Reliability Engineer

Emerson is seeking a hands-on Reliability Engineer to improve equipment availability and reduce unplanned downtime across its foundry operations in Erie, PA. In this onsite role, you will serve as a technical leader for asset reliability, preventive and predictive maintenance, CMMS administration, and root cause failure analysis, with added support for maintenance-related capital projects.

Key focus areas include strengthening maintenance systems across melt, mold, core, finish, material-handling, utility, and facility equipment, while using maintenance data to drive measurable reliability improvements.

Responsibilities

• Improve equipment reliability, availability, and maintainability across all foundry processes, including melt, mold, core, finish, material-handling, utility, and facility systems.
• Establish and maintain asset criticality rankings to prioritize reliability resources and improvement activity.
• Identify chronic and high-impact equipment issues and develop plans to eliminate recurring failures.
• Develop reliability strategies for critical and constraint equipment.
• Support equipment lifecycle planning, modernization, and obsolescence-risk mitigation.
• Own and administer the plant CMMS, including asset hierarchy, equipment records, preventive maintenance programs, job plans, failure codes, equipment history, parts relationships, and reporting.
• Establish data standards and audit CMMS accuracy and consistent use across Maintenance and Operations.
• Train employees on work-request, work-order, failure-coding, and maintenance-history requirements.
• Use CMMS data to identify failure trends, maintenance demand, backlog risk, and improvement priorities.
• Improve maintenance planning, prioritization, scheduling, execution, and closeout processes.
• Develop and optimize preventive maintenance based on asset criticality, failure history, OEM guidance, and operating experience.
• Evaluate and implement condition-based and predictive maintenance practices where economically justified, including vibration, thermography, ultrasound, oil analysis, and electrical testing.
• Improve maintenance job plans to include labor, parts, tools, safety requirements, acceptance criteria, and estimated duration.
• Track PM and scheduled-work compliance and lead corrective actions when performance is below expectation.
• Partner with Operations and Maintenance to develop operator care, inspection, cleaning, lubrication, and basic-condition standards.
• Lead or facilitate structured root cause failure analysis for significant, repeat, and high-cost equipment failures.
• Apply methods such as 5 Why, cause-and-effect analysis, and Failure Mode and Effects Analysis (FMEA).
• Develop corrective actions with clear owners and completion dates, and verify completed actions prevent recurrence.
• Update PMs, operating standards, training, spare-parts strategy, or equipment design based on lessons learned.
• Support continuous improvement focused on safety, uptime, throughput, quality, and cost.
• Define critical-spare requirements based on asset criticality, failure risk, lead time, consequence, and usage history.
• Work with MRO and Purchasing to establish appropriate inventory levels, reorder points, equipment bills of material, and obsolescence plans.
• Provide technical specifications and sourcing support for repair components and replacement equipment.
• Identify opportunities to reduce repair lead times and improve critical-part availability.
• Provide engineering support for maintenance, equipment, utility, and facility improvement projects, including developing scopes, technical specifications, cost estimates, risk assessments, and appropriation requests.
• Provide reliability and maintainability input during equipment selection, design, installation, commissioning, and startup.
• Support planned outages and shutdowns through scope development, job planning, readiness reviews, execution support, and follow-up.
• Ensure new and modified equipment has appropriate PMs, spares, drawings, manuals, training, and CMMS records before handoff.
• Coordinate with equipment manufacturers, contractors, and suppliers to resolve technical issues.
• Develop and report actionable maintenance and reliability measures, including unplanned downtime, MTBF, MTTR, PM and scheduled-work compliance, planned versus emergency work, backlog risk, repeat failures, and critical-asset availability.
• Prioritize analysis and improvement activity on constraint and high-criticality equipment where lost availability has the greatest operating impact.
• Participate in daily, weekly, and monthly operating reviews to communicate equipment performance, risks, action status, and resource requirements.
• Provide technical and leadership support during major equipment failures, shutdowns, and temporary coverage situations.
• Note: This role is not intended to replace routine maintenance supervision.

Requirements

• Bachelor’s degree in Mechanical, Electrical, Industrial, Manufacturing, or a related engineering discipline; or an associate or technical degree combined with substantial relevant industrial maintenance and reliability experience.
• Three or more years of engineering, maintenance, or reliability experience in manufacturing or industrial operations.
• Demonstrated troubleshooting experience with mechanical, electrical, hydraulic, pneumatic, controls, and utility equipment.
• Experience using a CMMS to manage asset records, PMs, job plans, failure history, backlog, and maintenance performance.
• Demonstrated use of structured problem-solving or root-cause methods.
• Ability to lead cross-functional improvement projects and communicate effectively with skilled trades, operators, supervisors, engineers, suppliers, and plant leadership.
• Strong organization, project management, and data-analysis skills, including proficiency with Microsoft Excel, Word and CAD.
• Legal authorization to work in the United States (no sponsorship provided).

Technologies

• CMMS
• Microsoft Excel
• Microsoft Word
• CAD
• 5 Why
• Failure Mode and Effects Analysis (FMEA)
• MTBF
• MTTR

Benefits

• Flexible, competitive benefits plans
• Medical insurance plans
• Dental and vision coverage
• Employee Assistance Program
• 401(k)
• Tuition reimbursement
• Employee resource groups
• Flexible time off plans
• Paid parental leave (maternal and paternal)
• Vacation and holiday leave

Preferred Qualifications that Set You Apart

• Foundry, metals, machining, heavy-industrial, or process-manufacturing experience.
• Experience with DISA molding, sand systems, furnaces, dust collection, cranes, conveyors, core-making, machining, compressed air, cooling-water, or comparable industrial systems.
• Experience with Maintenance Connection or a comparable CMMS or EAM platform.
• Predictive-maintenance experience in vibration, thermography, ultrasound, oil analysis, or motor and electrical testing.
• Knowledge of FMEA, Reliability Centered Maintenance, TPM, autonomous maintenance, and equipment failure analysis.
• PLC and industrial controls troubleshooting experience.
• Experience with capital projects, shutdowns, equipment installation, and commissioning.
• CMRP, CRL, vibration-analysis, thermography, or other relevant reliability certification.
• AutoCAD, Inventor, or other CAD software experience.

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