Reliability Engineer - Mechanical

The Reliability Engineer is responsible for building and sustaining equipment reliability across the Houston chemical facility. The incumbent collects and analyzes maintenance breakdown data, develops Pareto analyses to identify top bad actors, and leads the creation and execution of Reliability Action Plans (RAPs) designed to eliminate or significantly reduce unplanned downtime.

As an integral member of the Maintenance team, this role takes the lead in developing and driving the systems, processes, and tools needed to ensure long-term equipment reliability. The position aligns cross-functionally across operations, maintenance, and engineering - serving as the primary decision-maker for equipment reliability matters. The engineer is accountable for prioritizing root cause failure analysis (RCFA), deploying focused improvement (FI) methodologies, and providing the technical input required to achieve annual operating plan (AOP) targets.

Reliability Action Planning & Failure Elimination

Establish and lead improvement projects to prevent recurrence of maintenance failures. Drive Reliability Action Plans (RAPs) that directly support plant-level goals. Lead and manage RCFA processes, ensuring root causes are identified, documented, and resolved. Apply maintenance data analysis systematically to develop high-quality action plans, then own the deployment and implementation of those plans through to closure.

KPI Analysis & Focused Improvement

Analyze maintenance KPIs - including MTTR, MTBF, and breakdown frequency - to identify performance gaps and define improvement actions. Apply Focused Improvement (FI) methodologies to address major loss categories, maintaining a prioritized project list by operations area. Oversee asset lifecycle management to eliminate obsolescence and control natural equipment deterioration within the capital management framework.

Predictive Maintenance Program

Develop, implement, and sustain a suite of predictive maintenance tools to support proactive equipment care. Technologies include gearbox inspection, infrared thermography, oil analysis, vibration analysis, and Reliability Centered Maintenance (RCM). Maintain a register of potential failure modes, prioritize interventions based on criticality, and ensure decisions are made to avoid unplanned stoppages or catastrophic failures.

Asset Standards & Benchmarking

Maintain active operational functions in accordance with defined performance standards. Develop a thorough understanding of asset failure modes and their operational impact, forming the basis for proactive maintenance planning. Apply the ABC asset criticality curve (Ca) to focus resources appropriately. Lead benchmarking initiatives, technology updates, and knowledge sharing with peer facilities to drive continuous improvement.

Failure Investigation & Reporting

Participate in the investigation of significant and catastrophic failures, assuming the lead role on major events. Prepare comprehensive failure reports, maintain current status, and ensure follow-up on all corrective actions. Manage failure analysis action plans to closure. Analyze outputs from predictive maintenance tools and translate findings into defined maintenance actions.

Knowledge, Skills, & Abilities

• Deep understanding of maintenance systems and manufacturing equipment
• Hands-on experience with PdM technologies (vibration, IR, oil, ultrasound)
• Proficiency in RCM methodology and RCFA
• Strong background in safety, scheduling, and project management
• Proficient in maintenance KPI analysis (MTBF, MTTR, OEE)
• Skilled in Pareto analysis and data-driven prioritization
• Experience building and managing reliability programs and action plans
• Strong problem-solving mindset with root cause focus
• Strong internal and external customer focus
• Effective communicator across operations, maintenance, and engineering
• Ability to influence without direct authority
• Capable of leading cross-functional improvement teams

Education & Experience

Bachelor's Degree in Mechanical Engineering, Electrical Engineering, Engineering Technology, or a closely related field required

Master's degree in mechanical engineering, Electrical Engineering, Engineering Technology, or a closely related field preferred

• 3+ years in reliability engineering required
• Demonstrated experience in continuous improvement, TPM, zero-loss, or lean manufacturing environments required
• 2-3 years focused specifically on maintenance reliability in a manufacturing environment preferred
• RCM certification or formal reliability training (e.g., CMRP) preferred