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Processing Asset Engineer

at KLA Industries

Posted on 1/28/2012

Location: Joliet, IL

Job Type: Full Time

Job ID: W680739

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The 5th largest chemical manufacturer in the world, with plans to become #1, has an immediate need for an experienced Process Availability Leader. We are a global supplier of plastic resins and compounds widely used in automotive, healthcare, consumer electronics, transportation, performance packaging, building and construction, telecommunications and optical media applications.This facility of 220 converts raw material to manufacture ABS Acrylonitrile butadiene styrene.The most important mechanical properties of ABS are impact resistance and toughness. This is an important leadership role within the organization with an unlimited career path for advancement. Responsible for assembling and leading a diverse team through a Root Cause Event. With a background in maintenance, reliability, process and manufacturing this position will troubleshoot and compile data on equipment and machinery. They will go after the equipment that is causing the problem and discover Root Cause and work to rectify. Duties include:.
Owns the Assets within the Chemical Operations Quad, where a conversion of raw materials produces ABS Resin
Is responsible for optimizing the performance of the Assets in the most cost effective manner.
Champions the Asset Reliability, Asset Availability and Outage Management Work Processes in the Quad.
Drives the reliability methodologies (Criticality, RCA, RCM, PPM) and coaches the team in order to realize the culture shift to increased Asset Ownership, Operator Performed Maintenance, Troubleshooting and Extended Interval between Outages.
Identifies and communicates operating unit goals and technology plans with respect to health, safety, and environmental concerns, unit operations, and technical opportunities.
Support on-site EHS programs, recognizes and participates in resolution to hazards that are identified (ie. through PGR).
Define Functional Systems in Unit
Establish the Root Cause Analysis (RCA) level criteria
Lead Criticality Assessments on Functional Systems. Work together with the Site Reliability Team.
Lead implementation / Perform PPM Assessments together with Reliability team. Monitor & track the implementation of the resulting recommendations
Champion the FMEA’s for the (ex) Safety critical reassessments (one time effort). Monitor & track the implementation of the resulting recommendations
Perform at least every Quarter an Opportunity Analysis. Develop List of Top 10 +/- Bad Actors for Unit. Include sporadic & chronic issues. Use trend graphs of costs/ asset and unplanned production losses.
Review Simple RCA Results (5 why’s) & act as a mentor in the Quad and within operations for the 5 Why’s. Initiate Formal RCA’s (if necessary based on this review) and be able to deliver in depth 5X why training.
Apply Condition Based Monitoring inspection techniques and the data these inspections provide
Initiate RCM’s & FMEA’s based on criticality analysis.
Coordinate Detailed Hand offs of the recommendations.
Track the implementation of all recommendations coming out of various reliability methodologies applied in your Quad (eg, RCA, RCM, PPM, FMEA…). Measure effectiveness.

Qualifications:
Minimum of 3 years experience in the unit(s)/compounding technology assigned or other relevant technology.
Six Sigma Green Belt
Understanding of, and skill in the implementation of Leading by Commitment protocols and Critical Organizational Behaviors (COB’s)
Thorough understanding of unit operations, process equipment, and technology
Technical expertise in various maintenance and/or engineering disciplines (mechanical, electrical, instrument and piping).
Ability to apply probability, statistical, modeling and prediction reliability tools appropriately.
Ability to use in depth analysis and structured methodology to identify the true root causes of a situation or event.

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