Lead Mechanical Engineer Reliability

Job Purpose Provide reliability engineering expertise and support for assigned static machinery; identify reliability requirements for plant assets, establish an adequate reliability program to ensure asset optimization; utilize plant/equipment failure data and carry out timely analysis in order to identify the root causes of failures to facilitate recommendation and execution of corrective and preventive actions to improve reliability and availability of the plant in order to enhance long term efficiency, productivity, and uninterrupted and efficient operations of the assigned company assets, in line with defined industrial standards and company's quality policies and procedures.

Key Accountabilities

Supervision

Organize and supervise the activities and work of service providers to ensure that all work within a specific area of the reliability activity is carried out in an efficient manner which is consistent with operating procedures and policy.Budgets and Plans

Monitor the financial performance of a given area of activity versus budgets so that areas of unsatisfactory performance are identified and rectified promptly, and potential performance improvement opportunities are capitalized upon.Process Control Engineering

Develop and implement an effective machinery reliability management system for assigned asset type to monitor performance of major static machineries in order to improve reliability, availability of plant facilities. Conduct Reliability and Performance Analysis, Root Cause Failure Analysis; provide troubleshooting and engineering support and facilitate equipment failure investigations. Coordinate with Maintenance to improve maintenance programs and enhance plant major static equipment reliability and performance. Develop and implement machinery reliability and performance management programs such as development of scorecards to identify "bad actors" and tracking of shortfalls in equipment/system performance using SAP/CMMS systems. Ensure the adequate frequency of the scheduled major machinery reliability management programs in view of historical data on reliability and performance of static equipment malfunctions. Prepare detailed machinery reliability and performance monitoring check lists, and estimated man-hour and job requirements. Monitor and oversee the execution of machinery reliability management programs and activities as per defined guidelines. Review any machinery engineering project plans and drawings and provide technical advice and assistance and make recommendations based upon machinery reliability and performance data and needs. Ensure systematic and consistent implementation of work methods and procedures used in machinery reliability management and engineering and recommends improvements. Receive, investigate, and resolve complaints related to performance or reliability of major static machinery units. Evaluate innovative technologies, identify opportunities for improvement and recommend changes/upgrades to maximize reliability of plant major static equipment. Identify and recommend requirements for specialized contractor work. Monitor the quality and performance of the machinery reliability and performance management system against the KPIs and ensure continuous improvement of reliability management services. Carry out detailed data collection, analysis of data and root cause analysis, study for repeated failure incidents of various plant assets. Work with Operation operators, Maintenance Coordinators, and the Engineering Services Department personnel to identify the root causes of problems; establish equipment improvement projects and technical databases, data collection programs, data collection and data analysis routines. Ensure that failure data are properly recorded, monitored, and collected and analyzed to determine root causes. Analyze the reliability of the plant equipment by using high technology diagnostics techniques and also techniques based on probability, analysis or other analytical techniques which can be applied effectively to the analysis of outages of assets requiring maintenance. Analyze and identify human factors in reliability, availability, and maintainability assessment to ensure quality throughout minimize Operation cost, avoid problems/losses, meet legal requirements and industrial relations, and avoid sickness, absence and staff turnover. Participate in meetings related to equipment, unit general shutdown and makes recommendations as requested by Operation or Maintenance personnel on new techniques to result in improved reliability of equipment. Participate in the engineering studies related to modifications and project to incorporate reliability requirements and during inspections for safety and integrity assessment studies for the critical assets. Optimize and develop preventive maintenance programs for quality plant equipment for assigned specialism by incorporating applicable preventive maintenance tasks and effective maintenance intervals into the companys maintenance program. Communicate with vendors to find cost effective/optimum solutions regarding technological upgrades, obsolescence of equipment and issues related to the operation of equipment away from design data. Follow up and update incident reports issued by Operations and propose solutions of individual repeated incidents in the form of reliability report. Review and update the quality control methods for Operations Office group (Operation and Maintenance) when needed. Prepare training programs and propose materials for line staff to improve the quality of Technical Groups Activity. Conduct optimization studies related to spare parts management, lubrication management, maintenance procedure, utilization of inherent capacity of plant assets and utilization of precision data/tools for maintenance.Continuous Improvement

Contribute to the identification of opportunities for continuous improvement of systems, processes and practices taking into account global best practices", improvement of business processes, cost reduction and productivity improvement.System Administration

Supervise the effective administration of SAP processes within the assigned process engineering unit and adherence to SAP guidelines in all related aspects of annual and monthly planning, scheduling, master data management, in order to ensure system/data integrity in line with defined company standards. Ensure that system documents are updated to comply with quality standards.Networking

Develop and maintain effective business relationships with all relevant internal departments and external entities such as contractors, and service providers etc. with highest standards of business ethics, whilst promptly attending to all critical technical issues in-order to ensure the services required by the organization are delivered in the most effective manner. Represent the company externally with customers and stakeholders in all technical meetings to handle any escalated technical matters.Policies, Systems, Processes & Procedures

Provide inputs and implement departmental policies, systems, and procedure across the plant so that all relevant procedural/legislative requirements, fulfilled while delivering a quality, cost-effective service. Quality, Health, Safety & Environment Ensure compliance to all relevant quality, health, safety and environmental management procedures and controls within a defined area of activity to guarantee employee safety, compliance, delivery of high-quality products/service and a responsible environmental attitude. Collaborate with HSE and Quality on related issues such as process safety, maintaining and updating system documentation and continuous improvement systems, etc. to achieve and exceed target standards. Participate in incident investigation and root cause analysis and recommend corrective actions for improvement.Statement and Reports

Supervise and provide inputs in the preparation of timely and accurate departmental statements and reports to business coordination unit to meet company's and department requirements, policies and standards.Related Assignments

Perform other related duties or assignments as directed. Qualifications and Experience

Bachelors degree in Mechanical Engineering or a relevant engineering discipline. 7 years of related experience in the assigned field of reliability engineering with at least 3 years of growing supervisory/team leadership responsibilities. Job-Specific Skills (Generic/Technical)

Knowledge of ethylene and polyethylene processes In depth knowledge of reliability engineering methodologies and tools Original thinking, judgment, critical analysis, and problem-solving ability. Capacity to effectively prioritize and execute multiple tasks in a high-pressure environment. Knowledge of industry, regulatory guides and codes. Knowledge of process engineering methodologies and tools Knowledge of downtime analysis and good knowledge of problem-solving tools Project Management Mentoring, coaching and people management skills. Knowledge of the operations in petrochemical plants and of company operations and products Employee relations skills IT proficiency Strong performance management skills Health, Safety, Security & Quality Management skills Strong planning, organizing, and integration skills High level of integrity Meticulous attention to detail Conceptual and analytical skills Achievement orientation and result oriented skills Strong time management skills Customer orientation skills Decision making and problem-solving skills Inventory management skills Strong interpersonal, relationship building, negotiations, verbal and written communication skills

---