Job Description

General Summary

The EMSTEEL Asset Reliability Engineer is accountable for driving asset reliability performance and maintain high reliability for plant and associated equipment. The Reliability Engineer aims to provide continuous improvement and understanding of the performance of plant assets through all phases of the equipment life cycle. The role will be responsible for the development of cost-effective asset strategies across the plant assets. The role is accountable for the development, implementation and maintenance of EMSTEEL asset reliability standards, systems, and strategies. The role delivers these objectives through an integrated model of focused engineering inspections and legal compliance to relevant industry standards as a foundation for continuous improvement to plant asset reliability within the site’s asset management

Essential Duties and Responsibilities

(Key Accountabilities)

The EMSTEEL Asset Reliability Engineer must possess an unquestionable reputation for integrity, ethics, and personal values.

• Ensuring the capture and analysis of maintenance data and equipment work histories to provide accurate and timeous recommendations.
• Reviewing and analysing data from the operator routes.
• Leading Root Cause Failure Analysis efforts for incidents triggered by documented procedures.
• Leading disciplined and systematic equipment maintenance strategy development efforts.
• Leading the monthly review of equipment “bad actors” and creating action plans for increasing reliability and monitoring performance vs. plans.
• Identify operational and maintenance changes that will provide the solution to specific process unit problems.
• Actively participating in the capital projects process including providing reliability input.
• Work with maintenance teams to increase the operating availability and performance against reference rate of asset.
• Facilitate Root Cause Analysis, determine root cause of equipment failure, and put in place actions to prevent reoccurrence.
• Analyses records, troubleshoots equipment problems, and makes procedure recommendations to operations and maintenance or implement engineering solutions.
• Facilitate and lead RCM and FMECA workshops.
• Provide discipline related engineering support in shutdowns and breakdowns.
• Prepare cost and schedule estimates.
• Make recommendations as to the methodology, equipment, and material requirements as per asset life engineering.
• Document technical work by setting up work plans and preparing appropriate records and reports.
• Optimizing critical spares inventory as per asset life design and engineering.
• Leads projects as assigned by Reliability Section Head.
• Ensure new assets have reliability incorporated into the design, and ensure operational readiness is obtained when commissioned.
• Provide leadership, training and coaching on Reliability and Maintenance standards and best practice.
• Ensure analysis, upkeep and recording of all equipment failures databases and supply analyzed information as to top failure modes and come up with engineering and management solutions to improve MTBF (Mean Time Between Failure) as per plant targets and plant reliability.
• Ensure analysis, upkeep and recording of all the high cost equipment failures and supply engineering and asset strategy solutions to continuously improve budget costs on repairs and maintenance.
• Understand and identify critical and other equipment asset life cycle and upkeep information and initiate replacement when maintenance is no longer cost effective against capital replacement.
• Analyze operational data and machine performance history to identify and deliver improvement opportunities in machine performance including decreasing unscheduled downtime, PM compliance, schedule compliance, mean time between failures, mean time to repair and maintenance costs.
• Ensure upkeep of 10-year capital plan according to asset life.
• Drive reliability performance on the site.
• Monitor existing reliability programs, historical trends and KPI data for early identification and resolution of reliability issues.
• Strategic Contribution:
• Ensure optimized asset strategies focusing on asset reliability.
• Obtain approval and implement the Annual Plan, Policies & Procedures for the Reliability Department to enable the achievement of EMSTEEL agreed Business Objectives.
• Periodic review to align with Corporate Objectives. Initiate, Implement and Manage Plan.
• Provide professional advice and support to all levels of the business on reliability related issues to ensure the production capability of the business is optimized.
• Leadership:
• Ensure the effective achievement of Asset Reliability functional objectives through leadership and engineering.
• Budgeting & Cost Control:
• Assist in the preparation & management of the annual budget and operating plans that accurately represent anticipated equipment maintenance & development costs to allow accurate business planning and cost management.
• Budgeting and Control includes followings:
• Provide inputs into the preparation, review and optimization of the Annual OPEX Budget requirement with proper justification for each of the Cost Centers of Reliability Related items.
• Provide inputs into the preparation, review and optimization of the Annual CAPEX Budget requirement with proper justification for each of the Cost Centers of Reliability Related Items.
• Operational Management:
• Liaise with external parties to understand equipment requirements and changes.
• Personally, resolve critical problem to minimize the production downtime.
• Respond to emergencies, ensuring that operational targets are not unnecessarily prejudiced by breakdowns and losses are minimized.
• Provide technical input for the resolution of major Reliability problems to minimize down time and enhance plant performance.
• Maintenance Planning:
• Develop the reliability program in a systematic and predictive manner, so that the unplanned shutdowns are minimized.
• Capital Planning:
• Recommends capital expenditure in line with Asset Life strategies of equipment to ensure physical capability to meet its strategic objectives.
• Direct the ongoing review of the physical condition of all physical assets in the Maintenance Department to ensure that those assets are in a suitable condition to allow the organization to fulfill its strategic objectives and they comply with any relevant legislation.
• Safety, Quality & Environment:
• Direct & follow-up all relevant safety, quality and environmental management policies, procedures, and controls across the Reliability Department to promote awareness on employee safety, legislative compliance, delivery of high-quality products / services and a responsible environmental attitude.
• HSE responsibilities includes, but not limited to the following:
• Lead from the front by ensuring all personal HSE Leading KPIs are met.
• Direct, maintain and ensure self and team follow the EMSTEEL Health, Safety and Environment procedure through regular Audits and timely closure of H&S related Actions.
• Policies & Procedures:
• Direct the development of policies covering all areas of the Reliability department related to Reliability Items, so that all relevant procedural / legislative requirements are fulfilled while delivering a quality, cost-effective services to customers

Additional Responsibilities

• Any Engineering related concerns that are prioritised by EMSTEEL.
• Assist in implementing works management and related work processes

Knowledge, Skills and/or Abilities (attributes) required

To perform this job successfully, an individual must be able to perform each duty satisfactorily. The requirements listed below are representative of the knowledge, skills, and abilities required.

• Strong mechanical and electrical knowledge and aptitude.
• Strong knowledge of preventive maintenance programs and the tools associated with failure detection (i.e. vibration analysis, oil monitoring, thermography) as well as the software associated with them.
• Advanced computer skills.
• Knowledge of tools and techniques related to reliability-centered maintenance.
• Understands how to drive performance improvement across working groups to achieve high performance.
• In-depth knowledge of reliability programs.
• Steel making process i.e. Direct Reduction, Steel Melting, Billet Casting, Re-bar rolling and Material Handling equipment.
• Possess unquestioned reputation for integrity, ethics, personal values and solid character.
• Builds the trust of others, both internally and externally.
• Demonstrate innate business intellect, achievement orientation and competitive spirit.
• Exudes confidence yet be without strong ego needs.
• Is self-aware and open to feedback.
• Show courage to make decisions yet is patient to make the right ones.
• Model resilience and flexibility; adapts well to new circumstances and adversity.
• Demonstrate a bias to working in a team-oriented fashion, supporting other’s success
• Ability to problem solve complex issues.
• Ability to work directly with teams outside the reliability group to provide expert technical and engineering advice as required.
• Understand reliability / integrity engineering as well as preventative and predictive maintenance techniques.
• Ability to critically assess inspection reports

Minimum Education Qualifications (Must Haves)

Preferred professional training (Nice to have)

• University Degree in Mechanical/Electrical Engineering.
• CMRP, CRE, CRL or CRP
• Reliability Centred maintenance

Professional Experience (Must Haves)

Experience Recommended (Nice to have)

• 5 years Mechanical/Electrical maintenance experience in integrated steel plant or equivalent industry
• Working experience in any of the Middle East countries (familiar with rules and regulations, climatic conditions)
• Health & Safety compliance systems experience.
• Integrated steelworks experience preferential

Key Performance Indicators

• Standard EMSTEEL Integrity KPI’s
• Plant modification compliance
• Continuous improvement targets
• Cost and budget delivery (Cost improvements)
• MTBF (Mean Time Between Failure) and MTTR (Mean Time To Repair) and improvement
• Record, report and manage to metrics as per Corporate requirements
• Plant availability and improvement
• Continuous improvement and cost savings through Risk based inspection approach of statutory equipment
• RCA completion, improvements, and action plan adherence