Sr. Reliability Engineer

CSL•Kankakee, IL

2d•$108,000 - $128,000

About The Position

The Sr. Reliability Engineer is responsible for the reliability and maintenance strategy of utility and manufacturing equipment. The role monitors equipment performance and implements reliability-centered maintenance improvements, using data analysis, reliability modeling, failure analysis, and corrective-action methods to resolve recurring failures and other issues affecting plant operations. As the organization’s equipment reliability leader, this position mentors junior engineers and technicians, leads improvement teams, and collaborates across Operations, Maintenance, and Engineering. It develops and maintains maintenance strategies and mechanical integrity plans for plant equipment, improves preventive maintenance programs and asset data, and applies analytics and predictive technologies to reduce unplanned downtime and extend equipment life. The position oversees mechanical integrity and risk-based inspection programs for pressure vessels, piping, and rotating equipment; supports compliance with applicable industry and regulatory standards; and maintains CMMS data integrity. It also manages condition-based asset monitoring, reliability KPIs, reporting, and Power BI dashboards, and serves as a subject matter expert for internal and regulatory audits. The role promotes continuous improvement and adherence to CSL values and safety requirements.

Requirements

Bachelor’s degree in Engineering (Mechanical, Electrical, Chemical, or a related discipline).
At least 7 years of maintenance and engineering experience in biopharmaceutical, pharmaceutical, or regulated manufacturing environments.
Strong background supporting GMP manufacturing operations.
Experience with reliability engineering, maintenance strategies, and CMMS systems.
Experience with CMMS platforms such as Maximo, SAP, or TrackWise Digital.
Strong understanding of reliability engineering principles and asset management best practices.
Strong shop-floor leadership presence and ability to make timely operational decisions.
Strong analytical and problem-solving skills.
Excellent communication abilities.
Technical expertise in asset management.
Data-driven decision-making capability.
Change leadership and transformation capability.
Cross-cultural collaboration skills.
Commitment to CSL values, ethical behavior, inclusive teamwork, and modeling a positive, respectful culture.

Nice To Haves

Experience in aseptic, fill/finish, bulk, fractionation, or utilities manufacturing operations.
Knowledge of Six Sigma or Lean principles.
Certification in Data Analysis.
Certified Maintenance & Reliability Professional (CMRP) certification.
Certified Reliability Engineer (CRE) certification.
Mechanical integrity certification, such as API 510, 570, or 653.

Responsibilities

Serve as the reliability leader, mentoring and coaching junior engineers and technicians on equipment reliability and mechanical integrity best practices.
Lead reliability improvement teams and collaborate with Operations, Maintenance, Engineering, and other departments to address equipment issues and improve plant reliability.
Use reliability tools, including FMEA and RCA, to analyze maintenance and mechanical integrity data trends.
Promote reliability and continuous improvement through leadership, problem-solving, and cross-departmental collaboration.
Develop, implement, and maintain maintenance strategies and mechanical integrity plans for pressure vessels, piping, and rotating equipment.
Improve preventive maintenance programs, Bills of Materials, and spare-parts inventories to support regulatory compliance.
Collaborate on equipment classification, SAP location hierarchy, asset information population, and acquisition of equipment manuals.
Analyze equipment performance data using advanced data analysis, statistical modeling, and machine learning to predict potential failures.
Develop predictive maintenance models and implement proactive actions to minimize unplanned downtime and extend equipment lifespan.
Identify and implement reliability and mechanical integrity improvements to enhance equipment uptime and performance.
Develop Power BI dashboards to visualize reliability data and performance metrics for stakeholders.
Oversee mechanical integrity programs for the safe and reliable operation of pressure vessels, piping systems, and rotating equipment.
Implement and manage risk-based inspection programs in compliance with industry standards and regulatory requirements.
Recommend and implement improvements to maintenance and mechanical integrity programs.
Ensure equipment meets mechanical integrity standards through regular inspections and non-destructive testing methods.
Maintain CMMS data integrity to support preventive, predictive, condition-based maintenance, and mechanical integrity processes.
Oversee maintenance planning and evaluation of new predictive technologies.
Lead application of predictive maintenance technologies and non-destructive testing to minimize downtime and protect critical assets.
Oversee condition-monitoring technologies including vibration analysis, ultrasound scanning, infrared scanning, oil analysis, eddy current, liquid penetrating testing, and dynamic/static motor current testing.
Use monitoring tools to detect early equipment degradation and initiate proactive maintenance actions.
Implement and manage IoT- and sensor-based condition monitoring for critical asset health and mechanical integrity.
Use real-time sensor data to detect equipment degradation and initiate proactive actions.
Measure and report reliability and mechanical integrity metrics, including MTBF, MTTR, equipment downtime, and maintenance costs.
Develop performance reports and Power BI dashboards showing maintenance and mechanical integrity improvements.
Act as the subject matter expert for internal and regulatory audits concerning equipment reliability, mechanical integrity, and maintenance.
Ensure compliance with API 510, 570, and 653, ASME, OSHA, and other applicable mechanical integrity standards.
Continuously develop knowledge of biopharmaceutical 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 and applicable OSHA and health and safety mandates.