Sr Reliability Engineer

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

Job summary

FLSmidth Cement seeks a seasoned Reliability Engineer to develop and coordinate reliability activities during commissioning, startup, and operation, with emphasis on master maintenance plans and transition strategies.

You will evaluate failure modes, design maintenance programs, and improve safety culture while supporting equipment commissioning and final handover to operations.

Qualifications

• 8+ years as a reliability engineer with condition monitoring experience for float cells, screens, crushers, mills and pumps.

Responsibilities

• Design the Operational Transition Strategy from a reliability perspective.

Skills

Reliability engineering

Condition monitoring

Root cause analysis

Total Cost of Ownership

Maintenance strategy design

Weibull analysis

Project management

Detail-oriented

High-pressure environments

Team leadership

Tools

SolidWorks

AutoCAD

ISOgraph

Job description

Job Summary

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.

Responsibilities

• 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.