Senior Reliability Engineer

The Senior Reliability Engineer position is responsible for improving equipment reliability, asset performance, and long‑term equipment health across the facility. This role integrates engineering principles, data analytics, maintenance strategy, defect elimination, and predictive technologies to reduce failures, increase uptime, and lower total maintenance cost.

The Senior Reliability Engineer collaborates closely with Maintenance Planners, Schedulers, Area Technicians, Operations, Engineering, Outage Coordinators, Storeroom, and Leadership. The RE owns asset criticality, FMEA, RCA, PM optimization, PdM/CBM strategy, obsolescence management, and accuracy of CMMS/EAM master data.

• Asset Strategy/Criticality and Data Analysis

  • Develop and maintain asset criticality criteria and critical equipment lists.

  • Analyze equipment downtime, performance trends, and maintenance history for improvement opportunities.

  • Validate findings with technicians, operations, and leadership.

  • Ensure data updates flow into the CMMS and the Asset Health Register.

  • Support crew level problem solving and own action items.

• FMEA and Maintenance Strategy Development

  • Lead FMEA sessions and document failure modes, effects, controls, and risk priority numbers (RPNs).

  • Perform structured risk assessments and prioritize actions based on RPN and criticality.

  • Determine detectability methods (PdM/CBM, inspections, instrumentation) to eliminate or mitigate failures.

  • Translate findings into updates to PM tasks, CBM setpoints, job plans, and strategies.

• Reliability Centered Maintenance (RCM) and PM Optimization

  • Lead PM optimization cycles using FMEA, preventive task review, downtime data, and field feedback.

  • Ensure PM effectiveness by validating task value, frequency, inspection method, and labor requirements.

  • Administer and continuously improve the PM/PdM program and master calendar.

• Root Cause Analysis (RCA) and Defect Elimination

  • Lead RCAs for major events, repeat failures, and emerging chronic issues.

  • Develop engineered solutions, validate results, and ensure actions are implemented and closed.

  • Document standard corrective actions and support development of SOPs and diagnostic guides.

• Predictive Maintenance (PdM) and Condition-Based Monitoring (CBM)

  • Oversee PdM/CBM technology implementation and data review of (vibration, thermography, oil analysis, CBM sensors).

  • Review and PdM trend data in systems such as OSI Pision or IBA/PDA systems, able to confirm results with instrumentation and triggering follow‑up work and updating detection setpoints.

  • leverage CMMS system for data storage, trending, of PdM activity results.

• CMMS Data, Asset Health and Master Data Governance

  • Ensure accuracy of asset hierarchy, equipment records, and reliability‑related master data.

  • Maintain Asset Health Register with updated findings, PM changes, RCA outcomes, and risk scores.

  • Provide reliability KPIs, dashboards, and communication on leading/lagging indicators.

• Outage, Shutdown, and Capital Support

  • Provide engineering input to outage planning, scope development, and sequencing.

  • Participate in pre‑outage events to validate scope and identify risks.

  • Serve as reliability representative during new equipment design, installation, and commissioning.

  • Ensure life‑cycle cost, maintainability, and reliability design principles are included in new projects.

BASIC QUALIFICATIONS:

• Bachelor’s degree in Engineering from an accredited institution
• 3 years experience in a manufacturing environment
• 1 year experience in maintenance reliability systems
• 1 year project management experience
• Candidate must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.  Visa sponsorship is not available for this position.

PREFERRED QUALIFICATIONS:

• Prefer Mechanical or Electrical Engineering degree

• 3 years experience in maintenance reliability systems

• 3 year project management experience 

• 1 year continuous improvement experience