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.