Reliability Analysis Engineer

Reliability Analysis Engineer

Responsibilities:

This role requires proficiency in key elements of Reliability Engineering (RE). The focus of the role is to lead the collection and analysis of data to identify and recommend specific opportunities for improvements to site maintenance, automation and reliability programs. Position will build and refine business cases for, support implementation of and review effectiveness of recommendations.

The Reliability Analysis Engineer will work collaboratively with stakeholders to ensure that the Genentech/Roche facilities, utilities and equipment are maintained and operated using Reliability Centered Maintenance (RCM) principals and practices. Contribute to strategic planning for Reliability Engineering. Coach and mentor other reliability engineers. Apply RCM to GMP and Non-GMP equipment within the South San Francisco (SSF), Redwood City (RWC), Kentucky Distribution Center (KDC), and Dixon (DXN) campuses. Collectively the organization manages over 6MM square feet across 60+ buildings with the aim of increasing uptime and optimizing the Reliability, Maintainability and Availability (RMA) of systems.

This role will involve the following activities / tasks:

• Analysis of Criticality and Failures * Use existing databases (e.g. SAP CMMS, qualified and non-qualified Facilities Data Historian (FDH) and Building Automation System (BAS)), updating as required, to perform Pareto analysis and follow up to improve results. Since everything can’t be done at once, this role is the foundation for prioritizing all others.

o Manage and own the equipment criticality and risk ranking process.

• Analysis and Optimization (A&O)

o Organizing and leading the Daily Reliability Engineering Huddles. These meetings will concentrate initially on the implementation of reliability initiatives and then move to driving continuous improvement.

o Produce and use metrics to monitor and drive improvements in the Equipment Reliability program. Manage recommendations and metrics associated with the monitoring of equipment and maintenance program performance. These activities include leading interactions with the FOM (Facilities Operations & Maintenance), automation, Plant Engineering and Reliability (PEAR) and contractor organizations for data collection, analysis, and report-out activities.

o Ensure that the appropriate level of support, investigation and follow-up is pursued for actionable trends, emerging patterns, and identified problems or issues.

 Make equipment design change recommendations including evaluating and reporting the cost benefit of changes to improve reliability.

 Support quality and productivity improvements.

o Prepare the organizational budget required to support continuous improvements in reliability.

o Fulfill the role of Maintain Plant A&O Maintenance Analysis as required.

• Predictive Maintenance (PdM) Program

o Lead various aspects of the predictive maintenance program as laid-out in the following table involvement (Standard RACI definitions apply):

PdM program management and monitoring, coordination, and oversight

Data collection, analysis and report-out

Selection of new monitoring equipment and technology

Steam Trap Management Program (non-GMP & GMP)

• Project Support

o Assuring that reliability and maintainability principles are integrated into all large and small capital projects. The level of support will depend on the size, complexity, and phase of the project. Maintain communication with engineering and project management on Facility related projects.

o May approve payments of contractors and vendors relating to Facilities reliability.

o Drive proper collection and summarization of system and parts data for handover from projects to operations (responsibility rests with the project team including maintenance service and RE provider).

• Problem Investigations and Root Cause Analyses

o Lead problem investigation and analysis through the conduct and facilitation of Root Cause Analysis (RCA) for applicable equipment failures or trends. This includes investigation and support of emerging maintenance and operational issues in collaboration with equipment owners.

• Asset Management Strategy

o Lead and implement the Genentech/Roche Asset Management Strategy and associated program. This includes maintenance strategy and program coordination, and decision-making, appropriate to the equipment and its owner.

o Develop and maintain a strategic capital improvement plan for the site.

o Assess repair versus replacement options, providing input to projects, and assisting Project Managers with new equipment design, specification, and purchase decisions.

o Ensure that the maintenance strategies and actions employed are appropriate to the criticality of facilities, utilities and equipment.

o Ensure that standard designs, design specifications, installation guidance documents, operating and maintenance procedures incorporate the appropriate maintenance and reliability principals and considerations.

o Negotiate with vendors/contractors when needed.

Perform Evaluations (RCM, FMEA, FMECA, PHA, Weibull (Life Data) etc.)

Own and coordinate Business Criticality and Prioritization Efforts

Develop Maintenance Strategies (Strategy SME Role) * Assets owned by maintenance, production research or development.

Optimize Maintenance * Review and Improve Maintenance Strategies methods and intervals to develop quantifiable and repeatable procedures

Overhaul/Shutdown Support * Review equipment condition to ensure the right work, and only the right work, is performed. Commission equipment during startup using applicable technologies.

• Additional Accountabilities / Responsibilities

o Provide subject matter expertise in areas where this support is value added to the site and or network.

o Lead formal and informal training as needed for maintenance, production, research, development, engineering, project management, etc.

o Develop and use a formal skills progression program for evaluating and training maintenance personnel.

o Work collaboratively with stakeholders including but not limited to the network, site maintenance organizations, manufacturing customers, administrative, research, development and quality customers, engineering colleagues to implement strategic initiatives that optimize asset maintenance programs and improve equipment reliability for the equipment facilities and utilities located on the SSF campus.

o Respond to emergencies as directed by management and to the level trained.

Who You Are

Job Requirements:

• Bachelor degree in Mechanical, Industrial, Electrical, Chemical Engineering or equivalent and or experience.

• 10 years of experience in an industrial / manufacturing maintenance / operation environment with a multi-year focus on maintenance and reliability programs is required.

• Requires overall working knowledge of Reliability Centered Maintenance (RCM) with experience in the application and analysis of various Predictive Maintenance (PdM) methods, including at least 2 years experience with rotating equipment.

• Proficient, experienced or working knowledge in facilitating failure analysis with one or more of these methods:

• Failure Modes and Effects Analysis (FMEA)

• Failure Modes, Effects and Criticality Analysis (FMECA – U.S. Dept of Defense Military Standard 1629A)

• Reliability Centered Maintenance (RCM)

• Failure Reporting, Analysis and Corrective Action System (FRACAS)

• The “Five Why’s” or other Root Cause Failure Analyses (RCFA) methods.

• Formal training in some level of statistics and/or statistical process control required.

• Experienced in gathering, categorizing and analyzing large amounts of data.

• Certification as a Maintenance / Reliability Professional (CMRP or equivalent) strongly preferred.

• Proficiency with SAP CMMS (Computerized Maintenance Management System) desired.

• Technical expertise in maintenance and reliability and a proven track record in effective problem solving.

• Ability to remain unbiased and reject conventional wisdom.

• Certification in Continuous Improvement, Operational Excellence or Lean / Six Sigma methodologies preferred.

• Detail-oriented, self-motivated, results driven and self-directed while remaining a strong team player.

• Demonstrated leadership skills and ability to lead cross-functional and cross-site teams preferred.

• Demonstrates a drive for results and able to execute work with minimal direction.

• Ability to collaborate and build effective relationships.

• Excellent communicator – able to influence at all levels of the organization.

• Strategic thinker with the ability to challenge the system to affect an environment of continual improvement.

• May work with or near hazardous materials or chemicals.

• Climb ladders and scaffolding.

• Other Duties as required.

No relocation assistance provided for this role.

Desired Skills and Experience

See application page for details