Sr Engineer - Reliability

SunCoke Energy•East Chicago, IN

5d•Hybrid

About The Position

The Sr Engineer - Reliability will be responsible for analyzing equipment performance, failure trends, and downtime to identify reliability improvement opportunities. This role will lead various processes such as downtime reporting, Root Cause Failure Analysis (RCFA), and Management of Change (MOC). The engineer will establish and maintain asset criticality rankings, develop and optimize maintenance strategies, and ensure accurate data within the Computerized Maintenance Management System (CMMS). Additionally, the role involves driving continuous improvement initiatives, collaborating with cross-functional teams, and ensuring reliability activities align with safety, environmental, and regulatory requirements.

Requirements

Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Industrial Engineering, or related discipline
7+ years of experience in reliability engineering, maintenance engineering, or asset management
Strong working knowledge of reliability tools (RCFA, FMEA, Weibull analysis, Pareto analysis)
Experience working with CMMS systems (Maximo strongly preferred)
Strong analytical, problem-solving, and data interpretation skills

Nice To Haves

Certified Reliability Engineer (CRE), Certified Maintenance and Reliability Professional (CMRP), or equivalent certification
Experience in heavy manufacturing, process industries, or continuous operations
Familiarity with condition monitoring technologies (vibration, thermography, oil analysis)
Experience supporting multi-site operations or corporate reliability programs

Responsibilities

Analyze equipment performance, failure trends, and downtime to identify reliability improvement opportunities. Lead the downtime reporting process.
Lead Root Cause Failure Analysis (RCFA) process and develop corrective and preventive actions.
Lead the Management of Change (MOC) process and coordinate actions through to completion.
Establish and maintain asset criticality rankings to prioritize reliability efforts including the Mechanical Integrity Inspection and Repair program.
Develop and maintain relationships with Subject Matter Experts to support ongoing improvements (machinery, metallurgy, refractory, equipment, etc.).
Support reliability modeling, lifecycle cost analysis, and asset replacement strategies.
Develop, optimize, and sustain preventive, predictive, and condition-based maintenance strategies.
Lead Failure Modes and Effects Analysis (FMEA/FMECA) for critical assets.
Define maintenance task frequencies, job plans, and inspection standards adjusting Preventative Maintenance practices as appropriate.
Support transition from reactive to proactive and predictive maintenance practices.
Ensure accurate asset hierarchy, failure codes, and work order data to enable analysis.
Analyze CMMS data to track Key Performance Indicators (KPIs) such as Mean Time Between Failure (MTBF), Mean Time to Repair/Recovery (MTTR), availability, Reduction in repeat failures, unplanned downtime, lost production reporting by asset category, maintenance cost per unit of production, preventive and predictive maintenance effectiveness and equipment uptime.
Partner with maintenance planners and supervisors to improve work order quality and feedback.
Support continuous improvement of maintenance work processes within the CMMS.
Drive reliability-focused continuous improvement initiatives using Lean, Six Sigma, or similar methodologies.
Develop and maintain reliability standards, best practices, and engineering guidelines.
Support standardization across sites or asset classes, as applicable.
Partner with Operations to address operating practices that impact equipment reliability.
Support capital projects by providing reliability input during design, installation, and commissioning.
Provide technical guidance and mentoring to maintenance and operations personnel.
Ensure reliability activities align with safety, environmental, and regulatory requirements.
Identify and mitigate equipment-related risks that could impact personnel safety or production continuity.