Reliability Engineer

Cyient is seeking a highly experienced Senior Reliability Engineer to support Pratt & Whitney's aerospace Disc Manufacturing and Forging Operations, specializing in Overall Equipment Effectiveness (OEE), equipment reliability, and continuous improvement.

The ideal candidate will possess extensive technical expertise in isothermal forging presses, large-scale hydraulic systems, precision machining equipment, and complex industrial machinery. Responsibilities include investigating equipment failures, reducing unplanned downtime, optimizing manufacturing performance, and implementing sustainable engineering solutions.

This position requires exceptional analytical and troubleshooting capabilities, independent technical judgment, and effective collaboration with manufacturing engineering, maintenance, operations, and customer leadership.

Key Responsibilities

Equipment Reliability & Engineering Support

• Lead reliability improvement initiatives for aerospace disc manufacturing, forging presses, and associated equipment.
• Troubleshoot complex mechanical, hydraulic, electrical, and automated manufacturing systems.
• Investigate recurring equipment failures, performance degradation, and operational inefficiencies.
• Develop corrective and preventive actions to improve equipment availability, performance, and service life.
• Support equipment inspections, reliability assessments, and long-term maintenance strategies.

Overall Equipment Effectiveness (OEE)

• Analyze and improve equipment availability, performance efficiency, quality losses, and overall OEE.
• Identify and address downtime, production bottlenecks, reduced throughput, and cycle-time inefficiencies.
• Monitor failure trends, Mean Time Between Failures (MTBF), and Mean Time To Repair (MTTR).
• Develop measurable improvement initiatives to enhance equipment utilization and manufacturing capacity.
• Present OEE reports, reliability assessments, and technical recommendations to engineering and customer leadership.

Isothermal Forging Press & Hydraulic Systems

• Provide specialized reliability support for isothermal forging presses and large-scale hydraulic press systems.
• Evaluate hydraulic pumps, cylinders, valves, seals, pressure controls, and mechanical components.
• Investigate hydraulic failures, pressure instability, equipment wear, and mechanical malfunctions.
• Troubleshoot thermal controls, heating systems, sensors, instrumentation, and press automation.
• Support structural integrity assessments, preventive maintenance, and long-term press reliability improvements.

Root Cause Analysis & Continuous Improvement

• Lead Root Cause Analysis (RCA), Failure Mode and Effects Analysis (FMEA), and corrective action investigations.
• Apply 5 Whys, Fishbone Diagrams, Fault Tree Analysis, and other engineering methodologies.
• Analyze equipment failure history and maintenance data to identify recurring issues.
• Support Lean Manufacturing, Total Productive Maintenance (TPM), and continuous improvement initiatives.
• Implement and validate sustainable corrective actions through measurable reliability improvements.

Preventive & Predictive Maintenance

• Evaluate and optimize preventive maintenance programs based on equipment criticality and failure trends.
• Support predictive maintenance through vibration analysis, oil analysis, thermal monitoring, and equipment condition assessments.
• Develop reliability-centered maintenance recommendations to minimize unplanned downtime.
• Coordinate equipment inspections, maintenance improvements, and lifecycle reliability planning.

Technical Documentation & Customer Collaboration

• Prepare engineering reports, reliability assessments, corrective action documentation, and improvement recommendations.
• Collaborate with Pratt & Whitney engineering, manufacturing, maintenance, quality, and operations personnel.
• Communicate equipment concerns, technical findings, project progress, and improvement opportunities.
• Support Statement of Work (SOW) deliverables, operational objectives, and applicable aerospace safety and quality requirements.

Required Qualifications

• Bachelor's degree in Mechanical, Manufacturing, Industrial Engineering, or a related discipline.
• Minimum 8-10 years of relevant engineering experience in equipment reliability, manufacturing, or maintenance engineering.
• Extensive experience troubleshooting mechanical, hydraulic, electrical, and complex industrial manufacturing equipment.
• Experience supporting large hydraulic presses, forging equipment, or comparable heavy industrial machinery.
• Strong expertise in OEE, equipment availability, production efficiency, and manufacturing performance improvement.
• Proven experience with RCA, FMEA, corrective actions, and reliability investigations.
• Knowledge of preventive, predictive, and reliability-centered maintenance strategies.
• Experience analyzing downtime, failure trends, MTBF, MTTR, and equipment performance data.
• Ability to independently resolve complex technical issues and communicate effectively with cross-functional teams.

Preferred Qualifications

• 10-15+ years of experience in aerospace manufacturing, forging operations, or heavy industrial equipment reliability.
• Direct experience with isothermal forging presses used in aerospace turbine engine disc manufacturing.
• Advanced knowledge of high-pressure hydraulics, press controls, industrial automation, and thermal systems.
• Experience with titanium and nickel-based superalloy forging processes.
• Familiarity with CNC machining, precision manufacturing, PLCs, and industrial instrumentation.
• Knowledge of AS9100 aerospace quality management requirements.
• Proficiency with SAP, CMMS, Microsoft Excel, and Power BI.
• Certified Reliability Engineer (CRE), Certified Maintenance & Reliability Professional (CMRP), or Lean Six Sigma certification.
• Experience developing reliability improvement programs and supporting major equipment upgrades.

Desired Candidate Profile

A highly experienced, hands-on reliability engineer capable of independently troubleshooting complex manufacturing equipment, eliminating recurring failures, and implementing sustainable improvements.

The ideal candidate will demonstrate advanced technical expertise in hydraulic and isothermal forging press systems, strong analytical and communication skills, and a proven ability to improve equipment availability, OEE, manufacturing efficiency, and operational reliability.

The successful candidate must operate with minimal technical supervision while delivering measurable reliability improvements in a demanding aerospace manufacturing environment.