The Senior Process Equipment Reliability Engineer leads strategic initiatives to maximize the reliability, availability, and maintainability of critical process equipment across manufacturing facilities. This role spearheads complex root cause analyses, develops advanced maintenance strategies, and drives continuous improvement programs. Acting as a technical expert, the senior engineer collaborates with cross-functional teams to optimize equipment performance, support capital projects, and ensure compliance with food safety and regulatory standards.
Lead in-depth root cause failure analyses (RCFA) for major equipment breakdowns and chronic issues; develop and oversee implementation of corrective and preventive actions.
Design and optimize comprehensive reliability programs including preventive, predictive, and condition-based maintenance strategies specifically for process equipment such as pumps, valves, tanks, conveyors, and CIP systems.
Provide technical leadership on equipment reliability matters to Engineering, Maintenance, Operations, and Quality teams.
Utilize advanced reliability engineering tools and methodologies (FMEA, fault tree analysis, reliability block diagrams, Weibull analysis) to assess and improve equipment performance.
Collaborate closely with Capital Projects to review new equipment designs, specifications, and commissioning processes ensuring maintainability and reliability from the outset.
Drive continuous improvement initiatives leveraging data analytics, reliability software, and Industry 4.0 technologies (e.g., IoT sensors, condition monitoring).
Mentor and develop junior reliability engineers and maintenance staff.
Lead cross-functional teams to align reliability goals with production targets, safety, and regulatory compliance (FDA, USDA, FSMA, GMP).
Prepare and present reliability reports and metrics to senior management.
Champion a culture of reliability excellence and proactive maintenance throughout the organization.
Education:
Bachelor’s degree in Mechanical Engineering, Industrial Engineering, or related field; Master’s degree preferred
Experience:
7+ years of reliability engineering or maintenance experience, with at least 3 years in a senior or lead role
Extensive experience in food & beverage, pharmaceutical, or regulated manufacturing environments
Proven track record leading reliability improvement projects and root cause failure investigations
Certifications:
Certified Maintenance & Reliability Professional (CMRP) or equivalent highly desirable
Training in Six Sigma, Lean Manufacturing, or Reliability Engineering tools preferred
Technical Skills:
Deep expertise in process equipment (pumps, valves, conveyors, CIP systems) and hygienic design principles
Proficient with CMMS, reliability software, and advanced data analytics
Familiarity with food safety and regulatory compliance standards (FDA, USDA, FSMA, GMP)
Leadership & Soft Skills:
Strong leadership and mentoring abilities
Excellent communication and interpersonal skills
Strategic thinker with proven project management capabilities