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Maintenance & Reliability Manager

Company:

INEOS Oligomers USA LLC

Job title

Maintenance & Reliability Manager

Location        

Chocolate Bayou, Alvin, TX – USA

Closing date

July 7th, 2022

Organizational context and job purpose

Organizational Context:

With LAO manufacturing facilities in the US, Canada and Belgium, INEOS Oligomers is one of the large merchant suppliers of Linear Alpha Olefins (“LAO”). LAO’s are used in a variety of industries, with main markets being comonomers for polyethylene, feedstock for production of lubricants, surfactants, lubricant additives, and paper sizing chemicals, and base stock for drilling fluids. PAO is synthetic lubricant.

As part of its growth strategy, INEOS Oligomers is operating a world scale LAO & PAO production facility located on INEOS Olefins & Polymers site in Chocolate Bayou, Alvin, Texas (“Plant”).

As a Responsible Care company, we encourage our employees to embrace the principles of Responsible Care® by actively practicing them, promoting awareness of Responsible Care® and encouraging others to commit to these principles. Responsible Care® is the chemistry industry's commitment to sustainability - the betterment of society, the environment and the economy. Its ethic and principles compel us to innovate for safer and more environmentally friendly products and processes, and to work cooperatively to identify and eliminate harm throughout the entire life cycle of their products.

This position has accountability, in keeping with the INEOS Responsible Care principles and ethics, for all aspects of the operation of the Oligomers Plant, including safety/environment, people management, cost control, quality, production planning, project and process follow-up.

This position will embrace and promote the INEOS 20 safety principles.

Purpose of the job:

The Maintenance & Reliability Manager will report to the Asset Manager

The Maintenance & Reliability Manager is responsible for the safe and efficient planning and execution of routine maintenance services, turnaround planning and execution, equipment inspection and integrity services, reliability strategy and services, materials management, and the management of the onsite maintenance contractors.   Additionally, this role is responsible for support and execution of identified Project Expense work and small Capital projects.

In this role, the Maintenance & Reliability Manager will provide guidance to the Reliability and Maintenance teams, INEOS employees as well as third party service providers, to seek continuous unit reliability improvement and achieve best in class unit reliability performance within the constraints of safety performance, compliance with all applicable regulations, and minimum maintenance cost.

In addition, the Maintenance & Reliability Manager will be responsible for the planning and execution of the recurring unit turnarounds in close cooperation with the plant’s Operations department and manage and guide his/her Small Project Construction team in close co-operation with the plant’s Engineering group to implement any small cost, quality, safety, and reliability improvement projects on time and in budget. 

In support of these activities, the Maintenance Manager will be responsible, with his/her team, for providing adequate and optimized supply of warehouse spare parts, and for maintaining all technical plant information up to date.  The Maintenance Manager will also be responsible for ensuring that the site is compliant with INEOS standards and expectations around housekeeping.

Environment/Context:

 Internal factors:

  • Achieving durable mechanical and structural integrity, and highest degree of reliability of the facilities,

  • Achieving safe and injury free maintenance and construction activities,

  • Adapting organizational capabilities to the potentially substantial variation in service demand (capital investment plan, turn-arounds,)

  • Finding the right balance between internal and external resources and service capabilities for lowest possible service costs.

External factors:

  • Adapting warehouse stock levels, and sourcing of materials and external resources and services to continuously changing market situation and opportunities.

Responsibilities AND Accountabilities

Accountability 1: Manage Site Inspection and Maintenance Group.

Most important activities:

  • Develop, implement, and manage a risk-based inspection program,

  • Ensure adherence to all applicable regulatory requirements,

  • Set maintenance priorities and manage maintenance resources, both internal as well as external to deliver best in class maintenance performance and minimize intervention times,

  • Achieve continuous improvement of maintenance quality and capabilities through comprehensive training and motivation of all resources at all levels of the organization, internal as well as external,

  • Manage and optimize warehouse stock, maintenance equipment, machinery, and tools,

  • Organize, plan, and safely deliver unit turnarounds one to three years, on time and in budget.  Work with Operations to develop a 5-year look-ahead Outage schedule/budget for the LAO & PAO assets

Accountability 2: Manage Site Reliability Group

Most important activities:

  • Develop/implement and execute a comprehensive reliability/availability strategy for the site

  • Develop and manage an in-depth plant monitoring and troubleshooting system to create an environment of continuous learning and improvement,

  • Work with Reliability Group to drive maintenance focus away from correction towards prevention of plant facilities and equipment,

  • Ensure site team members partipate and stay engaged in the monthly OCB Reliability meetings to drive site reliability projects and obtain alignment with other departments

  • Work with Reliability Group and Maintenance Team to achieve best in class maintenance work practices,

  • Ensure the development and implementation of an annual training plan and budget for Maintenance, Reliability, and Inspection Departments.  This plan should cover technical development, craft skill developmentDevelop and deliver high quality training of maintenance organization in effective servicing and reconditioning all plant equipments, components and facilities, 

  • Maintain close contact with equipment, material, and component vendors to stay aware of, and capitalize on technological advances in the market.

Accountability 3: Manage Site Project Execution and Document Control

Most important activities:

  • Support Engineering with efficient and safe implementation of all Health, Safety, Environmental, Cost and Quality improvement projects

  • Ensure that department follows the proper Management of Change (MOC) process for changes and that all required documentation is completed

Accountability 4: Manage Department performance and annual budget

Most important activities:

  • Ensure and maintain a full set of technical documentation, specifications, standards, maintenance procedures and manuals to provide an adequate frame of reference for all departmental resources

  • Install a comprehensive set of departmental Key Performance Indicators to allow continuous measurement, reporting and improvement of departmental performance,

  • Develop and provide forecasts for annual departmental budget(s).  Manage and control annual departmental budget spend within budgeted amounts and execute spend within the Oligomers DOA prpcesses.

Accountability 5: Contribute to Plant Safety Performance

Most important activities:

  • Act as a champion around safety and take a visible role in the site’s safety related programs

  • Adhere to the SHE management system established for the site including participation in reporting, incident investigations, sharing of lessons learned, corrective action tracking and personal training on Incident Command in support of Incident Management System

  • Develop and install a departmental safety culture with focus on behavioral safety, individual safety responsibility, and shared prevention and correction of unsafe working conditions and practices,

  • Drive utilization of good safety practices such as toolbox meetings, job risk analyses, safety walk thru’s, departmental safety meetings, safety observations and near miss reporting, 

  • Support rigourous adhesion to site HSE and Management of Change procedures.

  • Ensures all non operating site areas in the asset maintance acceptable housekeeping standards.

Skills & Knowledge Required

Education/Experience

  • Mechanical Engineering degree. Electrical or other technical engineering degree acceptable if complemented with strong knowledge of mechanical engineering and manufacturing experience.

  • Minimum 10 years of experience in manufacturing or project engineering industry

  • Minimum 7 years of experience as maintenance and/or construction supervisor,

  • Turnaround Management, Planning and execution experience a plus.

Technical Skills

  • Strong trouble shooter and problem solver, based on thorough understanding of design and operating principles of machinery, stationary equipment, piping, instrumentation, and electrical components,

  • Strong job analysis and planning capabilities,

  • Ability to define both short term and long-term department goals

  • Basic understanding of unit operations,

  • Fluent in English

Behavioral skills

  • Strong communication and leadership skills, inspiring and motivating,

  • Good analytical and organisational skills,

  • Stress resistant and methodical.

ADA Physical requirements, visual acuity requirements and environmental conditions

While performing the duties of this job, the employee is regularly required to sit and perform tasks requiring repetitive use of hands. The employee must occasionally walk and stand. Exert up to 20 pounds of force occasionally, and/or up to 10 pounds of force frequently, and/or a negligible amount of force constantly to move objects.

Employee must have the ability to see written documents, computer screens and to adjust focus.

Hearing: Perceiving the nature of sounds at normal speaking levels with or without correction. Ability to receive detailed information through oral communication and to make discriminations in sound.

Work Environment:  This job is performed mainly in a temperature-controlled office environment.

Our culture is one of honesty and integrity with an emphasis on safety, health and environmental performance.On our team, people are acknowledged for embracing new practices that help create real value for customers.

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