Provides technical expertise on all matters of reliability engineering, assessment and monitoring for all process equipment (including mechanical, electrical and instrument / control equipment). The site Mechanical Integrity and Quality Assurance leader provides focus on the MI & QA Elements of the site Process Safety Management (PSM) program. This role provides leadership and technical expertise to ensure compliance with the Mechanical Integrity and Quality Assurance requirements of DuPont Process Safety Management standards, and statutory / regulatory requirements, in a way that decreases risk of PSM Incidents or regulatory non-compliance resulting from MI or QA deficiencies.
Participates on project teams to supply advice to design engineers on the enhancement of reliability of capital projects. Carries out reliability studies on existing equipment and recommends needed improvements to Operations management in the areas of equipment philosophies, strategies and best practices for asset productivity. This position focuses on improving equipment performance versus sustaining or returning it to current performance standards. This position is critical to the site PSM program.
- Serve as MIQA Leader for the site PSM program.
- Develop and implement equipment asset plans using Reliability Centered Maintenance (RCM), Risk Based Inspections (RBI) and other reliability techniques.
- Apply engineering theory, practices, and principles to perform physical failure analysis, determine root cause of equipment failures and conduct equipment performance evaluations
- Analyze equipment trends, historical data, and field data to recommend and justify improvements to obtain lowest life cycle cost on different classes of equipment.
- Work with Process ATO’s and Technology Guardians in determining how process variation and equipment operation can impact equipment reliability
- Continually promote consistency by standardizing procedures/equipment/operations within area of responsibility.
- Participate in PSM activities as defined by site manuals and practices, mainly focused in mechanical integrity (MI) and quality assurance (QA)
- Support capital projects by participating in setting equipment “fitness for use” criteria and specifications to optimize equipment/system reliability and life cycle cost. Also provide technical support for QA/QC, installation, and start-up of all new critical equipment.
- Participate as a member of mechanical turn-around/shutdown teams providing input into needed equipment inspection and repair procedures
- Participate in maintenance and reliability networks and share best practices, successes and failures.
- Participate in the interviewing, hiring and mentoring of new reliability co-ops, interns, and engineers. Participate in the mentoring of maintenance ATO’s.
- Participate in continuing education courses, professional organizations (e.g. SMRP, ASME) and reliability conferences to keep current on and evaluate new and emerging technologies for their applicability.
- Develop specific reliability competency areas and participate in SBU, Corporate and external networks/forums as appropriate to maximize contribution and qualify for professional progression up to that of a DuPont fellow.
- Construction and analysis of Reliability Models for new projects as well as existing production facilities for the purpose of giving estimates of future Uptime, Availability and Equipment Maintainability.
- BS degree in Engineering (e.g. Mechanical, Electrical or Instrument depending on their work focus); alternatively, 5-10 years of reliability work experience and training in the refining/petrochemical industry
- Strong leadership capability
- Ability to plan, prioritize and implement multiple concurrent projects.
- Good Communication and Presentation Skills (both oral and written)
- Good Interpersonal and Conflict Resolution Skills with the ability to influence managers, peers, and mechanics; able to take a “hands-on” approach with operators and mechanics to get things done.
- Good Analytical and Problem-solving skills
- Ability to Interact with and Promote the Capabilities of a Diverse Workforce (A Team Builder)
- Proven strong contributor with the capability to work independently
- Training and project experience with Six Sigma, as Black Belt or Green Belt
- Good personal computer and software skills e.g. Microsoft Office, CMMS, etc.
- Understanding of Business Performance Measures and Critical to Quality issues
- Understands the Process Safety Management (PSM) process particularly Management of Change (MOC)
- Good mathematical skills with an in-depth understanding Reliability Modeling tools and methods, including statistical distributions, growth models, analytical models and Monte Carlo simulations
- Basic understanding of the principles of:
- Maintenance & reliability best practices
- Rotating Equipment and alignment techniques
- Materials Science and physical failure analysis
- Power, electrical and steam generation
- Instrumentation and process control
- Predictive techniques for fixed and rotating equipment and instrumentation such as: Vibration Analysis, Tribology, Non-Destructive Testing, Thermography, etc.
- Total Equipment Effectiveness (Uptime)
- Equipment Life Cycle Cost
- Root Cause Failure Analysis (RCFA) and Failure Mode and Effect Analysis (FMEA)
- Reliability analytical tools such as Weibell analysis, reliability growth plots and modeling
- Industry and Corporate Engineering codes and their application
- ISO and other related quality standards
- Cost/Capital analysis and justification
- Reliability engineering principles and design improvement techniques