Senior Maintenance Reliability Engineer

DSJ Global; Louisville (KY); On-site; USD 90,000 - 130,000; Full time

Job summary

DSJ Global is seeking a Senior Maintenance Reliability Engineer for multi-site manufacturing in Kentucky. The role blends hands-on troubleshooting with reliability analysis to optimize preventive and predictive maintenance across facilities.

You will lead root cause investigations, apply FMEA/RCM, and use vibration, thermal imaging, and oil analysis to reduce downtime and improve equipment performance. Travel about 50% is required.

Qualifications

• Bachelor's degree in engineering (mechanical preferred).
• 3+ years of maintenance reliability experience in manufacturing.
• Experience with FMEA/RCM and reliability testing.
• Knowledge of MTBF/MTTR and root cause analysis.
• Experience with predictive maintenance technologies.

Responsibilities

• Analyze reliability data to identify trends and improvements.
• Develop preventive and predictive maintenance programs.
• Lead root cause investigations and corrective actions.
• Apply FMEA and RCM methodologies to improve performance.
• Utilize vibration, thermal imaging, and oil analysis data.
• Evaluate installations and modifications for reliability and safety.
• Provide troubleshooting support and cross-functional collaboration.
• Maintain reliability documentation and metrics.
• Support multiple sites with ~50% travel.

Skills

Maintenance reliability engineering

MTBF

MTTR

Root cause analysis

FMEA

RCM

Predictive maintenance

Vibration analysis

Thermal imaging

Oil analysis

Data-driven reliability analysis

Cross-functional communication

Education

Bachelor's degree in Engineering

Mechanical Engineering

Tools

FMEA

RCM

Vibration analysis tools

Thermal imaging equipment

Oil analysis techniques

Job description

Our client is a multi-site manufacturing organization is seeking a Senior Maintenance Reliability Engineer to improve equipment reliability, reduce unplanned downtime, and optimize maintenance programs across its production facilities. Reporting directly to the Senior Director of Engineering, this position will combine hands‑on troubleshooting with reliability analysis and long‑term preventive and predictive maintenance strategy.

What You'll Do

• Analyze equipment reliability data, including MTBF, MTTR, and failure rates, to identify performance trends and improvement opportunities.
• Develop and optimize preventive and predictive maintenance programs for critical manufacturing equipment.
• Lead root cause investigations and implement corrective actions to prevent recurring equipment failures.
• Apply FMEA and Reliability Centered Maintenance (RCM) methodologies to improve equipment performance.
• Utilize predictive maintenance techniques including vibration analysis, thermal imaging, and oil analysis.
• Evaluate new equipment installations, upgrades, and modifications for reliability and safety.
• Provide technical troubleshooting support to maintenance technicians and operations teams.
• Partner with engineering, quality, maintenance, and production teams on continuous improvement initiatives.
• Maintain reliability documentation, maintenance procedures, and performance metrics.
• Support multiple manufacturing locations with approximately 50% travel.

What You'll Bring

• Bachelor's degree in Engineering, Mechanical Engineering, or a related discipline; advanced degree preferred.
• 3+ years of maintenance reliability engineering experience within manufacturing.
• Food manufacturing experience preferred.
• Strong knowledge of FMEA, RCM, reliability testing, root cause analysis, MTBF, and MTTR.
• Experience with predictive maintenance technologies such as vibration analysis, thermal imaging, and oil analysis.
• Strong equipment troubleshooting and analytical skills.
• Knowledge of manufacturing safety and compliance requirements.
• Ability to manage multiple projects and priorities in a fast‑paced environment.
• Strong cross-functional communication skills.

Why This Role

• High‑impact position reporting directly to senior engineering leadership.
• Influence reliability and maintenance strategy across multiple production sites.
• Combination of technical troubleshooting, data‑driven reliability analysis, and strategic maintenance improvement.
• Opportunity to directly reduce downtime, improve equipment performance, and lower maintenance costs.