analysis tools and techniques.
Insure the implementation of all repairs/modifications resulting from Gap assessments, plant audits, and notifications and loss improvement activities
Master the use of AMM to manage the technical stores, scheduled Work Orders, labor hour allocation, equipment Bill of Material (BOM), system reporting and data analysis, including coaching of users and development of capability.
Ensure that the job planning, material and services planning process is appropriate, accurate and effective.
Ensure that the equipment history, damage code and root cause analysis are completed correctly and analyzed regularly for trends.
Update/Optimize Reliability Engineering tools and guidelines, to minimize unplanned and Planned Downtime, ensure a common approach, administration, and training
Utilize external suppliers, experts, other factories and corporate team to ensure proper technical solutions are defined and implemented to eliminate root causes.
Facilitate the evolution/refinement of Maintenance activities to minimize planned and unplanned downtime (PM’s, changeovers, etc.).
Support implementation and sustainability of TPM-PM Pillar in the factory.
Participate in analyzing the factory R&M budget, drive value-added and sustainable improvements with the assistance of the Maintenance Manager and Facilities Manager.