Reliability Expert

Overview
 
The prime objective of the Maintenance & Reliability Expert is to provide technical support and expertise
to eastern Canada cement manufacturing sites in order to achieve targeted maintenance KPI’s.  This
encompasses supporting operations through execution of major turnaround and capital project execution. 
This position will also facilitate the execution of maintenance related strategic initiatives from Group level.

Responsibilities
 
Health and Safety

 Responsible to drive H&S performance, including exemplary housekeeping, robust adherence to

standards and ensuring a strong positive H&S culture.
 Demonstrates a commitment to communicating, improving and adhering to safety policies in all
work environments and areas.
 Actively manages risks by ensuring that all related control activities are thoroughly implemented,
including safe work job planning.
 Drives committed and effective incident management through active participation in incident
review, investigation, and corrective action creation.
 Promotes a culture of vigorous risk assessment, incident reporting and leading indicators, i.e.,
Near Misses, Visible Personal Commitment (VPC), Boots on the Ground.

Environment

 In consultation with the Environmental team, ensures that operations are provided with the
technical support in order to comply with all relevant requirements (eg. Provincial regulatory,
certificate, permit, etc) .

Maintenance

 Review major mechanical safety incidents using root cause analysis and serious event reviews.
 Provide technical expertise in the fields of grinding equipment, filters, kilns, gears and reducers,
fans, blowers, compressors, coolers, hydraulics, conveying systems, packing machines,
preventive techniques, and welding.
 Provide first level assistance to plants in eliminating mechanical failures by using systematic and
methodical systems to determine root causes.
 Take ownership in the implementation of the Maintenance Management System (MMS) and its
integration into the plants organization in alignment with CIF.
 Support operations in the implementing of computerized maintenance management systems
(CMMS).
 Clarify plant needs regarding the technical expertise required for maintenance processes and
request additional support from Corporate CIP when needed.
 Agree on mechanical audits to be performed in the Country with Corporate CIP and lead or
support as needed to identify improvement areas and potential.
 Identify improvement opportunities to maximize equipment life cycle and efficiency.
  Support the planning, execution and supervision of complex jobs during major overhauls and
provide appropriate information on equipment malfunctions or failures.
 Collaborate with Project Management and Engineering in new projects and carry out design
reviews on new and critical mechanical equipment to ensure maintainability.
 Advise operations in developing an optimal replacement strategy for the main mechanical
equipment and identify and recommend critical spare parts and follow up implementation.
 Perform analysis to identify critical spare parts in order to optimize inventory and asset sharing.
 Cooperate with the regional purchasing team in optimizing sourcing of mechanical equipment and
parts, materials and services.
 Roll out new preventive maintenance routine and techniques, train others, and monitor progress
in alignment with the Holcim Cement Industrial Framework (CIF) best practices.
 Provide technical expertise in the fields of maintenance organization, preventive programs,
inspection, planning, scheduling, and spare parts management.
 Provide assistance to plants in reaching Country and plant objectives, and in optimizing
maintenance costs in a sustainable manner.
 Monitor relevant KPI’s to ensure achievement of objectives and propose action plans in case of
deviation.
 Provide support to the plants in the preparation of their Major Maintenance Turnarounds and
ensure scopes and resource allocation is aligned with operational requirements.
 Provide experience back to Corporate to enrich know how and share best practices in mechanical
equipment expertise
 Demonstrate teamwork, ensuring openness and respect for others, and welcome feedback.
 Support the development, design and execution of capital development projects
 Act as a cement process & production expert in developing, leading and participating in targeted
training programs within the region.

Relationship with Others

 Works closely with Cement and Slag site managers and their respective plant leadership teams
 Liaising with global cement industrial performance (CIP) teams
 Plant employees including Plant Managers; Maintenance Managers, Reliability Managers,
Inspectors, Planners and Supervisors; and Projects team
 Collaborate with members from other functions including Procurement, Project Management &
Engineering, Learning & Development, Information technology Services, and Health & Safety

Specific Accountabilities

 Zero Harm
 Maximizing equipment reliability, increasing NOEE, NAI, MTBF, etc.
 Consistency of product line maintenance operational best practices application.
 Communication of operational issues to operating Regions.
 Review and monitoring of operational KPIs

Dimensions

 Reporting to: Director, Manufacturing Performance

 Direct Reports: N/A
 Geography: Eastern Canada
 Scope: 3 Cement Manufacturing Plants and 5 Grinding Plants
 Volume: 5MT Cement, ## Slag, ## lightweight aggregate

Qualifications
 
Education and Work Experience:

 Bachelor of Mechanical Engineering or a related discipline

 5 to 7 years plant maintenance position in a heavy industry, preferably in Cement operations
 Extensive experience implementing maintenance processes.
 Bilingualism (French and English) a preference
 Strong computer skills and knowledge of computerized maintenance systems (eg. SAP), MS
office/google suite applications, etc

Preferred Skills:

 Knowledge of Predictive Maintenance tools and techniques (Vibration Analysis, Oil Analysis,
Ultrasound, Infrared Analysis, etc.)
 In depth knowledge of the Holcim MMS and CIF models and tools
 Knowledge of problem solving techniques (Statistical Process Control, Root Cause Failure
Analysis, etc.)
 Experience in the development and implementation of Maintenance programs.
 Strong mechanical aptitude
 Planning and scheduling experience
 Budgeting and cost management experience
 Demonstrated Project Management skills
 Strong communicator (both oral & written).
 Excellent interpersonal skills with demonstrated ability to interact with plant personnel.
 Highly motivated with ability to work with minimal supervision.
 Demonstrated commitment to achieving organizational and personal goals.
 Proven ability to work well in a team environment (co-workers, suppliers, etc.)
 Well organized and systematic.
Maintenance Inspector
Overview
The prime objective of the role is to monitor equipment condition on a continuous basis and analyze
trends in order to ascertain the required maintenance interventions (mechanical) necessary to maximize
equipment reliability, performance and life expectancy, at the lowest possible cost, while maintaining the
production functions.

Responsibilities

 To serve as a role model in the areas of safety, environmental stewardship, leadership,

teamwork, customer focus, and continuous improvement to ensure alignment with the company’s
vision and critical success factors.
 Monitors equipment condition by performing both a formal schedule of systematic walk by
inspections (WBIs) of plant equipment, and in-depth inspections (PMRs) as required during
equipment stoppages, and shutdowns. Enters notifications for corrective maintenance and
provides repair scope guidance to the planner.
 Validates notification from production, process or other departments
 Meets at least once per week with the maintenance planner to prioritize jobs
 If the job priority changes, the inspector must inform the planner about the new priority
 Review the oil and vibration reports and enters notifications as needed
 Inspect the area lubrication systems during the WBIs
 Interacts with production personnel regarding operating procedures which have an impact on
equipment. 
 The inspector should give PMRs feedback to improve their job plan, frequency or time required
 Supervises and manages millwright work during PMRs.
 Participates in the budgeting process and is the prime source of advice in prioritization and
scheduling of major maintenance activities. 
 Keeps up-to-date on advances in cement production technology and equipment through
participation in the Lafarge technical network, as well as by maintaining relationships with the
Technical Center and appropriate suppliers. 
 Uses SAP to help manage activities and generate the maintenance KPI’s which measure the
effectiveness of his function. 

Other Responsibilities          

 Assists the Reliability Engineer and Maintenance Planner with the preparation and consolidation
of the shutdown plan (personal, third party services, materials, spare parts, equipment, tools,
time, and critical path) for all departments with coordination meetings using Lafarge planning
guidelines and tools.
 Assists with equipment and systems troubleshooting as required.
 With the Planner, the Inspector may inspect repairs and/or rebuilds being made off-site
 Assists with preventative maintenance work orders during the outage by supervising contractors
 Knowledgeable in current safety regulations and guidelines and plays an active role in promotion
of plant safety.                                      

Results/Accountabilities
  Records and analyzes data, initiates the work orders, to maintain or replace equipment
components so equipment reliability and performance are maximized and costs minimized and
budgeted. 
 Systematic inspections of all assigned plant equipment (WBIs/PMs)
 Analysis of data collected, completed work orders, and process data in order to initiate
appropriate maintenance work orders which include a detailed scope of work
 Non-systematic inspections (repetitive problems, validate work requests, daily incidents)
 Manage Drive the PPM Program
 Support Plant Safety Program
 Document and monitor equipment history and trend files for PMRs
 Provide technical support for plant activities and the maintenance functions
 Coach/mentor plant employees
 Effective communication
 Active role in budget preparation, forecast updating and compliance
 Required to be part of on-call rotation
 Assigned administrative duties

Relationships with Others’ Jobs

The Maintenance Inspector is one of three inspectors reporting to the Reliability Engineer 

Qualifications
Education and Work Experience

Bachelor of Mechanical Engineering, Mechanical Engineering Technologist, or Millwright ticket and

substantial field experience. 
 
Preferred skills

 Knowledge of Predictive Maintenance tools and techniques (Vibration Analysis, Oil Analysis,
Ultrasound, Infrared Analysis, Thermography etc.)
 Knowledge of problem solving techniques (Statistical Process Control, Root Cause Failure
Analysis, etc.)
 Familiar with Cement production equipment
 Experience in developing Preventive Maintenance (PM) program in SAP.
 Strong computer skills.
 Strong mechanical aptitude
 Strong communicator (both oral & written).
 Excellent interpersonal skills with demonstrated ability to interact with plant personnel.
 Must be able to meet on-call responsibilities in a 24/7 operation.
 Must be able to work on night shift or weekend when required
 Highly motivated with ability to work with minimal supervision.
 Demonstrated commitment to achieving organizational and personal goals.
 Proven ability to work well in a team environment (co-workers, suppliers, etc.)
 Well organized and systematic.

Physical Demands
 
The Physical demands described herein are representative of those that must be met by an employee to
successfully perform the essential functions of this job.
  Frequent walking, standing, climbing, bending / stooping, kneeling, balancing, and able to reach
above shoulders
 4 Senses
 Good hand / eye coordination, fine finger movement, handling
 Good hearing,
 Good vision
 Good sense of smell

Work Environment
 
While performing the duties of this job, the employee is:

 Regularly exposed to moving mechanical parts, vibration and noise, 

 Frequently exposed to high, precarious places; fumes or airborne particles, confined space,
outside weather conditions, low lighting, and artificial lighting, 
 The inspector is regularly exposed to wet and/or humid conditions.
 The inspector will regularly walk over uneven grades 
Reliability Engineer
Overview
The Reliability Engineer is assigned to identifying, developing and implementing engineering and
system projects to improve plant condition, operability, equipment reliability, cost optimization, and comply
with environmental and safety performance. In carrying out the duties of this position, a primary objective
is to improve the value of all company assets through increased reliability and lower operating costs while
allowing the operation of the equipment to meet production requirements within budget guidelines.
 

Responsibilities

 Responsible for monitoring reliability-based systems including preventative maintenance

systems, lubrication, vibration analysis, and condition monitoring.
 Creation of preventative maintenance routines (PMRs) and bills of materials (BOMs) for new
equipment (including mobile equipment).
 Management of the preventive/predictive maintenance programs (Inspection, Vibration, Oil
Analysis, NDT, thermography, etc.) to ensure optimum equipment availability.
 Development and implementation of the DSCQP inspection program
 Analysis and elimination of repetitive problems through root cause analysis, Pareto analysis,
statistical review, FMEA and similar techniques.
 Support and guide sustainable improvements in MTBF and NAI of major equipment.
 Responsible for the facilitation of continuous improvement processes around equipment
availability and reliability.
 Responsible for the process of gathering input, and facilitate task completion through others.
 Coordinate SAP system operations in the area of preventative maintenance routine (PMR)
optimization.
 Provide technical support, training and development for maintenance functions with specific focus
on entrenching reliability concepts within the maintenance group.
 Develop area budget, and accountable for results based on defined KPIs
 Lead and facilitate the Mechanical Maintenance area, including management of core
maintenance systems and research/recommend new PM procedures based on new technology.
 Responsible to plan and prepare activities that have to be executed by the LafargeHolcim
employees, service companies or contractors. 
 Provides daily instruction to the maintenance lead hand and has a field presence to ensure safety
and effectiveness.
 
Relationships with Other Jobs:

 Assist production department with mechanical problems

 Work with maintenance to execute preventive and predictive maintenance program
 Work with preventive maintenance and with process teams in improving the plant reliability
 Provide assistance in the mechanical design and execution of plant capital projects.

Qualifications

 Required Education: Bachelor of Science degree in Mechanical Engineering. In the absence of

this, a Technologist Diploma with significant experience in the industry would be required
 Field of Study Preferred: Mechanical Engineering 
 Required Work Experience: 3 years in heavy industry
 Required Computer and Software Skills: Comprehensive computer software knowledge required,
including Excel, Word, Project, Auto CAD, SAP, etc. is preferred
 CMRP certificate desired

Additional Requirements:

 Good communication skills.

 Strong ability to work self-directed.
 Demonstrated problem solving skills and sound decision making based upon available
information.
 Is available outside of normal work hours in case of emergency repairs, and is responsible for
assessing the situation and assigning the call out
 Flexible, able to adjust to changing priorities and propose improvement actions.
 Able to facilitate the collaboration of people in assigned area.
 Initiative and self-starting abilities; willing to take action to resolve problems.
 Set and possess high work standards.
 Flexibility with working hours and ability to manage stress, to provide assistance and to
encourage the maintenance team in critical situations
 Customer focused, both internally and externally.
 Microsoft office computer experience required.