Reliability and Process Engineer

Summary

The Reliability and Process Engineer improves the reliability of critical equipment and tooling by eliminating chronic failures, reducing unplanned downtime, and mitigating the risk of major failures. The engineer leads root cause investigations and strengthens process performance across Hynes Industries’ roll forming and precision metals operations. Working closely with Engineering, Maintenance, Operations, Quality, and Analytics, the engineer implements and verifies permanent corrective actions to sustain safe, reliable, and capable production.

Essential Duties and Responsibilities

Equipment and Tooling Reliability 50%

• Evaluate equipment condition, tooling wear, alignment, loading, lubrication, and component life; develop improvements that reduce breakdowns, tooling failures, and unplanned downtime.
• Prioritize critical assets and tooling using failure history, risk, and production impact. Apply failure mode and effects analysis to identify and address vulnerabilities.
• Partner with Maintenance to improve preventive and condition-based maintenance, precision maintenance practices, tooling inspection standards, and critical spare recommendations.
• Use maintenance records, OEE losses, and condition monitoring data to identify recurring losses and turn credible equipment alerts into defined inspection or maintenance actions.
• Support equipment and tooling modifications, supplier coordination, commissioning, and acceptance testing to improve reliability and maintainability throughout asset life.

Investigations and Verification 30%

• Lead investigations of recurring equipment and tooling failures, dimensional variation, and chronic losses. Preserve evidence, test hypotheses, and separate machine, tooling, material, measurement, and operating causes.
• Develop permanent corrective actions with responsible teams; track implementation, verify effectiveness under representative production conditions, and confirm recurrence is reduced.
• Document findings, update technical standards, and train operators and technicians. Verify operational and financial improvements with Operations, Quality, and Finance.

Process Performance 20%

• Improve process capability, first-pass yield, setup repeatability, and throughput using controlled trials, statistical analysis, and validated operating windows.
• Develop setup and troubleshooting standards; support launches and process changes while maintaining safety, customer requirements, and reliable measurement.

Qualifications

Qualification Requirements

Education and Experience

• Bachelor’s degree in Mechanical, Manufacturing, Industrial, or related Engineering; equivalent technical education and substantial relevant experience may be considered.
• Minimum five years of manufacturing engineering or equipment reliability experience, including hands-on troubleshooting and implementation of sustained corrective actions.
• Experience with production machinery, tooling, and mechanical systems; roll forming or related precision metals manufacturing experience preferred.
• Ability to lead cross-functional projects, manage priorities, and communicate with operators, technicians, suppliers, and leadership.

Technical Skills

• Mechanical fundamentals in loading, torque, deflection, alignment, and wear; practical knowledge of power transmission, hydraulics, and pneumatics.
• Engineering drawings, GD&T, precision measurement, CAD, and relevant mechanical and controls schematics.
• Structured root cause and failure analysis, FMEA, controlled testing, and corrective action verification.
• SPC, Cp/Cpk and Pp/Ppk, measurement system analysis, and designed experiments; assessment of process stability before interpreting capability.
• Preventive and predictive maintenance, criticality, condition monitoring, and CMMS analysis; vibration analysis experience or reliability certification preferred.
• Excel, statistical software, and OEE/CMMS systems such as Vorne and Limble; SQL, Power BI, Python, or Databricks familiarity preferred.
• Safe troubleshooting, lockout/tagout, guarding, and change control; collaboration on sensors and automated inspection.

Physical Requirements

Ability to work on the production floor, stand, walk, and sit for extended periods; use precision instruments and small tools; and lift up to 50 pounds, with reasonable accommodation as applicable.

Work Environment

Manufacturing, mill, and office environments with required PPE. Some travel among Hynes facilities and occasional support across shifts or outside normal hours are required.

Competencies

Teamwork, Initiative, Professionalism, Analytical Thinking, Communication, Accountability, Problem Solving, Safety Awareness.