Reliability Engineer
PQ Corporation

Job Info

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For almost 200 years, PQ Corporation has envisioned the future of performance materials, chemicals and catalysts through collaborative innovation, making products that touch all of us, every day.

• Cleaner Emissions - Our Catalysts and Refining Services products and solutions help companies produce vehicles with improved fuel efficiency and cleaner emissions.
• Safer Travels - We produce highly engineered Performance Materials that help make highways and airports safer for drivers, pedestrians, pilots and passengers
• Better Care - Our products are critical ingredients in consumer applications that help make teeth brighter and skin softer
• Carbon-Free - With inorganic and carbon-free products, we contribute to improving the sustainability of our planet.

We are a leading global provider of specialty catalysts, materials, chemicals, and services that enable environmental improvements, enhance consumer products, and increase personal safety.

PQ Corporation is searching for a Reliability Engineer to be based at our Joliet, IL; St. Louis, MO; or Chester, PA location.

The Performance Chemicals Reliability Engineer is responsible for leading the implementation of the operational reliability program and systems within the Performance Chemicals NA assets. This role will work with the plants to identity and implement maintenance and reliability processes, programs, techniques, practices and policies. The individual will work with the plant teams to ensure the training and processes are in place to manage the reliability program on a daily basis. Actively engaging with the manufacturing sites, utilizing the reliability tools and techniques to identify root causes to unplanned events, and identifying permanent solutions to extend time between failures, extend the life of the asset and improve plant productivity, throughput and quality. Provide Leadership for Root cause analysis and implementation of long-term engineering solutions to prevent reoccurrences, manage KPI's including Run Hours, Mean Time between Failure (MBTF) and Cost to repair of equipment and systems. Fixed and Variable Manufacturing Cost reduction initiatives as well as increased site throughput leading to additional business growth are the ultimate measures of success for this role. The position reports to the Americas Operations Manager.

Responsibilities:

• Guides efforts to ensure reliability and maintainability of equipment, processes, utilities, facilities, controls and safety/security systems.
• 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
• 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
    • 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 (OEE)
  • 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.
• 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.
• 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.
• Anticipates in the final checkout of new installations. This includes factory and site acceptance testing that will assure adherence to functional specifications.
• Provides input to a risk management plan that will anticipate reliability-related and non-reliability-related risks that could adversely impact plant operations
• Responsible for managing safe working behavior demonstrating a high regard for personal and team HSE performance
• Produce and implement the site reliability policies for all equipment and systems, working with the plants to ensure all planned routines are defined, and critical spares are available to allow the maintenance team to effectively complete tasks.
• Supply reliability monthly business reporting analysis trends and results.

Travel:

• This role requires the ability to travel away from the primary location ~50% of the time, depending on current assignments.

Minimum Education, Experience and Core Competency Requirements:

• Bachelor's Degree in engineering or other related field, with 5-8 years relevant experience in Maintenance and Reliability leadership.
• Demonstrated strong team leadership and team building skills which focus on informal influencing of others with data driven logic vs. formal organizational hierarchy
• Effective written and oral communication as well as presentation skills with all levels of the organization.
• Demonstrated ability to coach, mentor and motivate employees through interpersonal and lean techniques to achieve site and corporate goals or initiatives.
• Experience in leading technical resources in safely maintaining production and distribution assets to achieve high levels of productivity (OEE, On Stream Time, etc.)
• Strong analytical and problem solving skills which includes the ability to make simple, meaningful conclusions from complex technical data including determining the final financial benefits or gains
• Self-motivated and able to work independently and with minimal direction from the Director of Manufacturing
• Must be willing to develop a strong understanding of "lean manufacturing" concepts and have the aptitude to build a deep understanding and ability to apply these concepts through Continuous Improvement / Lean Manufacturing tools and techniques.
• Ability to handle multiple projects in a fast-paced environment.
• Working knowledge of budgets and financial statements for use in analysis and utilization of financial data.

 

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