Chemicals Reliability Consultant
EFESO Management Consultants
full-time
Posted on:
Location Type: Remote
Location: United States
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Salary
💰 $140,000 - $220,000 per year
About the role
- Reliability Consultants to provide deep asset reliability expertise to clients across the chemicals industry.
- The role focuses on improving equipment reliability, asset availability, mechanical integrity, and plant stability across batch, continuous, and specialty chemical operations.
- Consultants will assess existing reliability practices, identify performance, and risk gaps, and implement best-in-class reliability strategies, standard work, and digital / AI-enabled tools to deliver sustainable improvements in asset integrity, cost, unplanned downtime reduction, and overall manufacturing performance.
- Independently assess asset reliability, and mechanical integrity practices across batch, continuous, and specialty chemical operations.
- Benchmark site performance against industry best practices and peer operations to identify gaps and improvement opportunities.
- Develop fact-based reliability excellence roadmaps, prioritizing initiatives based on risk, value, and ease of implementation.
- Provide objective, data-driven insights to client leadership on reliability risks, cost drivers, and asset performance.
- Lead or support implementation of reliability improvement initiatives, including asset criticality, failure mode management, and risk-based maintenance strategies.
- Identify and eliminate chronic equipment issues and systemic causes of unplanned downtime.
- Align operating discipline, maintenance practices, and execution routines to improve plant stability and asset life.
- Review and strengthen Mechanical Integrity and reliability-related PSM elements, including inspection regimes, MOC, PSSR, and asset risk management.
- Conduct field audits, maintenance walkdowns, and failure investigations to identify integrity and safety risks.
- Provide independent challenge and assurance that reliability improvements are implemented safely and in compliance with site and regulatory requirements.
- Assess reliability data quality and usage across CMMS/EAM, downtime systems, and condition monitoring tools.
- Define and implement reliability KPIs, dashboards, and governance routines to support sustained performance management.
- Quantify and track benefits from reliability initiatives, including reductions in downtime, maintenance cost, and operational risk.
- Review and optimize maintenance strategies, planning, and scheduling to improve execution effectiveness and wrench time.
- Assess and deploy digital and AI-enabled reliability tools (CMMS/EAM optimization, predictive analytics, condition monitoring) to improve decision-making.
- Build trusted client relationships through objective assessment, technical credibility, and hands-on implementation support.
Requirements
- Education: Bachelor’s degree in chemical engineering or a closely related field. A master’s degree is a plus.
- Certifications: CMRP (Certified Maintenance & Reliability Professional) or CRL (Certified Reliability Leader) preferred.
- Minimum 8+ years of experience in chemical manufacturing (petrochemical, specialty chem, or refining), with a strong emphasis on asset reliability, maintenance engineering, or reliability engineering roles within batch or continuous process environments.
- Hands-on experience working closely with operations and maintenance, including time spent in plant/area engineering, reliability engineering, maintenance leadership, or rotating equipment roles supporting day-to-day plant performance.
- Strong background in reliability fundamentals, including asset criticality analysis, failure modes and effects analysis (FMEA), RCFA, preventive and predictive maintenance strategies, and reliability data analysis.
- Direct involvement in turnarounds, shutdowns, and major maintenance events, including scope development, job planning, execution support, risk management, and post-event performance review.
- Demonstrated ability to drive reliability and asset performance improvements, such as reduced unplanned downtime, improved equipment availability, maintenance cost optimization, and increased mean time between failures (MTBF).
- Proven track record of delivering measurable improvements in reliability, safety, and cost through improved maintenance strategies, work management, spare parts optimization, and collaboration with operations.
- Familiarity with PSM requirements and mechanical integrity programs, including MOC, HAZOP/LOPA interfaces, inspection regimes, safe work practices, and disciplined asset lifecycle management in a regulated chemical environment.
Applicant Tracking System Keywords
Tip: use these terms in your resume and cover letter to boost ATS matches.
Hard Skills & Tools
asset reliabilitymechanical integrityreliability engineeringpreventive maintenancepredictive maintenancefailure modes and effects analysis (FMEA)root cause failure analysis (RCFA)reliability data analysismaintenance strategiesrisk management
Soft Skills
client relationship managementdata-driven insightsobjective assessmenttechnical credibilityhands-on implementation supportcollaborationleadershipcommunicationproblem-solvingperformance improvement
Certifications
CMRPCRL