Reliability Engineer

Cargill (Philippines Philippines, Philippines) 6 days ago

The Reliability Engineer is responsible to achieve the plant reliability objectives and will include:

Deployment, execution, and results of the BU Equipment Maintenance Strategy (EMS).

Asset Health Evaluation Model (AHEM), Reliability Centered Maintenance (RCM), Root Cause Analysis (RCA), Predictive Maintenance and Preventive Maintenance program, and the Asset Management System (AMS):

  • To maintain asset integrity, improve plant reliability, performance efficiency and effectiveness, plant throughput
  • To minimize unscheduled/unplanned plant interruptions
  • To optimize costs

Asset Reliability

-         (a) Define and execute the site Equipment Maintenance Strategy (EMS) for all assets.
(b) To mitigate equipment failure risk relevant to the failure risk profile and impact to the plant operation

-         (a) Deploy RCM principles
(b) To be able to use the RCM methodology to determine the right maintenance requirements in case the BU Equipment Maintenance Strategy (EMS) require so.

-         (a) Manage and lead RCM with cross-functional disciplines.
(b) To determine function, capability, functional failure modes, probability of failure, clarify impact/severity and identify acceptable risk.

-         (a) Review repetitive failures and conduct inspections of the plant facilities. Manage and be the leader of the RCA process within Maintenance organisation, keep the initiative alive and train personnel.
(b) To develop improvement ideas, together with technicians and Maintenance Planner. To increase the capabilities inline with new technologies and to increase a culture focussed on solutions based on basic causes.

-         (a) Analyse bad actor list of the assets and facilitate solutions.
(b) To improve plant reliability, optimize plant throughput and reduce avoidable maintenance costs.

-         (a) Lead, organize and report downtime meetings.
(b) To increase the capabilities in line with new technologies and helps to develop a culture focussed on solutions

Asset Management Program / P(d)M Program  

-         (a) Take ownership of and lead / review the Criticality Assessment of all (new) assets. Based on the results, determine the functional failures and pro-active work (Predictive Maintenance (PdM) and Preventive Maintenance (PM) to prevent those from happening.
(b) To make sure each asset is monitored and maintained according to the right priority and criticality.

-         (a) Responsible for monitoring, improving and reporting Asset Health.
(b) Asset Health is an indicator for asset reliability of the plant. Good Asset Health results in a more reliable plant (less downtime, higher throughput), better efficiency of maintenance costs and results in doing less failure maintenance and doing more pro-active maintenance

-         (a) Coordinate all PdM contracts for agreed results.
(b) To measure and secure an upward trend of the Asset Health. To identify and implement opportunities for improvement of the Asset Health.

-         (a) Conduct/coordinate training in PdM technologies/issues for (new) personnel.
(b) To maintain the PdM process and personnel up to date.

-         (a) Communicate all P(d)M issues to the Maintenance Manager and being the team-leader for appropriate actions.
(b) To make sure management is informed and can follow up.

-         (a) Responsible for developing P(d)M plans/schedules for equipment that must be based on RCM methodology. Being the team-leader for technicians and the Maintenance Planner in the reliability process.
(b) To establish the required maintenance needed to preserve asset function.

-         (a) Responsible for updating and improving the P(d)M program and update current P(d)M plans/schedules in Asset Management System. Review the P(d)M program if there are changing conditions.
(b) To establish cycles of refinement and a sustainable reliability process.

-         (a) Report KPI’s monthly

(b) To trend improvements of assets on performance.

-         Production schedule requirements often affect the time available to implement corrective action.

-         Suppliers of services and goods of maintenance

-   Compliance with all business unit/facility policies and procedures related to safety, housekeeping, HACCP, and external legislations.

-   The timely execution of the recommended work

Critical Inventory optimization

-         (a) Responsible to identify critical spares
(b) To ensure the right critical spares are available when needed

-         (a) Identify pro-active work to preserve condition of critical spares
(b) To ensure critical spares are in good condition when needed.

Work execution and improvement process

-         a) Review of all new work order requests for planning and scheduling with the Planner.
(b) To investigate scope of work orders and prioritize work orders to be scheduled.

-         (a) Provide pro-active work (=PdM and PM) input to the scheduling function
(b) To enable scheduling of pro-active work.

-         (a) Evaluate completed work to identify the effectiveness and results.
(b) To refine future pro-active work and address required follow up work.

-         Identify what work needs to be done why, when, how and by which craft to prevent functional failure and ensure assets continue to perform as needed.

-         Monitoring, improving and reporting Asset Health.

-         Setting up, performing and managing the Criticality Assessment of all (new) assets.

-         Coordination of all PdM activities, converting identified discrepancies in actionable tasks.

-         Developing and improving P(d)M plans/schedules.

-         Managing and leading the RCM and RCFA process within Maintenance organisation, keeping initiative alive, training personnel.

-         Leading/reporting downtime meetings and reporting KPI

-         Pre-scheduling of pro-active work.

-         Weekly review of work order backlog with the Planner.

-         Change of equipment that have a significant influence on process/safety/environment/cost/budget

- Trained quality control inspector

- Execute site inspection/or act as Mechanical Quality Inspector as may deem necessary

- Execute CDT,SDT,EDT planning as may deem necessary

Required Qualifications

  • Bachelor’s degree in engineering or equivalent knowledge.
  • Good knowledge of Maintenance process and activities.
  • Advanced computer skills.
  • Extensive knowledge of Maintenance Management System
  • Minimum 5 years maintenance experience.
  • Fluent verbal and written English.
  • Understanding operating context of site assets / process systems
  • Working and practical knowledge applicable PdM technologies such as: Vibration Analysis, Oil Analysis, Infra Red, Ultra Sound, and Motor Circuit Evaluation
  • Working knowledge of Maintenance Management systems.
  • Conversant with RCA.
  • Conversant with RCM / FMEA.
  • Develop and conduct trainings/toolboxes (concerning P(d)M Maintenance).

Preferred Qualifications

  • Ability to organize, coordinate and accomplish multiple tasks.
  • Demonstrated ability to build and maintain effective working relationships internally and externally.
  • Strong communication and organizational skills.
  • Experience working with or establishing a team. Ability to be a team leader.
  • Demonstrated effective systematic problem solving skills.

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