Primary Functions: Oversee the management of equipment assets by identifying reliability risks, implementing strategies to improve equipment reliability and implementing Life Cycle Asset Management (LCAM).
Essential Responsibilities: To perform this job successfully, an individual must be able to perform these essential duties and responsibilities:
Manages the overall program for the comprehensive development, review and analysis of corrective and preventive maintenance activities utilizing risk assessment and condition-based maintenance methodologies. Work product includes formulation of continuous improvement strategies for asset preservation to support manufacturing, infrastructure and development activities. Responsible for managing direct reports for the gathering and interpretation of predictive technologies such as vibration analysis, oil analysis, infrared thermography, etc.. Recommends replacement strategy derived from collected data indicating equipment condition and operating efficiency. Responsible for developing and implementing asset life cycle management strategies for newly and modified installations. Develop engineering solutions to repetitive failures that affect safety, capacity, quality, cost and regulatory compliance. Works closely with Engineering and Operations utilizing data analysis techniques that can include:
- Statistical Process Control
- Reliability modeling and prediction
- Fault Tree Analysis
- Weibull Tree Analysis
- Six Sigma (6σ) Methodology
- Root-cause and Root-Cause Failure Analysis (RCA, RCFA)
- Failure Reporting, Analysis and Corrective Action System (FRACAS)
Serve as the site Mechanical Integrity Coordinator. Ensures direct reports and contractors comply with the current Mechanical Integrity program by performing routine audits and evaluations of present work practices, equipment data collection and training documentation compliance. Develop and recommend training programs which ensure regulatory compliance. Provides any applicable training as required to reflect revisions in operating procedures. Serves as point of contact for any OSHA inquiry regarding Mechanical integrity issues. Carry out supervisory responsibilities in accordance with the organization’s policies and applicable laws. Responsibilities include interviewing, hiring and training employees; planning, assigning and directing work; appraising performance; rewarding, developing and disciplining employees; addressing complaints and resolving issues.
Provide input to senior management concerning long and short term maintenance goals and strategies. Participate and/or facilitate Cause Map analyses as deemed appropriate. Ensures the effective execution of root cause and failure modes and effects analysis and the presentation of technical documentation and reports. Work closely with Operations, Engineering and Maintenance personnel to identify and solve repetitive equipment problems and failures and to provide technical support. Serve as technical resource for Plant Engineers, Production personnel and Maintenance personnel on all reliability issues. Offer reliability input (from the Maintenance perspective) prior to the specification and/or acquisition of new equipment. Develop updates and report monthly key reliability performance indicators. Work with Engineering and Maintenance personnel in scoping, planning and executing small projects. Perform other duties as required.
To competently perform this job, a candidate will need the education and experience generally obtained with a Bachelors of Science in Mechanical, Chemical or Electrical Engineering with 12-15 yrs of experience in an industrial maintenance setting. Specific expertise in maintenance best practices (e.g., reliability engineering, predictive technologies) is essential. A fundamental understanding of OSHA PSM is required.
The preferred level of competency could generally be obtained through the above with supervisory responsibility. Knowledge of cGMP or ISO regulations, especially in an active pharmaceutical ingredient (API) manufacturing setting are also preferred.
Special Training or Competence: Certification for Maintenance and Reliability Professionals (CMRP) or Certified
Reliability Engineer (CRE) certification preferred.
Physical Demands/Requirements: While performing the duties of this job, the employee is regularly required to stand; use hands to finger, handle, or feel; reach with hands and arms; sit and to talk, or hear. The employee is occasionally required to walk and stoop, or kneel, crouch. Specific vision abilities required by this job include close vision and ability to adjust focus.
The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made for persons with disabilities - evaluation to determine fitness will be made by company physician(s). While performing the duties of this job, the employee is:
Occasionally exposed to risk of electrical shock. Exposed to a noise level in the work environment that is (please describe): Noisy as a result of large equipment operating Occasionally exposed to various types of chemical substances. (MSDS information for review on an on-going basis).
Employee must comply with all applicable safety and security procedures:
Determine appropriate action beyond guidelines. Report potentially unsafe conditions.