Maintenance Reliability Engineer

HYCAST LLC; Fairfield (IA); On-site; USD 85,000 - 125,000; Full time

Job summary

HyCast Foundry in the United States is seeking a Maintenance Reliability Engineer to improve equipment reliability, uptime, and maintainability across all foundry operations. This role bridges maintenance, engineering, and operations to reduce unplanned downtime and support cost-effective production.

Key focus areas include RCFA, PM/PdM optimization, condition monitoring, and continuous improvement using Lean, TPM, or Six Sigma methods to ensure safe, compliant, and efficient casting operations.

Qualifications

• Bachelor’s degree in Mechanical, Electrical, Industrial Engineering or related field.
• 5–10 years in maintenance, reliability, or engineering within heavy industry.
• Strong knowledge of rotating equipment, hydraulics, pneumatics, and power systems.
• Experience with CMMS and reliability data analysis.
• Proven ability to lead RCFA and drive corrective actions.

Responsibilities

• Develop reliability strategies for critical foundry assets.
• Lead RCFA and implement permanent corrective actions.
• Track MTBF, MTTR, uptime, and downtime trends.
• Design, optimize, and maintain PM and PdM programs.
• Support condition monitoring and analysis of failure data.
• Perform FMEA on existing and new assets; standardize parts and procedures.
• Drive Lean, TPM, or Six Sigma improvement initiatives.
• Ensure safety, regulatory, and documentation compliance.
• Collaborate with operations, maintenance, engineering, and purchasing.

Skills

RCFA leadership

Reliability mindset

Data analysis

Cross-functional leadership

Problem solving

Communication

Education

Bachelor’s degree in Mechanical/Electrical/Industrial Engineering

Tools

CMMS

FMEA

Vibration analysis tools

Job description

Job Description

Job Title

Reports To

Maintenance Manager

Position Summary

The Maintenance Reliability Engineer is responsible for improving equipment reliability, uptime, and maintainability across all foundry operations. This role bridges maintenance, engineering, and operations to eliminate unplanned downtime, extend asset life, and support safe, cost-effective production. The position focuses on root cause failure analysis, preventive and predictive maintenance optimization, reliability-centered maintenance (RCM), and continuous improvement of foundry equipment and systems.

Key Responsibilities

Reliability & Asset Performance

• Develop and execute reliability strategies for critical foundry assets including melting furnaces, molding lines, core machines, shakeout, sand systems, conveyors, and material handling equipment
• Lead Root Cause Failure Analysis (RCFA) and implement permanent corrective actions
• Track, analyze, and report reliability KPIs such as MTBF, MTTR, equipment availability, and downtime trends
• Identify chronic equipment issues and drive long-term solutions

Maintenance Strategy & Planning

• Design, optimize, and maintain Preventive Maintenance (PM) and Predictive Maintenance (PdM) programs
• Support condition monitoring efforts (vibration, thermography, oil analysis, ultrasound, etc.)
• Improve job plans, task frequencies, and maintenance standards based on failure data
• Partner with maintenance planners and supervisors to improve schedule compliance and wrench time

Engineering & Continuous Improvement

• Support capital projects, equipment upgrades, and new equipment installations with a focus on reliability and maintainability
• Perform Failure Modes and Effects Analysis (FMEA) on existing and new assets
• Standardize parts, tools, and maintenance procedures to reduce complexity and cost
• Drive continuous improvement initiatives using Lean, TPM, or Six Sigma methodologies

Safety, Compliance & Documentation

• Ensure all reliability and maintenance activities comply with safety, environmental, and regulatory requirements
• Support MOC (Management of Change) processes related to equipment modifications
• Maintain accurate asset records, BOMs, and maintenance documentation within the CMMS

Cross-Functional Collaboration

• Work closely with operations, maintenance, engineering, and purchasing teams to align reliability goals
• Provide technical guidance and training to maintenance technicians
• Support outage planning and major maintenance events

Required Qualifications

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Industrial Engineering, or related field is preferred
• 5–10 years of experience in maintenance, reliability, or engineering within a foundry or heavy industrial environment
• Strong understanding of rotating equipment, hydraulics, pneumatics, and industrial power systems
• Experience with CMMS systems and reliability data analysis
• Proven ability to lead RCFA and drive corrective actions

Preferred Qualifications

• Foundry-specific experience (iron, steel, aluminum, or other metal casting)
• Certification or training in Reliability Engineering, RCM, TPM, or Six Sigma
• Experience with furnace systems, sand handling, dust collection, and high-temperature processes
• Familiarity with OSHA, NFPA, and environmental compliance in industrial settings

Key Competencies

• Analytical and problem-solving mindset
• Strong communication and cross-functional leadership skills
• Hands-on technical aptitude
• Data-driven decision making
• Continuous improvement orientation

Physical & Work Environment

• Manufacturing/foundry environment with exposure to heat, dust, noise, and industrial equipment
• Ability to walk plant floor, climb ladders, and respond to equipment issues as needed
• Occasional off-shift or weekend support during outages or critical failures

Company Description

HyCast Foundry is a premier U.S. foundry specializing in the production of high-quality gray and ductile iron castings. Committed to safety, sustainability, and operational excellence, HyCast aims to drive innovation in the metal casting industry while fostering a collaborative and dynamic workplace culture.

Company Description

HyCast Foundry is a premier U.S. foundry specializing in the production of high-quality gray and ductile iron castings. Committed to safety, sustainability, and operational excellence, HyCast aims to drive innovation in the metal casting industry while fostering a collaborative and dynamic workplace culture.