Senior Reliability Engineer

FLSmidth; Chennai District; On-site; INR 1,500,000 - 2,300,000; Full time

Benefits offered by this job

Health insurance

PTO and holidays

Flexible work schedule

401(k) with company matching

Continuing education support

Employee Assistance Program

Job summary

FLSmidth seeks a seasoned Reliability Engineer to lead condition monitoring and maintenance strategy development for processing equipment. You will design transition strategies to ensure capacity and product quality during commissioning, startup, and operation, focusing on master maintenance plans and cost-effective solutions.

Responsibilities include predicting failures, performing root cause analyses, and selecting robust maintenance approaches while collaborating with cross-functional teams

Qualifications

• 8 years of experience in reliability engineering with in-depth condition monitoring of mining equipment.
• Ability to predict equipment failures and initiate mitigations.
• Knowledge of metallurgical processes for maintenance strategy design.
• Root cause failure analysis and design of mitigation solutions.

Responsibilities

• Design and implement Operational Transition Strategy from a reliability perspective.
• Define safe operating ranges and transition criteria for process stages.
• Identify control points and criteria between operating scenarios.
• Support commissioning activities and training for process issues.
• Monitor critical variables and review constraints; adjust recommendations based on performance.
• Promote safety culture and participate in HSEQA plans and investigations.

Skills

Reliability engineering

Condition monitoring

Root cause analysis

Weibull analysis

Finite element analysis

CAD (SolidWorks/AutoCAD)

TOC modeling

Equipment commissioning

Education

Bachelor's degree in Mechanical Engineering

Tools

ISOgraph

SolidWorks

AutoCAD

Job description

This role focuses on developing, coordinating, and conducting technical reliability activities for providing support from a reliability perspective to develop operational transition strategies and monitoring and compliance services for all processes, in order to achieve processing capacity and product quality during the commissioning, startup and operation stages, with a focus on the development of master maintenance plans.

Job Scope

• Design of the Operational Transition Strategy and reability point of view
• Definition of recommended ranges and safe limits for each stage of the process from a realibility point of view.
• Identification of control points and transition criteria between operating scenarios from a realibility point of view.
• Initial operational decision trees and deviation management, from a realibility point of view.
• Support for FLS Equipment Commissioning activities related to process issues. Training and instruction.
• Monitoring of critical variables, review of constraints.
• Evaluation of failure modes, critical spare parts, and ramp-up inspection practices. Adjustment of operational ranges and operating recommendations based on actual performance.
• Promoting a culture of safety and self-care, both personally, within the team, and throughout the company, integrating our stakeholders who may be impacted by our activities, and complying with established standards, policies, and requirements. Active participant in the activities programmed in the annual HSEQA plans and programs; reporting every incident, near miss, substandard act or condition that occurs and, if required, ensuring their active participation in an investigation.

Responsible for providing support from a reliability perspective to develop operational transition strategies and monitoring and compliance services for all processes, in order to achieve processing capacity and product quality during the commissioning, startup and operation stages, with a focus on the development of master maintenance plans.

Requirements

• 8 years of experience as a reliability engineer with in-depth experience in condition monitoring of float cells, screens, gyratory crushers, high-pressure grinding rolls, mills, thickeners, cyclones and slurry pumps.
• Proven ability to predict equipment failures before they happen and initiate effective mitigation strategies.
• A clear understanding of the metallurgical processes in crushing and separation technologies in order to design appropriate maintenance strategies.
• Proficiency in performing root cause failure analysis on failed components and designing of solutions to mitigate future failures.
• Firm ability to model Total Cost of Ownership simulations in ISOgraph for float cells, screens, gyratory crushers, high-pressure grinding rolls, mills, thickeners, cyclones and slurry pumps.
• Experience with statistical analysis on failures including Weibull failure modelling.
• Sound experience in mechanical engineering design and selection of ferrous, non-ferrous and polymer materials.
• Ability to perform finite element analysis simulations of failed components.
• Experienced in equipment commissioning and fault-finding under pressure and outside of standard working hours.
• Experience in the use of CAD programs, preferably SolidWorks and/or AutoCAD.
• Proven customer relationship management skills with the ability to work in high-pressure environments and deliver results.
• Ability to manage direct reports, deal with conflict and find resolutions to time-sensitive problems.
• Demonstrated ability to deliver in a fast-paced, changing environment while maintaining high attention to detail.
• Good organization, multitasking and time-management skills.
• Perform condition monitoring of FLSmidth equipment, predict failures before they happen and initiate effective mitigations.
• Evaluate equipment failures, perform root cause analysis and design effective solutions to mitigate future failures.
• Design maintenance management programs that enable FLSmidth equipment to achieve maximum productivity for our clients.
• Create and then optimize Total Cost of Ownership models to accurately forecast plant budgets, maintenance schedules and spare part requirements.
• Be fully committed to FLSmidth’s core environmental and safety values.

What we offer

• Competitive benefit package including health, dental, disability, life, and voluntary insurance options.
• Time to recharge through PTO, plus 10 annual holidays, and parental leave.
• Work-life balance with a flexible work schedule so you can focus on professional and personal priorities.
• Retirement preparation with a 401(k) and company matching.
• Financial support for continuing education.
• Employee Assistance Program.

An equal opportunity employer committed to creating a diverse and inclusive workplace.

A global network of supportive colleagues and growth opportunities.

As an equal opportunity employer, FLSmidth embraces diversity and equality by promoting an environment of inclusion.

We encourage applicants of all backgrounds and perspectives to apply - the more diverse our employees are, the stronger our team is.

About FLS

About FLS FLSmidth is the full flowsheet technology service supplier to the global mining and cement industries. We are an international engineering company with an annual turnover of approx. EUR 2.7 bn. We help our customers improve performance, lower operating costs and reduce environmental impact. With our MissionZero programme, we have set a target of providing solutions for zero-emissions mining and zero-emissions cement production by 2030, supporting a green transition built upon sustainable materials. We are the world’s leading supplier of plants, machinery, services and spare parts to the cement and minerals industries. To maintain our market-leading position, we invest massively in technological innovation, R&D and training of our 11,900 employees worldwide. For further information on FLSmidth business and services, visit www.flsmidth.com. We offer all employees access to a dedicated recognition platform, empowering you to celebrate achievements, share appreciation and stay connected globally. FLS is a leading, full flowsheet minerals processing supplier to the global mining industry. We deliver proven technologies and services across the lifecycle of operations, and have set targets of providing solutions for zero-emissions mining by 2030 with our MissionZero programme.