Reliability Manager

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Job title: Reliability Manager

Job Location: Chocolate Bayou Works in Alvin, TX

Salary Range: $179,138.00 - $223,923 commensurate with experience

Organizational Context and Job Purpose

The Olefins & Polymers USA division of INEOS is one of the largest producers of olefins and polyolefins in North America. From its manufacturing locations at Chocolate Bayou and the Battleground Manufacturing Complex, it is a merchant marketer of butadiene, ethylene, polypropylene and high-density polyethylene with annual revenue of over $4B.

The Chocolate Bayou Site is located in Southeastern Texas about 40 miles South of Houston and consists of two Olefins units that produce approximately 4bn pounds/year of ethylene, 2 Polypropylene units that produce approximately 1B pounds/ year of polypropylene, and the Light Ends storage & transfer facilities at Stratton Ridge.

The Reliability and Integrity Manager is responsible for all aspects of Routine and Unusual inspection and reliability programs activities for the various areas of the facility.  The role is responsible for routine and unusual integrity inspection activities, which average approximately $11M per year. In addition, this position has responsibility for developing and implementing the reliability program at the site, with a direct cost of $4 M per year that supports the site asset base ($6.5B Asset Replacement Value).  This position is responsible for ensuring that all inspection activities are executed in a timely, safe, and efficient manner and that equipment is maintained to ensure mechanical integrity and reliability. This role reports to the Site Director and has responsibility for both embedded contractors and INEOS employees.

Responsibilities and Accountabilities

• The position is accountable for understanding and putting into practice the INEOS 20 Principles.  Additionally, the Reliability Manager has a special responsibility to cascade the understanding of these principles through their team.
• Ensure HSE delivery and compliance for Reliability and Integrity activities in the unit areas; serving as a champion for safe work practices for both INEOS employees and contractors working within the areas.
• Jointly responsible for improvement of overall equipment and process reliability; this includes budgeting for and supporting areas such as API-570, API-571, API-580, and API-581 piping inspections, vessel CUI re-conditioning, Area Reliability Teams, asset criticality, serving as Single Point of Accountability (SPA) for various capital reliability projects and focus on root cause failure analysis and defect elimination.
• Ensure the effective planning and execution of TAR and project-related activities to include: drive effective use of TAR and Capex Processes; integrate capital projects into TAR plans; serve as TAR Execution Coordinator for Facilities.
• Develop and maintain strategic long-term plan for site assets.  Interacts with industry experts to seek out and apply new technology and best practices to improve equipment lifecycle performance.  Act as the company SPA for canvasing input from industry experts, the Asset Team, Operations, Maintenance, and Procurement to update long-term plan with equipment upgrades and revamps needed across the technology platforms to maintain competitiveness and improve reliability performance.
• Act as the SPA for developing and maintaining close relationships with national suppliers for inspection and reliability providers.  Liaison with Procurement to negotiate pricing and timing.  Active vendor management includes various 3rd party inspection and engineering consultancy companies.
• Responsible for development and cost reporting for several Reliability and Integrity cost centers for both routine and unusual maintenance budgets.  This includes providing monthly updates during the Group financial outlook (GFO) financial process.

Responsible for developing the overall Reliability strategy for all assets at the site:

• Ensure that preventive maintenance (PM) plans are created and scheduled in accord with recommendations from the Technical Authorities.
• Develop and maintain Equipment Criticality and Work Criticality Indices.
• Work with central engineering function to standardize reliability and integrity work processes and deploy best practices across the site
• Develop and publish reliability and integrity metrics for the site.
• Develop equipment monitoring and modelling capability and drive improvements in online analysis/technology.
• Prioritize, with operations customer base, the overall improvement plan and implement new/different technologies to deliver cost reduction, increased reliability and operational flexibility.
• Prioritize and represent capital request for the site equipment and spare parts that are consistent with the long-term sustainability of the asset and the business strategy.

Responsible for development and execution of the overall Integrity Management Plan for the site:

• Provide Inspection services and assurance for site mechanical integrity at CBW.
• Ensure assets are inspected according to leading best practices such as API 653, 570, 571, 580, and 581.  Maintain evergreen damage mechanism reviews and update of inspection plans based on operating conditions, envelope excursions, and learnings.
• Mastery of knowledge and expertise in the application of mechanical codes and standards, industry standard practices, and recommended practices
• Serves as a technical Resource related to the site’s engineering standards and procedures including compliance to the O&P PS&IM Policy.  Internal customers are: Project Engineering, Operations, Inspection, TAR, Reliability, and Maintenance
• Accountable for safety of the work team inclusive of training, incident prevention behaviors, near miss reporting/root cause analysis and shared learning, and championing the MOC and related PSM processes. Lead team within the 20P principles.
• Devise and manage a discipline strategy consistent with the long and short term technology and business strategies.
• Develop needed resource skill sets to support site teams’ efforts (hiring, training, development, discipline know how).  Responsible for leading and developing the site and company Subject Matter Experts (SMEs) across multiple disciplines including Analyzer, Instrumentation, Electrical, Fixed, Inspection, and Rotating
• Ensure Mechanical, Electrical, and Instrumentation Engineering Training program is current, that proper training funds are budgeted annually, and that the required training is completed.
• Ensure the acquisition and sharing of best practices across the company. Develop company and external industry contacts to network issues on codes, standards and practices. Facilitating network and relationship development, including Europe, to enable technology to optimise the process.
• Ensure team is deployed to support operations in times of abnormal operation and crisis as required.
• Accountable for annual and interim performance review discussions (deliverables and competencies).
• Develop and maintain annual budget and propose fixed and capital expenditure needs for total site asset sustainability.
• Coaching and mentoring of project teams on project execution and business context.
• Monitor capability and verify compliance with standards.
• Single Point of Accountability for large equipment (compressors, gearbox, transformers) rebuild, sparing, and revamp strategies during TARs or unplanned outages.
• Act as a company authority with knowledge and expertise in the application of codes and standards, industry standard practices, and recommended practices.
• Responsible for both the Reliability and Inspection cost center budgets and monthly updates.

Accountability 1: Safety performance in area of responsibility

• Ensure HSE delivery and compliance for Reliability and Integrity activities in the unit areas; serving as a champion for safe work practices for both INEOS employees and contractors working within the areas.
• Ensures adherence to policy, procedures and practices
• Ensures compliance to INEOS Group Guidance Notes (IGGN) standards and 20 Principles
• Attendance at daily, weekly and monthly safety meetings
• Ensures utilization of HRP (Hazard Recognition Plus), job observation cards, Job Safety Analysis (JSA), Behavioral Safety Program (BSP), and incident tracking system (Gensuite)

Accountability 2: Compliance with internal and external policies and regulations

• Timely completion of HAZOP, incident investigation, PSM, and other recommendations
• Ensure inspection records, Relief Valves (RV’s), Safety Critical PMs, and legally required PM’s are current on all equipment and piping circuits.

Accountability 3: Ensure mechanical integrity of assets

• Adherence to API, ASME and ANSI standards and industry practices
• Working knowledge of industry standards and emerging trends
• Audit compliance with PSIM standard and take corrective action as necessary
• Considered company expert for integrity and reliability codes, standards, and best practices.

Accountability 4: Ensure availability of asset

• Technical support to TAR planning and execution
• Technical support to capital planning and execution
• Leverages technology and procedural efficiencies to implement best practices and reduce lifecycle cost
• Develop and keep evergreen the long term asset strategy, including revamps and new technology upgrades
• Lead and implement reliability projects for improved production and reduced fixed and variable costs.
• Recognized as the authority for applying engineering principles and best practices to achieve optimum asset business performance.

Accountability 5: Forecast and manage Reliability and Integrity budget

• Develop annual budget

• Forecast spending pattern for the year.  Review actual costs and provide monthly variance analysis

• Actively manage vendor relationships to optimize delivery, pricing, and work performance of suppliers and contractors. Act as the SPA for developing and maintaining close relationships with national suppliers for contract inspection providers and engineering services.

Accountability 6: Forecast and manage strategic capital plan and annual budget

• Develop and maintain strategic long-term reliability and integrity plan for critical assets. 
• Interacts with industry experts to seek out and apply new technology and best practices to improve equipment lifecycle performance, building these upgrades into the long-term plan.
• Work with capital team to develop annual capital budget related to equipment reliability and integrity
• Work with operations and project teams to scope and review capital projects that are approved for the annual budget.

• Actively manage vendor relationships to optimize delivery and work performance of suppliers and contractors. Act as the SPA for developing and maintaining close relationships with reliability and engineering service providers.

Accountability 7: Strategic Planning for Site and Asset Optimization

• Key participant in strategic planning for long term asset strategy and optimization
• In addition to monthly KPIs, ensure robust asset multi-year analysis to assess success/robustness of reliability program and assets.
• Key member of Furnace Optimization/Furnace Safety team
• Drive negotiations with strategic vendors
• Develop strategic planning/vision for Reliability roadmap.   Develop monthly metrics to track progress to the plan.

Skills and Knowledge Required

Educational Background and Work Experience

Undergraduate degree in Engineering or equivalent experience leading a reliability organization is required. 

A minimum of 10 years’ experience in chemical, refining or industrial manufacturing with prior responsibility for facilitating critical functions and best practice implementation. 

A minimum of 5 years of direct leadership experience in a reliability organization.

Skills and Competencies

Technical skills

• Deep knowledge and experience in Integrity codes including API570, API571, API580, API581, and API653
• Deep knowledge and experience in Reliability best practices including Reliability Centered Maintenance, Predictive Maintenance, Total Plant Maintenance, Asset Criticality, Asset Lifecycle, and organizations such as Society of Maintenance and Reliability Professionals
• Experience and knowledge of chemical operations and maintenance
• Experience and knowledge of OSHA 1910.119
• Experience and knowledge of TAR/Capital planning and execution
• Experience in multi disciplines (I/E, Mechanical Fixed, Rotating, Analyzer)
• Experience in multi disciplines (I/E, Mechanical Fixed, Rotating, Analyzer)
• Strong financial acumen
• Familiarity with process and personnel safety systems
• Deep expertise required in engineering practices and codes
• Recognized as the company authority in Reliability and Integrity in applying engineering principles to achieve optimum business goals
• Has the insight based on knowledge and experience to identify undefined restrictions in processes and systems and create solutions
• Interacts with industry experts to apply new technology as intended to existing practices to achieve improved business performance

Behavioral skills

• Integrity and trust
• Strong work ethic
• Results driven
• Strong decision-making skills
• Ability to prioritize and organize work
• Able to relate to multiple levels in the organization
• Able to delegate and hold people accountable
• Ability to establish and grow cross-functional team to accelerate improved performance
• Strong communication skills
• Ability to communicate effectively at all levels of the organization. 
• Effectively balance competing priorities and provide direction and leadership for their teams.
• Ability to resolve conflict
• Willingness to challenge the status quo.
• Considers a broad range of internal and external factors when solving problems.
• Can see applications and practices from different processes and industries that could benefit our business.

Line Management Responsibility

This Reliability and Integrity Manager has approximately seven (7) direct reports and thirty (30) indirect employees.  The position provides direct INEOS oversite for approximately 41 embedded contractors along with the bidding, planning, job rep support, and management of additional contractors on an annual basis for inspection integrity services (API inspection, Real Time Radiography, Digital Radiography, and NDE support).

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.