Corporate Sr. Reliability Engineer

ASR Group is the world’s largest refiner and marketer of cane sugar, with an annual production capacity of more than 6 million tons of sugar. The company produces a full line of grocery, industrial, food service and specialty sweetener products. Across North America, ASR Group owns and operates six sugar refineries, located in Louisiana, New York, California, Maryland, Canada and Mexico. In the European Union, the company owns and operates sugar refineries in England, Portugal.  ASR Group also owns and operates mills in Mexico and Belize.  The company’s brand portfolio includes the leading brands Domino®, C&H®, Redpath®, Tate & Lyle®, Lyle’s® and Sidul®.

OVERVIEW

The role of the Corporate Senior Reliability Engineer (Sr. RE) is to identify and mitigate risks that could adversely affect plant or business operations. The Sr. RE provides leadership and technical expertise in support of asset management strategies and associated practices, to ensure maximum equipment reliability at minimum life cycle cost. This self-driven, self-motivated individual works equally well independently or as a part of a team. The Sr. RE must be capable of analyzing conditions, performing technical troubleshooting, and identifying the root cause(s). The Sr. RE must be capable of communicating and building consensus for solutions to issues. The Sr. RE assists in training and mentoring of mechanics in electrical, mechanical, hydraulic, and pneumatic maintenance and repair of assets. The Sr. RE is responsible for evaluating asset/equipment conditions using invasive and non-invasive practices/technologies to monitor equipment for early signs of deteriorating condition allowing for early prediction and failure analysis. They document and oversee mitigation and intervention of identified issues to ensure that the temporary/permanent resolution is planned, scheduled, and implemented.  This role is instrumental in driving consistency of best reliability practices across all of the manufacturing locations.

DETAILED ROLES & RESPONSIBILITIES

• Guides efforts to ensure reliability and maintainability of equipment, processes, utilities, facilities, mechanical, electrical, control, and safety/security systems.
• Defines, develops, administers, and refines the asset management plans, maintenance plans, and preventive/predictive maintenance programs.
• Reduces and improves maintenance work wherever feasible, assuring efficient and productive operation of processes and equipment. Protects and prolongs the economic life of assets at the lowest practical cost.
• Be proactive in addressing strategic long-term problems/issues affecting the organization.
• Be a team player that champions and leads the reliability process.
• Can communicate and build relationships with various functional, engineering, and business leaders to drive continuous improvement.
• A self-starter capable of managing multiple priorities with minimal oversight; working as a single entity with the ability to influence others to gain alignment.
• Supports the capital project process to ensure the reliability and maintainability of new and modified installations.
• Participates in the qualification and validation of capital installations to ensure adherence to functional specifications.
• Guides designs to ensure reliability and maintainability of equipment and processes.
• Participates in the design review of capital additions and changes to ensure full life cycle maintainability of equipment, utilities, and facilities.
• Participates in approval of all new installations, including those done by contractors, to ensure their maintainability and reliability follows life cycle costing methods.
• Supports the Asset Operating Plan that provides standardized processes and procedures for proper operation and operator care of production, utility, and auxiliary assets.
• Develops engineered solutions to mitigate repetitive failures and problems that adversely affect plant availability, performance, capacity, quality, cost, or regulatory compliance.
• Be competent with data analysis techniques that can include:
  • Statistical Process Control
  • OEE Overall Equipment Effectiveness
  • Reliability modeling and prediction
  • RCFA fault analysis techniques
  • Six Sigma (6σ) methodology
• Be competent in the implementation of Predictive/Maintenance Methods/Technologies that include:
  • Vibration Sampling and Analysis
  • Lubrication Sampling and Analysis
  • Thermography: Mechanical, Electrical
  • Ultrasonic Thickness, Ultrasonic Sound: Electrical, Mechanical, Air
  • Motor Circuit Analysis
  • Machine Alignment and Balancing
• Facilitate root-cause and root-cause failure analysis (RCA, RCFA).
• Support failure reporting; analysis and corrective actions systems.
• Maintains the Asset Maintenance Plans that define the maintenance practices for production, utility, and auxiliary assets. Including the development and optimization of the predictive and preventive maintenance programs for assets.
• Works with all levels of maintenance and operations obtaining owner approval prior to implementation and changes.
• Analyzes planned idleness of operating equipment to develop and improve PM/PdM schedules.
• Periodically compares PM/PdM frequencies to downtime reports and equipment histories to identify where frequencies require adjustment. Refines the frequencies on an “economic” basis to avoid “over maintenance”.
• Regularly review equipment failures. Determine what PM action might have been taken to prevent failure to protect against reoccurrence.
• Participates in the optimization of maintenance to maximize production capacity based upon analysis of preventive maintenance time needs, repair histories, inspection reports, etc.
• Develop standardization programs and processes, which influences new equipment purchases including construction, materials, equipment, and spare parts.
• Supports CMMS / ERP Plant Maintenance master data requirements, including asset hierarchies, construction of maintenance plans, utilization of work management processes, and drives consistent system utilization.

WORK EXPERIENCES

• Minimum of 10 years’ experience in reliability engineering related processes required
• Expertise in multiple areas of maintenance and reliability, material management, planning and scheduling, and CMMS / EAM / ERP optimization preferred
• Must understand the RCM process, failure mode identification, defect analysis, cause and effect analysis, loss elimination, determination of probability, and consequence of failures; along with the use of FMEA’s, RCFA decision logic, and writing tasks to mitigate identified failures required
• Experience required with belt conveyors, screw conveyors, bucket elevators and cranes, evaporators, condensers, heat exchangers, piping, pumps, motors, blowers, generators, gearboxes, rotary dryers, kilns, and vacuum pans required
• Demonstrated experience and skills within a food manufacturing environment preferred

EDUCATION REQUIREMENTS

• Bachelor's degree in a Mechanical Engineering, Electrical Engineering, or Systems Engineering field required
• Must have at least one certification in reliability: (CMRP, CRL, etc.), and be willing to continually pursue knowledge and certifications in reliability and predictive technologies.

CORE CAPABILITIES

• Must demonstrate knowledge of problem solving with demonstrated RCA facilitation skills.
• Must have strong mechanical and electrical knowledge.
• Have a solid knowledge of equipment assembly, installation, and repair.
• Must understand Asset Management, its various components and organization.
• Must understand condition monitoring principles, tools, and application.
• Ability to communicate/teach reliability best practices, condition monitoring, and precision methods.
• Excellent interpersonal and communication skills.
• Must be proficient with Microsoft Office products and SAP.

CORE COMPETENCIES

• Analytical Thinking & Decision Making – Identifies and understands trends and/or issues; connects data points through analysis to arrive at a logical conclusion.
• Business & Financial Acumen – Demonstrates knowledge and understanding of the financial, accounting, marketing and operational functions of our organization; interpreting and applying understanding of key financial indicators to make better corporate decisions.
• Effective Communication – Expresses ideas and information in a clear and concise manner by tailoring one's message to fit the interests and needs of the audience.
• Customer Orientation – Keeps internal and/or external customer(s) in mind at all times.  Strives to proactively address customer concerns and needs.  Assists business partners and customers to achieve their work goals via application of their own skills and knowledge; strives to provide consistent customer satisfaction.
• Establishes Trust – Gaining the confidence and faith of others by actions and words that promote being honest, forthcoming, integrious and vulnerable.
• Problem-Solving – Anticipates, evaluates, diagnoses, and resolves problems in a systematic and fact-based manner.
• Results Orientation & Accountability – Takes accountability, identifies, executes and drives actions to consistently achieve desired results.
• Teamwork & Collaboration – Creates a climate that fosters commitment to a common vision and shared values that promote cooperation and working together through trust and support of others.
• Adaptability/Flexibility – Maintaining effectiveness in varying environments and with different tasks, responsibilities and people.
• Continuous Improvement – Establishes methods and utilizes specialized techniques to monitor and improve performance of systems and processes.
• Self-Development – Seeks feedback on one’s strengths and weaknesses and initiates activities to increase or enhance their knowledge, skills, and proficiency in order to perform more effectively or enhance their career.

• Change Management – Achieves success through change: identifies opportunities for improvement and innovation, removes barriers and resistance, and enables behaviors that support desired outcomes.
• Develops Others – Plans for the growth of others, diligently addressing performance issues and conflicts, both at the individual and organizational level with the purpose of achieving results through the activities of other people.
• Strategic Mindset – Understands company's short and long-term priorities and aligns department priorities and behavior around achievement of those objectives.

LOCATION OF ROLE

• At one of the ASR US refinery locations (Baltimore, MD, Chalmette, LA, Yonkers, NY, or Crockett, CA)
• An average of 50% travel (primarily domestic with some international)

We are an equal opportunity employer. We do not discriminate on the basis of race, color, creed, religion, gender, sexual orientation, gender identity, age, national origin, disability, veteran status or any other category protected under federal, state, or local law.  All employment is decided on the basis of qualifications, merit, and business need.