Sr. Reliability Engineer

CSL Behring seeks a Senior Reliability Engineer to safeguard the reliability of utilities and manufacturing assets at its Kankakee, IL site. This role leads reliability analytics, maintains CMMS data integrity, and drives predictive maintenance and mechanical integrity programs for critical plant equipment across utilities and manufacturing operations.

Responsibilities

• Develop maintenance strategies for new, critical utilities and manufacturing plants to form the foundation of maintenance plans.
• Serve as the reliability leader, mentoring engineers and technicians on equipment reliability and mechanical integrity best practices.
• Head reliability improvement teams and collaborate with Operations, Maintenance, and Engineering to address equipment issues and raise overall plant reliability.
• Foster a culture of reliability through proactive leadership, problem solving, and cross‑department collaboration.
• Create and maintain comprehensive maintenance strategies and mechanical integrity plans for plant equipment, including pressure vessels, piping, and rotating equipment, with emphasis on new, critical plants.
• Continuously enhance maintenance programs (PMs), BOMs, and spare parts inventories to ensure regulatory compliance.
• Coordinate with engineering on equipment classification, SAP FLOC structure, asset information population, and acquisition of manuals.
• Apply reliability tools such as data analysis, SPC, reliability modeling and prediction, fault tree analysis, Six Sigma, and machine learning; conduct RCA, FMEA, and FRACAS in line with global standards to analyze maintenance and integrity trends.
• Develop predictive maintenance models to forecast failures and implement proactive maintenance actions to minimize downtime and extend asset life.
• Identify and implement opportunities to improve reliability and mechanical integrity to boost uptime and performance.
• Develop KPI dashboards to visualize reliability data and communicate improvements to stakeholders.
• Measure and report reliability and mechanical integrity performance metrics, including MTBF, MTTR, downtime, and maintenance costs.
• Oversee mechanical integrity programs to ensure safe and reliable operation of pressure vessels, piping systems, and rotating equipment.
• Implement risk-based inspection programs to ensure compliance with API, ASME, and OSHA standards.
• Ensure equipment meets mechanical integrity standards through regular inspections and non-destructive testing methods.
• Maintain CMMS data integrity to support preventive, predictive, and condition-based maintenance and mechanical integrity requirements.
• Oversee maintenance planning and evaluation of new predictive technologies in collaboration with the global Maintenance & Utilities Excellence organization to align with global strategy.
• Lead the application of predictive maintenance and non-destructive testing to minimize downtime and preserve structural integrity of critical assets.
• Collaborate with the global Maintenance & Utilities Excellence organization to stay aligned with the global strategy.
• Implement and manage condition-based monitoring programs using IoT and sensor technologies to monitor the health of critical assets.
• Use real-time sensor data to detect early signs of degradation and trigger proactive actions.
• Lead the deployment of predictive maintenance technologies to monitor and improve reliability and take proactive maintenance actions to prevent unplanned downtime.
• Act as the subject matter expert for internal and regulatory audits related to equipment reliability, mechanical integrity, and maintenance.
• Ensure compliance with mechanical integrity standards such as API 510, 570, 653, ASME, and OSHA.
• Continuously advance knowledge in biopharmaceutical industry best practices for mechanical integrity and problem solving.
• Adhere to CSL Behring’s Safety Program and health and safety mandates, particularly in mechanical integrity areas.
• Complete additional duties assigned by senior management to support reliability, mechanical integrity, and plant operations.

Technologies

• CMMS
• SAP 4/HANA
• Power BI
• Qlick Sense
• IoT

Education

• Bachelor’s degree in mechanical, electrical, or industrial engineering preferred, or an M.S. in a related engineering field.
• Certifications in Data Analysis (preferred but not required).
• Certified Maintenance & Reliability Professional (CMRP) and/or Certified Reliability Engineer (CRE) preferred but not required.
• Certifications in Mechanical Integrity (API 510, 570, or 653) preferred.

Experience

• 7+ years of relevant experience with a Bachelor’s degree, or 5+ years with a Master’s degree.
• Relevant experience in maintenance engineering, mechanical integrity, or reliability engineering, ideally in the pharmaceutical or manufacturing industry.
• Solid knowledge of reliability concepts such as TPM, RCM, and FMEA.
• Hands-on experience with failure analysis methodologies (RCFA) and process improvement methods like Lean and Six Sigma.
• Strong proficiency in computerized maintenance management systems (CMMS).
• Familiarity with visualization tools such as Power BI and Qlick Sense for dashboards.
• Familiarity with cloud platforms like SAP 4/HANA.
• Experience with AI/ML project deployment pipelines is a plus.
• In-depth knowledge of GMPs, FDA standards, and other regulatory guidance.
• Strong verbal and technical writing skills, along with effective interpersonal abilities.
• Ability to work cross-functionally, collaborate with diverse teams, and solve complex technical problems.

Competencies

• Drives Results
• Customer Focus
• Strategic Mindset
• Innovation
• Collaboration