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Director of Reliability Engineering

Location: Morristown, NJ
Posted: about 2 years ago
Contract Type: Permanent
Industry: Disciplines, Operations and Technology Management, People, Process and Technology Change Management, Strategic Management, Leadership and Growth
Contact Name: Sheila Walsh
Contact Email: sheila.walsh@pacific-international.com

Job Description

Our client, Covanta, is a world leader in the sustainable waste management and renewable energy space. Covanta's 45 Energy-from-Waste (EfW) facilities provide an environmentally sound solution to solid waste disposal needs for communities and businesses around the world. These solutions use waste to generate clean, renewable energy. 

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. This energy output is sold across a variety of industries. Covanta's facilities also recover and recycle 400,000 tons of metal per year.

ABOUT THE ROLE
The Director, Reliability Engineering will be responsible for identifying and managing asset reliability risks that could adversely affect facility or business safety, compliance and operational efficiency. This individual will oversee three primary functional areas: loss elimination, risk management and life cycle asset management.

KEY PROJECTS/DELIVERABLES:
1.    Design and drive transformation of the Maintenance Division, including but not limited to the organizational structure, culture, etc. 
2.    Design a structured approach to root cause analysis assessments in order to increase efficiency 
3.    Develop specific procedure and methodology governing loss elimination, risk management, and life cycle asset management 

KEY AREAS OF ACCOUNTABILITY:
Loss Elimination
The Director, Reliability Engineering will track production losses and abnormally high maintenance costs, 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 partnership with the operations team) develops a plan to eliminate or reduce losses through root cause analysis, and obtains approval of the plan and facilitates the implementation.

Risk Management
The Director, Reliability Engineering also leads risk management aimed at achieving the 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 hazard 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
Works with project engineering to ensure reliability and sustainability of new and modified installations. The 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:
o    Value-added preventive maintenance tasks
o    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: 
o    Data analysis techniques that can include:
o    Statistical process control
o    Reliability modeling and prediction
o    Fault tree analysis
o    Weibull analysis
o    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.

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