Reliability Consultant

EFESO Management Consultants - Americas; United States; On-site; USD 110,000 - 170,000; Full time

Benefits offered by this job

Medical insurance

Dental coverage

Yearly bonus

401(k)

Paid time off

Job summary

EFESO Management Consultants seeks experienced Chemicals Reliability Consultants to deliver deep asset reliability expertise for clients across the chemicals industry. The role emphasizes improving equipment reliability, asset availability, mechanical integrity, and plant stability in batch, continuous, and specialty operations.

Consultants will assess current reliability practices, identify gaps, and implement best-in-class reliability strategies, standard work, and digital/AI-enabled tools to

Qualifications

• Bachelor’s degree in chemical engineering or closely related field; master’s is a plus.
• CMRP or CRL certification preferred.
• 3+ years in chemical manufacturing with asset reliability focus.

Responsibilities

• Assess asset reliability and mechanical integrity across batch, continuous, and specialty operations.
• Benchmark performance and identify gaps and improvements.
• Develop reliability roadmaps prioritizing initiatives by risk and value.
• Lead or support maintenance and reliability improvement projects.

Skills

Reliability engineering

Maintenance planning

Asset management

Communication skills

Education

Bachelor’s degree in chemical engineering

Master’s degree (preferred)

CMRP or CRL certification

Tools

CMMS/EAM systems

SAP

IBM Maximo

Infor/Hexion

Job description

EFESO Management Consultants is a global leader in operations strategy and performance improvement. We work closely with clients across a broad range of industries to deliver real results tailored to their unique needs. Our end-to-end services integrate industrial AI, digital solutions, sustainability, and people development, transactions and turnaround, R&D and product profitability, cost and value engineering manufacturing, procurement, and supply chain.

We drive transformation through 1,500+ projects annually in over 75 countries. Powered by deep industry knowledge and a commitment to lasting impact, EFESO works closely with global brands, mid-sized companies, and private equity to build resilience and future-ready operations.

EFESO. Real results, Together

About the Role

We are seeking experienced Chemicals Reliability Consultants to provide deep asset reliability expertise to clients across the chemicals industry. The role focuses on improving equipment reliability, asset availability, mechanical integrity, and plant stability across batch, continuous, and specialty chemical operations. Consultants will assess existing reliability practices, identify performance, and risk gaps, and implement best-in-class reliability strategies, standard work, and digital / AI-enabled tools to deliver sustainable improvements in asset integrity, cost, unplanned downtime reduction, and overall manufacturing performance.

Work Environment & Additional Information

• Type of role: Full Time
• Location: Project location varies by client
• Travel: Consultant roles will require 80% travel on a weekly basis.
• Work Authorization: Must have work authorization that does not now or in the future require sponsorship of a visa for employment authorization in the United States.
• Background Checks: Must be able to pass DISA background check for client projects.

Key Responsibilities

Reliability Excellence Assessment & Roadmap Definition

• Independently assess asset reliability, and mechanical integrity practices across batch, continuous, and specialty chemical operations.
• Benchmark site performance against industry best practices and peer operations to identify gaps and improvement opportunities.
• Develop fact-based reliability excellence roadmaps, prioritizing initiatives based on risk, value, and ease of implementation.
• Provide objective, data-driven insights to client leadership on reliability risks, cost drivers, and asset performance.

Asset Performance & Reliability Improvement Implemenation

• Lead or support implementation of reliability improvement initiatives, including asset criticality, failure mode management, and risk-based maintenance strategies.
• Identify and eliminate chronic equipment issues and systemic causes of unplanned down time.
• Align operating discipline, maintenance practices, and execution routines to improve plant stability and asset life.
• Translate recommendations into practical, site-ready actions with clear ownership and timelines.

Mechanical Integrity, Safety & Risk Assurance

• Review and strengthen Mechanical Integrity and reliability-related PSM elements, including inspection regimes, MOC, PSSR, and asset risk management.
• Conduct field audits, maintenance walkdowns, and failure investigations to identify integrity and safety risks.
• iProvide independent challenge and assurance that reliability improvements are implemented safely and in compliance with site and regulatory requirements.
• Support closure and sustainability of corrective and preventative actions.

Reliability Analytics, KPIs & Performance Control

• Assess reliability data quality and usage across CMMS/EAM, downtime systems, and condition monitoring tools.
• Define and implement reliability KPIs, dashboards, and governance routines to support sustained performance management.
• Quantify and track benefits from reliability initiatives, including reductions in downtime, maintenance cost, and operational risk.
• Provide transparent reporting to site and corporate leadership on progress and impact.

Maintenance Strategy, Turnarounds & Execution Excellence

• Review and optimize maintenance strategies, planning, and scheduling to improve execution effectiveness and wrench time.
• tSupport turnaround and shutdown assessments, readiness reviews, scope optimization, and post-event learning.
• Embed lessons learned into standard work and future maintenance strategies.

Digital Enablement & Capability Transfer

• Assess and deploy digital and AI-enabled reliability tools (CMMS/EAM optimization, predictive analytics, condition monitoring) to improve decision-making.
• Transfer knowledge through coaching, training, and development of standard work to ensure sustainability post-engagement.
• Build trusted client relationships through objective assessment, technical credibility, and hands‑on implementation support.

Qualifications:

Education

• Education: Bachelor’s degree in chemical engineering or a closely related field. A master’s degree is a plus.
• Certifications: CMRP (Certified Maintenance & Reliability Professional) or CRL (Certified Reliability Leader) preferred.

Experience

• Minimum 3 years of experience in chemical manufacturing (petrochemical, specialty chem, or refining), with a strong emphasis on asset reliability, maintenance engineering, or reliability engineering roles within batch or continuous process environments.
• Hands‑on experience working closely with operations and maintenance, including time spent in plant/area engineering, reliability engineering, maintenance leadership, or rotating equipment roles supporting day‑to‑day plant performance.
• Strong background in reliability fundamentals, including asset criticality analysis, failure modes and effects analysis (FMEA), RCFA, preventive and predictive maintenance strategies, and reliability data analysis.
• Direct involvement in turnarounds, shutdowns, and major maintenance events, including scope development, job planning, execution support, risk management, and post‑event performance review.
• Demonstrated ability to drive reliability and asset performance improvements, such as reduced unplanned downtime, improved equipment availability, maintenance cost optimization, and increased mean time between failures (MTBF).
• Proven track record of delivering measurable improvements in reliability, safety, and cost through improved maintenance strategies, work management, spare parts optimization, and collaboration with operations.
• Familiarity with PSM requirements and mechanical integrity programs, including MOC, HAZOP/LOPA interfaces, inspection regimes, safe work practices, and disciplined asset lifecycle management in a regulated chemical environment.

Technical Skills

• Strong knowledge of chemical plant reliability and maintenance practices, including asset criticality, mechanical integrity programs, preventive and predictive maintenance, work management, and reliability‑centered maintenance (RCM).
• Working knowledge of core chemical processes (e.g., reaction, distillation, crystallization, polymerization, separation, drying, blending) with an understanding of how process conditions and operating discipline impact equipment health, failure modes, and asset life.
• Familiarity with PSM and Mechanical Integrity requirements, including PHA/HAZOP interfaces, MOC, PSSR, inspection and testing regimes, and safe work practices in regulated chemical environments.
• Experience with reliability‑focused digital tools, such as CMMS/EAM systems (SAP, IBM Maximo, Infor/Hexion, etc), condition monitoring and predictive analytics, mobile maintenance execution, reliability dashboards, and visual management of asset performance.

Soft Skills

• Exceptional analytical and problem‑solving skills.
• Strong written and verbal communication skills, including the ability to present complex technical information to non‑technical stakeholders.
• Ability to work independently and as part of a global, multi‑disciplinary team.
• Willingness to travel extensively to client sites.

Compensation

The wage range for these roles considers a wide range of factors considered in making compensation decisions including skill sets; years of experience and training; level brought in, licensure and certifications, and other business and organizational needs. The disclosed range estimate has not been adjusted for the applicable geographic differential associated with the location at which the position may be filled. It is not typical for an individual to be hired at or near the top of any range for their role and compensation decisions are dependent on the facts and circumstances of each case. The salary range is $110,000- $170,000 USD, based on level identified in the interview process.

Featured Benefits

We offer a competitive compensation package where you’ll be rewarded based on your performance and recognized for the value you bring to our business. In addition, Benefits includes medical and dental coverage, yearly bonus, 401(k) plan, PTO, observed holidays and more.

Company Statement

EFESO Management Consultants provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

Other Employment Statements

Applicants for employment in the US must have work authorization that does not now or in the future require sponsorship of a visa for employment authorization in the United States.