Sr. Operations Reliability Engineer

Roquette•Newark, NJ

1d•$120,365 - $162,900•Hybrid

About The Position

Roquette is a family-owned global leader in plant-based ingredients and a leading provider of pharmaceutical excipients. Want to help us make a difference? Using plant-based resources, we collaborate with our customers and partners to imagine and offer ingredients to better feed people and treat patients. Each of our ingredients responds to unique and essential needs, and they enable healthier lifestyles. The Role: We are looking for our next Packaging & Reliability Engineer, within our maintenance department. The role is a hybrid role. The Packaging Engineer will have a deep knowledge of packaging line equipment and systems and will drive continuous improvement efforts on packaging systems. The Reliability Engineer will have a good working knowledge of Plant safety, quality, maintenance, reliability, and work management best practices. The individual must be able to analyze data across multiple systems to identify opportunities and drive improvements to safety, quality, and plant assets. This person must have the organizational capability to network with various resources and teams across multiple functions (EHS, quality, operations, maintenance, engineering, technology, external vendors, etc.) and be able to communicate well across all levels (operators, mechanics, peers, manufacturing and business leadership, etc.). The Reliability Engineer will report to the Maintenance and Reliability Manager and shall serve as a backup for the Maintenance and Reliability Manager when needed. This position is located in Newark, DE. Compensation: The current salary range for this role is estimated to be $120,365 - $162,900 in addition, this position may also be eligible to earn performance-based incentive compensation. The specific compensation offered to a candidate will be influenced by a variety of factors including but not limited to skills, qualifications, experience, and location. What You’ll Do: Packaging Develop, justify and drive implementation of packaging upgrade projects to meet customer and business needs. Maintain expected GMP standards for packaging unit operations working with business, quality, regulatory, operations and MT key stakeholders. Working with equipment suppliers, site operations and MT develop packaging technology documentation as a reference for technology and equipment use for upgrade projects. Assist with early Front-End Loading (FEL) on packaging CapEx projects to include business case & scope development. Support detailed design, lead commissioning & start-up activities, RTO as appropriate. Work with HPS packaging engineer on the analysis of the HPS packaging product customer offering to include pack type vs. customer need, packaging cost and overall spend and develop proposals to optimize package type offering to provide required package quality, product stability, standardized presentation and optimized cost. Support the business and site quality functions on any product/packaging stability trials, studies or improvement initiatives. Develop knowledge and expertise in packaging technology and systems becoming the Subject Matter Export (SME). Support site operations and quality in packaging related critical customer complaints. Drive OEE performance measurement of packaging lines to enable improved overall production line performance and facility capacity debottlenecking and reduced operational cost. Reliability Maintain and serve as subject matter expert on plantwide utilities (Air compressors, Boiler, Moving equipment, etc,) Assist with maintenance department goals to implement Company Core Principles and Food Safety Guidelines. Provide technical expertise to analyze data to quantify impacts to site, prioritize bad actors, complete FMEA+ analysis and report metrics. Lead or participate in Root Cause Failure Analysis (RCFA) or incident investigations. Proactively network with other Company Engineering technical disciplines (e.g., Consultants for Materials, Engineering Mechanics, Instruments & Process Controls, Electrical and Energy), plant and business personnel, and suppliers and contractors to improve reliability and maintain equipment. Develop engineering solutions for chronic and sporadic equipment reliability problems and collaborate with technical, operations, and maintenance to implement solutions. Participate in capital project reviews with focus on maintainability, verification that installation plan meets OEM recommendations or basic installation practices, equipment life cycle costs, and documentation requirements. Excellent organizational skills and ability to sort through, verify relevance and accuracy, and file equipment documentation. Support maintenance personnel during equipment overhauls and outages. Develop and review maintenance procedures to ensure that maintenance and repairs are sustained. Analyze equipment failure data to identify patterns and trends. Conduct root cause analysis to determine the underlying cause of equipment problems/failures. Developing and implementing new maintenance procedures. Design and implement new procedures for monitoring and testing equipment. Find new technologies and processes that can improve equipment performance and reliability. Provide technical support to production, maintenance management and technical personnel. Apply value analysis to repair/replace, repair/redesign, and make/buy decisions. Analyze vibration and machine performance data and issue recommendations. Maintain equipment library including vendor information, drawings, history, and track of equipment spare parts inventory. Recommend alternatives for spare parts if not available. Provide technical information for field repair backed up with equipment history, vibration data, and process data intended for area maintenance. Review the Mechanical PM Defect Report and evaluate corrective actions. Communicate with vendors, suppliers, and manufacturers for equipment reliability support.

Requirements

B.S. degree in Engineering or equivalent (Mechanical, Chemical, Food, Industrial, Packaging, etc.)
Minimum of 5 years’ experience in a technical field with packaging responsibility, preferably in pharma, food manufacturing or consumer goods industry.
>10 years experience in a chemical/manufacturing plant (or related industry) with a focus on maintaining equipment, reliability, or PSM, preferably in a pharmaceutical or food manufacturing environment.
Experience in food/pharma manufacturing operations preferred.
Working knowledge of the National Electrical codes (NEC).
Knowledge of various predictive technologies (i.e. vibration analysis, oil sampling, ultra-sonics, thermography).
Analytical thinking: the ability to think critically and logically, as well as the ability to work with large sets of data and make sense of them.
Technical aptitude: a strong understanding of the systems, equipment, and processes at hand. This includes knowledge of the engineering principles and specific systems used.
Problem-solving: the ability to think creatively and come up with innovative solutions to complex problems.
Communication: the ability to explain technical concepts in a clear and understandable manner, as well as the ability to collaborate effectively with others.
Project management: the ability to manage multiple projects and tasks simultaneously and effectively including planning, scheduling, and organizing.
Data management skills: the ability to use statistical analysis tools as well as the ability to interpret and communicate the results of the analysis.
A continuous improvement mindset: identifying and implementing ways to continuously improve reliability.
Safety-conscious: the ability to identify potential hazards and take the necessary steps to mitigate them.
Excellent computer aptitude, communication and interpersonal skills.
Self-directed and self-motivated.
Solid written and oral communication skills.
Ability to work as a team member in a respectful manner in a diverse work environment.
Strong analytical skills with demonstrated ability to consistently solve problems in a decisive and efficient manner.
Demonstrates understanding of statistical analysis to be used for process improvement.
Demonstrates ability to lead root cause analyses and implement corrective actions to prevent recurrence.
Demonstrates understanding of quality control procedures,
Demonstrates expertise in processing equipment and plant utilities, or equivalent experience at a manufacturing plant.
Interpersonal skills for working in teams across functions.

Nice To Haves

Experience using and understanding of Enterprise Resource Planning (ERP) and software systems such as SAP®, FMEA+, database/SQL infrastructures, and document control a plus.
Six Sigma Greenbelt certified, experience with 5S, and understanding of lean principles a plus.

Responsibilities

Develop, justify and drive implementation of packaging upgrade projects to meet customer and business needs.
Maintain expected GMP standards for packaging unit operations working with business, quality, regulatory, operations and MT key stakeholders.
Working with equipment suppliers, site operations and MT develop packaging technology documentation as a reference for technology and equipment use for upgrade projects.
Assist with early Front-End Loading (FEL) on packaging CapEx projects to include business case & scope development.
Support detailed design, lead commissioning & start-up activities, RTO as appropriate.
Work with HPS packaging engineer on the analysis of the HPS packaging product customer offering to include pack type vs. customer need, packaging cost and overall spend and develop proposals to optimize package type offering to provide required package quality, product stability, standardized presentation and optimized cost.
Support the business and site quality functions on any product/packaging stability trials, studies or improvement initiatives.
Develop knowledge and expertise in packaging technology and systems becoming the Subject Matter Export (SME).
Support site operations and quality in packaging related critical customer complaints.
Drive OEE performance measurement of packaging lines to enable improved overall production line performance and facility capacity debottlenecking and reduced operational cost.
Maintain and serve as subject matter expert on plantwide utilities (Air compressors, Boiler, Moving equipment, etc,)
Assist with maintenance department goals to implement Company Core Principles and Food Safety Guidelines.
Provide technical expertise to analyze data to quantify impacts to site, prioritize bad actors, complete FMEA+ analysis and report metrics.
Lead or participate in Root Cause Failure Analysis (RCFA) or incident investigations.
Proactively network with other Company Engineering technical disciplines (e.g., Consultants for Materials, Engineering Mechanics, Instruments & Process Controls, Electrical and Energy), plant and business personnel, and suppliers and contractors to improve reliability and maintain equipment.
Develop engineering solutions for chronic and sporadic equipment reliability problems and collaborate with technical, operations, and maintenance to implement solutions.
Participate in capital project reviews with focus on maintainability, verification that installation plan meets OEM recommendations or basic installation practices, equipment life cycle costs, and documentation requirements.
Excellent organizational skills and ability to sort through, verify relevance and accuracy, and file equipment documentation.
Support maintenance personnel during equipment overhauls and outages.
Develop and review maintenance procedures to ensure that maintenance and repairs are sustained.
Analyze equipment failure data to identify patterns and trends.
Conduct root cause analysis to determine the underlying cause of equipment problems/failures.
Developing and implementing new maintenance procedures.
Design and implement new procedures for monitoring and testing equipment.
Find new technologies and processes that can improve equipment performance and reliability.
Provide technical support to production, maintenance management and technical personnel.
Apply value analysis to repair/replace, repair/redesign, and make/buy decisions.
Analyze vibration and machine performance data and issue recommendations.
Maintain equipment library including vendor information, drawings, history, and track of equipment spare parts inventory.
Recommend alternatives for spare parts if not available.
Provide technical information for field repair backed up with equipment history, vibration data, and process data intended for area maintenance.
Review the Mechanical PM Defect Report and evaluate corrective actions.
Communicate with vendors, suppliers, and manufacturers for equipment reliability support.