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Director, Reliability Engineering

Covanta


Location:
Morristown, NJ
Date:
04/26/2017
Job Code:
5949
Categories:
  • Mechanical Engineering - Applied Mechanics
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Job Details

- Director, Reliability Engineering - Morristown NJ 07960 Skip Navigation
 
Job Details
Director, Reliability Engineering
Job ID 5949           
Morristown, NJ
Operations (Morristown)
          
Maintenance Technology
Full-Time Regular
          
Bachelors Degree
More than 10 years
          
Maybe


Covanta is a world leader in sustainable waste management and renewable energy. Covanta's 45 Energy-from-Waste (EfW) facilities provide communities and businesses around the world with an environmentally sound solution to their solid waste disposal needs by using waste to generate clean, renewable energy. Covanta is a listed company under the symbol CVA.

Annually, Covanta's modern Energy-from-Waste facilities safely and securely convert approximately 20 million tons of waste into 9 million megawatt hours of clean renewable electricity and almost 9 billion pounds of steam that are sold to a variety of industries. Covanta's facilities also recover 400,000 tons of metal per year for recycling.

To learn more about how Covanta's facilities provide sustainable waste management for the communities it serves, visit www.covanta.com. Information on our facilities is available at http://www.covanta.com/facilities.aspx. For career opportunities, visit http://www.covanta.com/careers. Covanta is an Equal Opportunity Employer.


The Director, Reliability Engineering, working under direction of the VP Maintenance Technology will have the responsibility of identifying and managing asset reliability risks that adversely affect facility or business safe, compliant and efficient operations.

The primary role of the Director, Reliability Engineering is to identify and manage asset reliability risks that could adversely affect plant or business operations.

This broad primary role can be divided into three smaller, more manageable roles: loss elimination, risk management and life cycle asset management.

 

Loss Elimination
One of the fundamental roles of the Director, Reliability Engineering is to track the production losses and abnormally high maintenance cost assets, then find ways to reduce those losses or high costs. These losses are prioritized to focus efforts on the largest/most critical opportunities.

The Director, Reliability Engineering (in full partnership with the operations team) develops a plan to eliminate or reduce the losses through root cause analysis, obtains approval of the plan and facilitates the implementation.

Risk Management
Another role of the Director, Reliability Engineering is to manage risk to the achievement of an organization’s strategic objectives in the areas of environmental health and safety, asset capability, quality and production.

Some tools used by the Director, Reliability Engineering to identify and reduce risk include:

  • Preliminary hazards analysis
  • Failure modes and effects analysis
  • Criticality analysis
  • Simplified failure modes and effects analysis
  • Maintainability information
  • Fault tree analysis
  • Event tree analysis

Life Cycle Asset Management
Studies show that as much as 95 percent of the total cost of ownership (TCO) or life cycle cost (LCC) of an asset is determined before it is put into use.

This reveals the need for the Director, Reliability Engineering to be involved in the design and installation stages of projects for new assets and modification of existing assets.

Director, Reliability Engineering Responsibilities and Duties
Here’s a list of responsibilities and duties commonly found in the job description of a Director, Reliability Engineering

Works with project engineering to ensure the reliability and maintainability of new and modified installations.

The Director, Reliability Engineering Director, Reliability Engineering is responsible for adhering to the life cycle asset management (LCAM) process throughout the entire life cycle of new assets.
  • 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.
  • Participates in the final check-out of new installations. This includes factory and site acceptance testing that will assure adherence to functional specifications.
  • Guides efforts to ensure reliability and maintainability of equipment, processes, utilities, facilities, controls and safety/security systems.
Professionally and 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
  • Provides input to a risk management plan that will anticipate reliability-related and non-reliability-related risks that could adversely impact plant operations.
  • 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 Director, Reliability Engineering 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 analysis of assets including:
    • Asset utilization
    • Overall equipment effectiveness
    • 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.

DUTIES/RESPONSIBILITIES:

Tasks

  1. Identifying asset reliability risks via enhanced RCA program and reliability based maintenance KPI and statistical analysis. Managing the risk elimination or reduction will include RCA action item completion, PM program audits and statistical analysis of maintenance and operations data.
  2. Provide maintenance effectiveness audits, guidance and technical recommendation for reliability programs at facilities based on statistical performance analysis.
  3. Assist in maintenance related report development of indicative KPIs and best method of communicating their implications, lessons learned, performance and areas for improvement.
  4. Work assigned reliability projects as required.


(Education, Skills, Certificate, Licenses, Experience):

  • Certification in industrial standard reliability expertise. Example: CMRP, CRL, or other.
  • 10 years applicable work experience in industrial facility equipment reliability centered maintenance engineering and or program management.
  • 5 years minimum work experience in petro-chemical, utility, EfW or equal a requirement.
  • Required frequent facility visits in pursuit of assignments. No limitations to working in industrial environment.
  • Statistical data analysis as required for maintenance and equipment performance assessment.
  • Knowledge of required and or former use of preferred of following are important for position skills:
    • Detail work/ job planning and work hazard analysis
    • Failure mode analysis and failure analysis techniques
    • Risk or criticality analysis for equipment or process
    • Industrial facility maintenance practices
    • Standard fault/ event tree construction and analysis
    • Knowledge of machinery vibration analysis methods, thermography, condition assessment via instrumentation and field experience performing each or other NDT methods.
    • Six Sigma methodology
  • Demonstrated root cause analysis experience in industry standard method: Kepnor-Tragoe, 5 Whys, Fishbone diagram, other.
  • Demonstrated experience in industry standard comprehensive reliability program such as TPM, RCM or other.
  • Strong facility process understanding via P&IDs, drawings and specifications.
  • Safe working leadership.
  • Strong report writing skills and ability to communicate orally and in written format.
  • Motivated, self-starter.
  • Work location is to be in Morristown, NJ office.

Bachelor’s degree in Engineering

  • Industry standard reliability professional certification.
  • Practical field experience involving equipment installation, maintenance, overhaul and operation.
  • High proficiency in MS Office, especially with Excel (spreadsheets, modeling, and pivot tables), Outlook, and Access. Working knowledge of maintenance management or asset management enterprise system.
  • Ability to communicate effectively and easily with management/ employees at different levels of the organization in office or remotely.
  • Lean Six Sigma qualification or experience a plus. Green belt desirable.

Experience

  • Minimum of 10 years of relevant experience in industrial maintenance and Director, Reliability Engineering.
  • Practical skills such as welder, millwright, machinists, operator, etc. a plus.
  • Formal Six Sigma training a plus.

Physical Demands

  • Operating facility environment with OSHA required PPE, safety training for areas of steam boiler and turbine – generator operation. Access to all areas of facility required as well as to confined spaces and respirator required areas. .
  • Job requires physical demands consistent with work in industrial environment.
  • Travel to facilities is required.

Work Environment

  • 25%- 30% Travel and facility based work/ support
  • Balance Office

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