|Title:||Operational Reliability Leader|
The primary role of the Operational Reliability Leader is to identify and manage risks associated with physical assets that could adversely affect PGTI plant or business operations. Within this primary role, the Leader shall direct and implement Asset Management Plans and PGTI Operational Reliability business processes that will improve asset availability and total cost of ownership.
The Operational Reliability Leader is the primary steward of PGTI’s installed capacity and shall develop and administer Asset Operating Plans that will assure optimum utilization and operating efficiency of physical assets. As part of the overall Asset Management Strategy, the Leader is responsible for the development of Asset Maintenance Plans that will ensure adequate levels of sustaining performance for assets within PGTI operations.
To support Asset Management Strategies, the Leader shall implement established Operational Reliability engineering business processes within the following domains: Reliability Engineering, Maintenance Work Management, Maintenance Materials Management, and Operator Care.
ESSENTIAL DUTIES AND RESPONSIBILITIES include the following. Other duties may be assigned.
* Professionally and systematically define, design, develop, monitor and refine Risk Management Plans that will anticipate reliability-related and non-reliability-related risks that could adversely impact plant operations.
* Guides efforts and utilizes established Operational Reliability engineering business processes to ensure reliability, availability, and maintainability of equipment, processes, utilities, facilities, controls, and safety/security systems.
* Professionally and systematically defines, designs, develops, monitors and refines Asset Maintenance Plans that include:
o Value-added preventive maintenance tasks
o Effective utilization of predictive and other condition-based nondestructive testing methodologies designed to identify and isolate inherent reliability problems
* Professionally and systematically define, design, develop, monitor and refine Asset Operating Plans that will provide standardized processes and procedures for proper operation and operator care of production, utility and auxiliary assets.
* Works with Manufacturing and Project Engineering to ensure the reliability, availability, and maintainability of new and modified installations. The Leader is
responsible for adherence to the Life Cycle Asset Management (LCAM) process throughout the entire life cycle of assets.
* Participates in the final check out of asset modifications and installations. This includes factory and site acceptance testing that will ensure adherence to functional specifications.
* Develops engineering solutions to repetitive failures and all other problems that adversely affect plant operations. These problems shall include capacity, quality, cost or regulatory compliance issues. To fulfill this responsibility the Operational Reliability Leader shall apply:
o Data analysis techniques that can include:
* Statistical Process Control
* Reliability modeling and prediction
* Fault Tree Analysis
* Weibull Analysis
* Six Sigma (6σ) Methodology
* Root-cause and Root-Cause Failure Analysis (RCA, RCFA)
* Failure Reporting, Analysis and Corrective Action System (FRACAS)
* Analyses of asset and production system performance to include:
o Asset Utilization
o Overall Equipment Effectiveness
o Cost of Goods Sold
o Remaining useful life
o Other parameters that define operating condition, reliability and costs of assets
* Provides subject matter expert level technical support to production and maintenance management and technical personnel.
* Applies value analysis to repair/replace, repair/redesign, and make/buy decisions.
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
EDUCATION and/or EXPERIENCE
Required Bachelor of Science Degree in Engineering, preferably Mechanical, Industrial, Electrical or Manufacturing with 10 years of applied experience in an industrial environment. Preferred Masters in Engineering or Business related field of study with applied experience.
LANGUAGE / COMMUNICATION SKILLS
Strong written and oral communication skills in the English language with the ability to effectively communicate at all levels within the organization. Preferred ability to communicate in Spanish at a conversational level.
Advanced mathematic reasoning and calculation skills required to effectively conduct data analysis requirements. This includes statistical methods for failure analysis and correlations. Strong skills required to graphically communicate equipment and financial information.
Must be able to effectively manage multiple initiatives at multiple plant sites and utilize business information to prioritize work across business units.
CERTIFICATES, LICENSES, REGISTRATIONS
Preferred certifications include: Certified Maintenance and Reliability Professional (CMRP), American Society for Quality Certified Reliability Engineer (ASQRE), Certified Reliability Leader (CRL), Certified Lean Six Sigma Black or Green Belt, IAM Certification or Diploma, Licensed Professional Engineer
PHYSICAL DEMANDS / WORK ENVIRONMENT
The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
* Typical office environment with frequent sitting, walking, and standing, and occasional climbing, stooping, kneeling, crouching, crawling, and balancing.
* Additional mobility required to walk manufacturing and utilities operations to observe operations up to 6-8 hours per day
* Frequent use of eye, hand, and finger coordination enabling the use of office machinery.
* Oral and auditory capacity enabling interpersonal communication as well as communication through automated devices such as the telephone.
Ability to travel domestically and internationally. Estimated domestic travel of 30-50%, international travel of 5% - travel requirements will vary based upon individual’s primary office location and business unit needs.
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