Mechanical Reliability & Project Engineer

Position Summary:

We are seeking a highly motivated Mechanical Engineer to join our team at an alumina refinery. This role is critical in driving equipment reliability, managing change processes, and executing capital and improvement projects. The successful candidate will lead root cause analysis (RCA) for equipment failures, champion continuous improvement initiatives, and manage projects using the Front-End Loaded (FEL) process.

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Key Responsibilities:

• Monitor and improve the OEE of assigned area – Red/White Side mechanical systems
• Improve the onstream factor of mechanical industrial manufacturing system in your assigned area: pumping systems, filters, digesters, kilns, conveyors, etc.
• Ensure systems are performing at their optimum throughput.
• Guide the maintenance department on best practices to reduce failures, reduce total operating cost of equipment, maintenance frequency and how to.
• Root Cause Analysis (RCA):
• Lead investigations into equipment failures and chronic reliability issues.
• Facilitate cross-functional RCA sessions and develop actionable recommendations.
• Track and report on corrective actions and effectiveness.
• Management of Change (MoC):
• Own and lead or participate in the MoC process for mechanical systems and equipment modifications.
• Ensure compliance with safety, environmental, and operational standards.
• Collaborate with operations, maintenance, and engineering teams to assess risks and impacts.
• Continuous Improvement:
• Identify improvement opportunities, prepare business cases and execute change as per the FEL process.
• Utilize field data collection and analysis to identify failure trends and reliability opportunities.
• Develop and implement strategies to eliminate repeat failures and improve equipment uptime.
• Support reliability-centered maintenance (RCM) and predictive maintenance programs.
• Project Management (FEL Process):
• Lead mechanical projects from concept through execution using the FEL methodology.
• Develop scopes, budgets, schedules, and risk assessments for capital and improvement projects.
• Coordinate with internal stakeholders and external contractors to ensure successful project delivery.

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Key Performance Indicators (KPIs):

• RCA Effectiveness:
• % of RCAs completed within target timeframe.
• % of corrective actions implemented and verified.
• Reduction in repeat failures of critical equipment.
• MoC Compliance:
• % of MoC processes completed on time.
• Number of MoC-related incidents or deviations.
• Audit compliance score for MoC documentation.
• Reliability & Uptime:
• Mean Time Between Failures (MTBF) for key assets.
• % reduction in unplanned downtime.
• % improvement in equipment availability.
• Project Execution:
• % of projects delivered on time and within budget.
• FEL stage gate compliance rate.
• Stakeholder satisfaction score (post-project reviews).
• Continuous Improvement:
• Number of CI initiatives implemented annually.
• Estimated cost savings or value creation from CI efforts.
• % of field data collection targets achieved.

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Qualifications:

• Bachelor’s degree in Mechanical Engineering or related field.
• 5+ years of experience in heavy industrial environments, preferably in alumina or similar refining operations.
• Proven experience in RCA, MoC, and project management.
• Strong analytical and problem-solving skills.
• Familiarity with reliability tools (e.g., FMEA, RCM), CMMS systems, and data analysis software.
• Excellent communication and leadership skills.

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Preferred Skills:

• Certification in reliability engineering (e.g., CMRP).
• Experience with FEL project methodology.
• Knowledge of alumina refining processes and equipment.

Qualifications:

• Bachelor’s degree in Mechanical Engineering or related field.
• 5+ years of experience in heavy industrial environments, preferably in alumina or similar refining operations.
• Proven experience in RCA, MoC, and project management.
• Strong analytical and problem-solving skills.
• Familiarity with reliability tools (e.g., FMEA, RCM), CMMS systems, and data analysis software.
• Excellent communication and leadership skills.

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Preferred Skills:

• Certification in reliability engineering (e.g., CMRP).
• Experience with FEL project methodology.
• Knowledge of alumina refining processes and equipment.

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