Reliability Engineer, Rotary Kiln

SUMMARY:

The Rotary Kiln Reliability Engineer is responsible for maintaining and improving the operational efficiency of high temperature rotary kilns, with special focus on reliability. The Rotary Kiln Reliability Engineer analyzes equipment & processes, performs root cause analysis on failures and efficiency deviations, and develops strategies, processes, and procedures to ensure continuous improvement of the rotary kilns.

ESSENTIAL DUTIES AND RESPONSIBILITIES:

Reasonable accommodations may be made to enable individuals with disabilities to perform the essential duties and responsibilities.

• Promote a culture of safety within the process engineering team by setting a positive example and fostering environments where safe practices are a priority.
• Perform detailed analysis of kiln performance data to identify and explain trends, patterns, pops, and potential failure points.
• Develop strategies for equipment and process optimization to enhance performance efficiency.
• Lead investigations into equipment failures, conducting thorough root cause analysis and facilitating development of corrective and preventative actions.
• Utilize Lean/Six Sigma tools to improve rotary kiln performance including 6S, 5Why/Cause Mapping, CEDAC, Capability Studies, PDCA, DMAIC, Process Mapping, FMEAs, etc.
• Collaborate with cross-functional teams to implement corrective actions, preventative actions, and continuous improvements.
• Design and implement proactive maintenance strategies, including predictive and preventive maintenance programs.
• Oversee the execution of maintenance plans and ensure compliance with industry standards.
• Innovate and develop new procedures and processes to minimize downtime and enhance kiln OEE and efficiency.
• Work with operational personnel to develop and standardize best practices and new technologies.
• Manage projects related to kiln reliability from initial conception through to completion.
• Ensure projects are delivered on time, within budget, and meet all safety and performance criteria.
• Provide technical expertise and support to plant personnel on kiln operations.
• Lead and mentor junior engineers and technicians, fostering a culture of continuous improvement.
• Perform other duties as assigned.

SKILLS AND EXPERIENCE:

• Bachelor’s degree in Mechanical or Chemical Engineering or a related field.
• Minimum of 5 years of experience in a similar role, preferably in an industrial or manufacturing environment utilizing lean principles.
• Strong understanding of rotary kiln technology and mechanical systems.
• Proficiency in data analysis and reliability software tools, including Minitab, PowerBI, Excel, and Osisoft PI Vision.
• Familiarity with database entry, report creation and running, preferably SAP.
• Excellent problem-solving skills and the ability to work under pressure.
• Strong verbal and written communication and leadership abilities.

HEALTH, SAFETY, & WORK ENVIRONMENT:

• Perform all work in accordance with RHI Magnesita’s Health and Safety policies.
• Adhere to all EHS and IMS policies and job expectations.
• The work is performed outdoors and/or indoors, enduring heat, cold, rain, dust, wind, and other elements.
• Capable of operating various types of office equipment including but not limited to computers, phones, copiers, and scanners.

PHYSICAL CAPABILITIES:

• Physical demands include but are not limited to standing, walking, sitting, bending, kneeling, pushing, pulling, climbing, and lifting – 50 pounds maximum.
• Must be able to wear all required personal protective equipment (including hard hat with chin strap, safety glasses, safety shoes, and gloves).

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