PURPOSE OF POSITION

The Reliability Engineer plays one of the most important roles in a business, oversees monitoring of the equipment to prevent any failures that could impede business operations and potentially lead to downtime or a loss in profits. The goal is always the same: reduce maintenance costs as much as possible without interrupting business operations.

The primary role of the reliability engineer is to identify and manage asset reliability risks that could adversely affect plant or business operations. This broad primary role is divided into three smaller, more manageable roles: loss elimination, risk management and life cycle asset management (LCAM).

EDUCATION AND WORK EXPERIENCE

• BSEE or BSME or related discipline required from an accredited four-year tertiary institute.
• Experience with rotating equipment
• Experience in Predictive, and Preventative Maintenance and Reliability preferred.
• Experience in communicating and presenting data and technical concepts to audiences with varying backgrounds
• Experience with MS Office suite (Excel, Word, etc.)
• Degree in math/statistics or engineering

KNOWLEDGE, SKILLS AND ABILITIES

•    Must be self-driven and motivated to learn new data science skills with minimal supervision

•    Proficient in written and verbal communication skills

•    Willingness to adapt in order to thrive in a collaborative environment

•    Demonstrated quantitative analysis skills and proficiency in working with applications developers, IT, and other technical domains

•    Knowledge of various predictive technologies (i.e. vibration analysis, oil sampling, ultrasonic, thermograph

•    Ability to communicate well with all levels of the organization including technicians, engineers, contractors, and management

•    Ability to do moderate to heavy stair climbing (including vertical ladders), along with the ability to work above floor surfaces (heights)

RESPONSIBILITIES

• Works with project engineering to ensure the reliability and maintainability of new and modified installations. The reliability engineer is responsible for adhering to the life cycle asset management (LCAM) process throughout the entire life cycle of new assets.
• Participates in the development of design and installation specifications along with commissioning plans. Participates in the development of criteria for and evaluation of equipment and technical MRO suppliers and technical maintenance service providers. Develops acceptance tests and inspection criteria.
• Participates in the final check-out of new installations. This includes factory and site acceptance testing that will assure adherence to functional specifications.
• Guides efforts to ensure reliability and maintainability of equipment, processes, utilities, facilities, controls and safety/security systems.
• Professionally and systematically defines, designs, develops, monitors and refines an asset maintenance plan that includes:
•     Value-added preventive maintenance tasks
•     Effective utilization of predictive and other non-destructive testing methodologies designed to identify and isolate inherent reliability problems
• Provides input to a risk management plan that will anticipate reliability-related and non-reliability- related risks that could adversely impact plant operations.
• Develops engineering solutions to repetitive failures and all other problems that adversely affect plant operations. These problems include capacity, quality, cost or regulatory compliance issues. To fulfill this responsibility, the reliability engineer applies:
• Data analysis techniques that can include:
  • Statistical process control
  • Reliability modeling and prediction iii.   Fault tree analysis
  • Weibull analysis
  • Six Sigma (6σ) methodology

•      Root cause analysis (RCA) and root cause failure analysis (RCFA)
•      Failure reporting, analysis and corrective action system (FRACAS)
•      Works with Production to perform analyses of assets including:
•      Asset utilization
•     Overall equipment effectiveness c.   Remaining useful life
•     Other parameters that define operating condition, reliability and costs of assets
•     Provides technical support to production, maintenance management and technical personnel.
•     Applies value analysis to repair/replace, repair/redesign and make/buy decisions.
• Develop operational reliability measurements. Work with field service (including distributors or
  • 3^rd party service) to create and maintain site reliability and performance metrics
•      Test development and execution as well as ability to design/perform elemental engineering studies into failures to facilitate investigations and data-based decision making, choose appropriate level of testing required
•      Bridge from failures to design improvements
•      Assist or perform root cause failure analysis
•       Identify and suggest corrective action for process as well as equipment
•       Reliability on full product lifecycle; from corrective actions during design to corrective actions after fielding equipment.
•      Reliability mitigations through preventative maintenance
•      Economic modeling of reliability as well as assessing economic impact of corrective actions.
•     Compare alternatives with economic assessment
•      Reliability modeling at a system level
•      Consider impact of costs on recommended action plans for avoiding/correcting problems during design, or remedial action for correcting reliability problems on installed equipment
•      Work with suppliers to improve quality product and processes

Loss Elimination

One of the fundamental roles of the reliability engineer is to track the production losses and abnormally high maintenance cost assets, then find ways to reduce those losses or high costs.

These losses are prioritized to focus efforts on the largest/most critical opportunities. The reliability engineer (in full partnership with the operations team) develops a plan to eliminate or reduce the losses through root cause analysis, obtains approval of the plan and facilitates the implementation.

Risk Management

Another role of the reliability engineer is to manage risk to the achievement of an organization’s strategic objectives in the areas of environmental health and safety, asset capability, quality and production. Some tools used by a reliability engineer to identify and reduce risk include:

▪    PHA – Preliminary hazards analysis

▪    FMEA – Failure modes and effects analysis

▪    CA – Criticality analysis

▪    SFMEA – Simplified failure modes and effects analysis

▪    MI – Maintainability information

▪    FTA – Fault tree analysis

▪    ETA – Event tree analysis

Life Cycle Asset Management

Because 95 percent of the total cost of ownership (TCO) or life cycle cost (LCC) of an asset is determined before it is put into use. This reveals the need for the reliability engineer to be involved in the design and installation stages of projects for new assets and modification of existing assets.

 HEALTH & SAFETY

• Ensure that all health and safety at work statutory requirements and company policies are implemented within the Department including its respective work areas.  Through meetings, etc., maintains sufficient liaison with safety representatives.
• Responsible for ensuring necessary steps are taken to identify hazards and assess the risks arising from operations within your team.
• To provide and maintain safe systems of work.
• Establish and maintain a safe and healthy working environment.  Identifying and assessing the competence of subordinates, identifying training needs and arranging for training, provision of information and instruction to all associates employed in your area of responsibility.
• Establish and maintain consultation arrangements and procedures with Safety Manager.
• Ensure compliance with Company Safety Policy in areas under your control.
• Ensure that no team member is allowed to work in situations which may be hazardous.
• Ensure that risk assessments are carried out for all activities undertaken in your area of responsibility and properly recorded in accordance with Company Procedure.

COMPANY’S EXPECTATION OF EMPLOYEE

• Adhere to Company Policy and Procedures
• Act as a role model within and outside the Company
• Perform duties as workload necessitates
• Maintain a positive and respectful attitude
• Communicate regularly with Engineering Manager
• Demonstrate flexible and efficient time management and ability to prioritize workload
• Consistently report to work on time prepared to perform duties of position
• Meet FCP’s productivity KPIs.

HEALTH & SAFETY

• To provide and maintain safe systems of work within and by team.
• Ensure compliance with Company Safety Policy in areas under your control.
• Check for potential hazards and unsafe acts and to take corrective action.
• Ensure that protective clothing issued by the Company is worn as required.
• Ensure that no person can work in situations which may be hazardous.  In relatively non-hazardous
   areas certain employees may be permitted to work alone, if necessary, but arrangements must be
   made to ensure their well-being.
• Ensure the prompt evaluation and expedite the appropriate action on safety complaints and employee
  comments on health and safety at work.

• Ensure that FCP OHSAS and ISO9001 standards are adhere too.
• Adhere and support FCP Security Policies

SAFETY CONDUCT

Employees are reminded of their legal duties to co-operate with the company taking reasonable care of him or herself and any other person who might be affected by their acts or omissions.  In addition, employees are responsible to report to their employer any equipment defects, hazards or unsafe acts that might cause an accident and result in injury.